Dodge Dakota (R1). Manual — part 630
(9) Remove bolts attaching overdrive unit to trans-
mission (Fig. 128).
CAUTION: Support the overdrive unit with a jack
before moving it rearward. This is necessary to pre-
vent damaging the intermediate shaft. Do not allow
the shaft to support the entire weight of the over-
drive unit.
(10) Carefully work overdrive unit off intermediate
shaft. Do not tilt unit during removal. Keep it as
level as possible.
(11) If overdrive unit does not require service,
immediately insert Alignment Tool 6227-2 in splines
of planetary gear and overrunning clutch to prevent
splines from rotating out of alignment. If misalign-
ment occurs, overdrive unit will have to be disassem-
bled in order to realign splines.
(12) Remove and retain overdrive piston thrust
bearing. Bearing may remain on piston or in clutch
hub during removal.
(13) Position drain pan on workbench.
(14) Place overdrive unit over drain pan. Tilt unit
to drain residual fluid from case.
(15) Examine fluid for clutch material or metal
fragments. If fluid contains these items, overhaul will
be necessary.
(16) If overdrive unit does not require any service,
leave alignment tool in position. Tool will prevent
accidental misalignment of planetary gear and over-
running clutch splines.
DISASSEMBLY
(1) Remove transmission speed sensor and O-ring
seal from overdrive case (Fig. 129).
(2) Remove overdrive piston thrust bearing (Fig.
130).
OVERDRIVE PISTON
(1) Remove overdrive piston thrust plate (Fig.
131). Retain thrust plate. It is a select fit part and
may possibly be reused.
(2) Remove intermediate shaft spacer (Fig. 132).
Retain spacer. It is a select fit part and may possibly
be reused.
Fig. 128 Overdrive Unit Bolts
1 - OVERDRIVE UNIT
2 - ATTACHING BOLTS (7)
Fig. 129 Transmission Speed Sensor Removal
1 - SOCKET AND WRENCH
2 - SPEED SENSOR
3 - O-RING
Fig. 130 Overdrive Piston Thrust Bearing Removal
1 - THRUST BEARING
2 - OVERDRIVE PISTON
3 - THRUST PLATE
21 - 164
AUTOMATIC TRANSMISSION - 42RE
AN
OVERDRIVE UNIT (Continued)
(3) Remove overdrive piston from retainer (Fig.
133).
OVERDRIVE CLUTCH PACK
(1) Remove overdrive clutch pack wire retaining
ring (Fig. 134).
(2) Remove overdrive clutch pack (Fig. 135).
NOTE: The 42RE transmission has three clutch
discs and two clutch plates.
(3) Note position of clutch pack components for
assembly reference (Fig. 136).
Fig. 131 Overdrive Piston Thrust Plate Removal
1 - OVERDRIVE PISTON
2 - OVERDRIVE PISTON SPACER (SELECT FIT)
Fig. 132 Intermediate Shaft Spacer Location
1 - INTERMEDIATE SHAFT
2 - INTERMEDIATE SHAFT SPACER (SELECT FIT)
Fig. 133 Overdrive Piston Removal
1 - PISTON RETAINER
2 - OVERDRIVE PISTON
Fig. 134 Removing Overdrive Clutch Pack Retaining
Ring
1 - OVERDRIVE CLUTCH PACK RETAINING RING
Fig. 135 Overdrive Clutch Pack Removal
1 - OVERDRIVE CLUTCH PACK
AN
AUTOMATIC TRANSMISSION - 42RE
21 - 165
OVERDRIVE UNIT (Continued)
OVERDRIVE GEARTRAIN
(1) Remove overdrive clutch wave spring (Fig.
137).
(2) Remove overdrive clutch reaction snap-ring
(Fig. 138). Note that snap-ring is located in same
groove as wave spring.
(3) Remove Torx™ head screws that attach access
cover and gasket to overdrive case (Fig. 139).
(4) Remove access cover and gasket (Fig. 140).
Fig. 136 42RE Overdrive Clutch Component
Position
1 - PRESSURE PLATE (TO FRONT)
2 - OVERDRIVE CLUTCH PACK
3 - CLUTCH DISC (3)
4 - CLUTCH PLATE (2)
5 - REACTION PLATE (TO REAR)
Fig. 137 Overdrive Clutch Wave
1 - WAVE SPRING
Fig. 138 Overdrive Clutch Reaction Snap-Ring
Removal
1 - REACTION RING
2 - CLUTCH HUB
Fig. 139 Access Cover Screw Removal
1 - TORX SCREWDRIVER (T25)
2 - ACCESS COVER SCREWS
Fig. 140 Access Cover And Gasket Removal
1 - ACCESS COVER AND GASKET
21 - 166
AUTOMATIC TRANSMISSION - 42RE
AN
OVERDRIVE UNIT (Continued)
(5) Expand output shaft bearing snap-ring with
expanding-type snap-ring pliers. Then push output
shaft forward to release shaft bearing from locating
ring (Fig. 141).
(6) Lift gear case up and off geartrain assembly
(Fig. 142).
(7) Remove snap-ring that retains rear bearing on
output shaft.
(8) Remove rear bearing from output shaft (Fig.
143).
DIRECT CLUTCH, HUB AND SPRING
WARNING:
THE
NEXT
STEP IN
DISASSEMBLY
INVOLVES COMPRESSING THE DIRECT CLUTCH
SPRING.
IT
IS
EXTREMELY
IMPORTANT
THAT
PROPER EQUIPMENT BE USED TO COMPRESS
THE SPRING AS SPRING FORCE IS APPROXI-
MATELY 830 POUNDS. USE SPRING COMPRESSOR
TOOL 6227-1 AND A HYDRAULIC SHOP PRESS
WITH A MINIMUM RAM TRAVEL OF 5-6 INCHES.
THE PRESS MUST ALSO HAVE A BED THAT CAN
BE ADJUSTED UP OR DOWN AS REQUIRED.
RELEASE CLUTCH SPRING TENSION SLOWLY AND
COMPLETELY TO AVOID PERSONAL INJURY.
(1) Mount geartrain assembly in shop press (Fig.
144).
(2) Position Compressor Tool 6227-1 on clutch hub
(Fig. 144). Support output shaft flange with steel
press plates as shown and center assembly under
press ram.
(3) Apply press pressure slowly. Compress hub and
spring far enough to expose clutch hub retaining ring
and relieve spring pressure on clutch pack snap-ring
(Fig. 144).
Fig. 141 Releasing Bearing From Locating Ring
1 - EXPAND BEARING LOCATING RING WITH SNAP-RING
PLIERS
2 - ACCESS HOLE
Fig. 142 Removing Gear Case From Geartrain
Assembly
1 - GEARTRAIN ASSEMBLY
2 - GEAR CASE
Fig. 143 Rear Bearing Removal
1 - OUTPUT SHAFT
2 - REAR BEARING
3 - SNAP-RING
AN
AUTOMATIC TRANSMISSION - 42RE
21 - 167
OVERDRIVE UNIT (Continued)
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