Dodge Dakota (R1). Manual — part 636

Inspect the geartrain spacers, thrust plates, snap-

rings, and thrust washers. Replace any of these parts
that are worn, distorted or damaged. Do not attempt
to reuse these parts.

The planetary gear thrust washers are different

sizes. The large diameter washers go on the front
planetary and the smaller washers go on the rear
planetary. All the washers have four locating tabs on
them. These tabs fit in the holes or slots provided in
each planetary gear.

Inspect the output shaft carefully. Pay particular

attention to the machined bushing/bearing surfaces
on the shaft and the governor valve shaft bore at the
shaft rear.

Replace the output shaft if the machined surfaces

are scored, pitted, or damaged in any way. Also
replace the shaft if the splines are damaged, or
exhibits cracks at any location (especially at the gov-
ernor valve shaft bore).

The annulus gears can be removed from their sup-

ports if necessary. Just remove the snap-rings and
separate the two parts when replacement is neces-
sary. In addition, the annulus gear bushings can be
replaced if severely worn, or scored. However it is not
necessary to replace the bushings if they only exhibit
normal wear. Check bushing fit on the output shaft
to be sure.

ASSEMBLY

(1) Lubricate output shaft and planetary compo-

nents with transmission fluid. Use petroleum jelly to
lubricate and hold thrust washers and plates in posi-
tion.

(2) Assemble rear annulus gear and support if dis-

assembled. Be sure support snap-ring is seated and
that shoulder-side of support faces rearward (Fig.
208).

(3) Install rear thrust washer on rear planetary

gear. Use enough petroleum jelly to hold washer in
place. Also be sure all four washer tabs are properly
engaged in gear slots.

(4) Install rear annulus over and onto rear plane-

tary gear (Fig. 208).

(5) Install assembled rear planetary and annulus

gear on output shaft (Fig. 209). Verify that assembly
is fully seated on shaft.

(6) Install front thrust washer on rear planetary

gear (Fig. 210). Use enough petroleum jelly to hold
washer on gear. Be sure all four washer tabs are
seated in slots.

(7) Install spacer on sun gear (Fig. 211).
(8) Install thrust plate on sun gear (Fig. 212). Note

that driving shell thrust plates are interchangeable.
Use either plate on sun gear and at front/rear of
shell.

Fig. 207 Removing Driving Shell, Rear Planetary

And Rear Annulus

1 - REAR ANNULUS
2 - REAR PLANETARY
3 - DRIVING SHELL
4 - OUTPUT SHAFT

Fig. 208 Assembling Rear Annulus And Planetary

Gear

1 - REAR ANNULUS GEAR
2 - TABBED THRUST WASHER
3 - REAR PLANETARY

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PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

Fig. 209 Installing Rear Annulus And Planetary On

Output Shaft

1 - REAR ANNULUS AND PLANETARY GEAR ASSEMBLY
2 - OUTPUT SHAFT

Fig. 210 Installing Rear Planetary Front Thrust

Washer

1 - FRONT TABBED THRUST WASHER
2 - REAR PLANETARY GEAR

Fig. 211 Installing Spacer On Sun Gear

1 - SUN GEAR
2 - SUN GEAR SPACER

Fig. 212 Installing Driving Shell Front Thrust Plate

On Sun Gear

1 - SPACER
2 - SUN GEAR
3 - THRUST PLATE

AN

AUTOMATIC TRANSMISSION - 42RE

21 - 189

PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

(9) Hold sun gear in place and install thrust plate

over sun gear at rear of driving shell (Fig. 213).

(10) Position wood block on bench and support sun

gear on block (Fig. 214). This makes it easier to align
and install sun gear lock ring. Keep wood block
handy as it will also be used for geartrain end play
check.

(11) Align rear thrust plate on driving shell and

install sun gear lock ring. Be sure ring is fully seated
in sun gear ring groove (Fig. 215).

(12) Install assembled driving shell and sun gear

on output shaft (Fig. 216).

(13) Install rear thrust washer on front planetary

gear (Fig. 217). Use enough petroleum jelly to hold
washer in place and be sure all four washer tabs are
seated.

(14) Install front planetary gear on output shaft

and in driving shell (Fig. 218).

(15) Install front thrust washer on front planetary

gear. Use enough petroleum jelly to hold washer in
place and be sure all four washer tabs are seated.

Fig. 213 Installing Driving Shell Rear Thrust Plate

1 - DRIVING SHELL
2 - SUN GEAR
3 - REAR THRUST PLATE

Fig. 214 Supporting Sun Gear On Wood Block

1 - SUN GEAR
2 - DRIVING SHELL
3 - WOOD BLOCK

Fig. 215 Installing Sun Gear Lock Ring

1 - LOCK RING GROOVE
2 - SUN GEAR LOCK RING
3 - DRIVING SHELL
4 - REAR THRUST PLATE

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AN

PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)

(16) Assemble front annulus gear and support, if

necessary. Be sure support snap-ring is seated.

(17) Install front annulus on front planetary (Fig.

218).

(18) Position thrust plate on front annulus gear

support (Fig. 219). Note that plate has two tabs on it.
These tabs fit in notches of annulus hub.

(19) Install thrust washer in front annulus (Fig.

220). Align flat on washer with flat on planetary hub.
Also be sure washer tab is facing up.

(20) Install front annulus snap-ring (Fig. 221). Use

snap-ring pliers to avoid distorting ring during
installation. Also be sure ring is fully seated.

(21) Install

planetary

selective

snap-ring

with

snap-ring pliers (Fig. 222). Be sure ring is fully
seated.

(22) Turn planetary geartrain assembly over so

driving shell is facing workbench. Then support
geartrain on wood block positioned under forward
end of output shaft. This allows geartrain compo-
nents to move forward for accurate end play check.

(23) Check planetary geartrain end play with

feeler gauge (Fig. 223). Gauge goes between shoulder
on output shaft and end of rear annulus support.

(24) Geartrain end play should be 0.12 to 1.22 mm

(0.005 to 0.048 in.). If end play is incorrect, snap-ring
(or thrust washers) may have to be replaced. Snap-
rings are available in three different thicknesses for
adjustment purposes.

Fig. 216 Installing Assembled Sun Gear And Driving

Shell On Output Shaft

1 - SUN GEAR/DRIVING SHELL ASSEMBLY
2 - OUTPUT SHAFT

Fig. 217 Installing Rear Thrust Washer On Front

Planetary Gear

1 - FRONT PLANETARY GEAR
2 - REAR TABBED THRUST WASHER

Fig. 218 Installing Front Planetary And Annulus

Gears

1 - FRONT PLANETARY GEAR
2 - FRONT THRUST WASHER
3 - FRONT ANNULUS GEAR

Fig. 219 Positioning Thrust Plate On Front Annulus

Support

1 - FRONT ANNULUS
2 - THRUST PLATE

AN

AUTOMATIC TRANSMISSION - 42RE

21 - 191

PLANETARY GEARTRAIN/OUTPUT SHAFT (Continued)