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AUTOMATIC TRANSMISSION - 42RLE

AUTOMATICTRANSMISSION-42 RLETABLEOFCONTENTS pagepageAUTOMATIC TRANSMISSION - 42 RLEDESCRIPTION .. 38 OPERATION .. 40 DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - AUTOMATICTRANSMISSION .. 46 DIAGNOSIS AND TESTING - ROAD TEST .. 46 DIAGNOSIS AND TESTING - HYDRAULICPRESSURE TESTS .. 47 DIAGNOSIS AND TESTING - CLUTCH AIRPRESSURE TESTS .. 50 DIAGNOSIS AND TESTING - FLUIDLEAKAGE .. 50 STANDARD PROCEDURE - ALUMINUMTHREAD REPAIR .. 51 REMOVAL .. 51 DISASSEMBLY .. 53 ASSEMBLY .. 69 INSTALLATION .. 85 SCHEMATICS AND DIAGRAMS - 42 RLETRANSMISSION .. 88 SPECIFICATIONS42 RLE AUTOMATIC TRANSMISSION .. 101 SPECIAL TOOLS42 RLE AUTOMATIC TRANSMISSION .. 103 ACCUMULATORDESCRIPTION .. 106 OPERATION .. 106 ADAPTER HOUSING SEALREMOVAL .. 106 INSTALLATION.

AUTOMATIC TRANSMISSION - 42RLE (Continued) ELEMENTS IN USE AT EACH POSITION OF SELECTOR LEVER ShiftLever Position INPUTCLUTCHES HOLDINGCLUTCHES Underdrive Overdrive Reverse 2/4 Low/Reverse P-PARK X R-REVERSE X X N-NEUTRAL X OD-OVERDRIVE First X X Second X X Direct X X Overdrive X X D-DRIVE* First X X Second X X …

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Transcription of AUTOMATIC TRANSMISSION - 42RLE

1 AUTOMATICTRANSMISSION-42 RLETABLEOFCONTENTS pagepageAUTOMATIC TRANSMISSION - 42 RLEDESCRIPTION .. 38 OPERATION .. 40 DIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - AUTOMATICTRANSMISSION .. 46 DIAGNOSIS AND TESTING - ROAD TEST .. 46 DIAGNOSIS AND TESTING - HYDRAULICPRESSURE TESTS .. 47 DIAGNOSIS AND TESTING - CLUTCH AIRPRESSURE TESTS .. 50 DIAGNOSIS AND TESTING - FLUIDLEAKAGE .. 50 STANDARD PROCEDURE - ALUMINUMTHREAD REPAIR .. 51 REMOVAL .. 51 DISASSEMBLY .. 53 ASSEMBLY .. 69 INSTALLATION .. 85 SCHEMATICS AND DIAGRAMS - 42 RLETRANSMISSION .. 88 SPECIFICATIONS42 RLE AUTOMATIC TRANSMISSION .. 101 SPECIAL TOOLS42 RLE AUTOMATIC TRANSMISSION .. 103 ACCUMULATORDESCRIPTION .. 106 OPERATION .. 106 ADAPTER HOUSING SEALREMOVAL .. 106 INSTALLATION.

2 106 BEARINGSADJUSTMENTSBEARING ADJUSTMENT PROCEDURES .. 106 BRAKE TRANSMISSION SHIFT INTERLOCKMECHANISMDESCRIPTION .. 107 OPERATION .. 108 REMOVAL .. 108 INSTALLATION .. 108 ADJUSTMENTSADJUSTMENT - BRAKE TRANSMISSIONSHIFT INTERLOCK CABLE .. 108 DRIVING CLUTCHESDESCRIPTION .. 109 OPERATION .. 109 FLUID AND FILTERDIAGNOSIS AND TESTINGDIAGNOSIS AND TESTING - CAUSES OFBURNT FLUID .. 110 EFFECTS OF INCORRECT FLUID LEVEL .. 110 FLUID CONTAMINATION .. 110 STANDARD PROCEDURESTANDARD PROCEDURE - FLUID LEVELCHECK.. 111 STANDARD PROCEDURE - FLUID/FILTERSERVICE .. 111 STANDARD PROCEDURE - TRANSMISSIONFILL .. 112 GEARSHIFT CABLEREMOVAL .. 113 INSTALLATION .. 113 HOLDING CLUTCHESDESCRIPTION .. 114 OPERATION .. 114 INPUT CLUTCH ASSEMBLYDISASSEMBLY.

3 114 ASSEMBLY .. 121 INPUT SPEED SENSORDESCRIPTION .. 131 OPERATION .. 131 REMOVAL .. 131 INSTALLATION .. 132 OIL PUMPDESCRIPTION .. 132 OPERATION .. 132 DISASSEMBLY .. 132 ASSEMBLY .. 133 OUTPUT SPEED SENSORDESCRIPTION .. 134 OPERATION .. 134 REMOVAL .. 134 INSTALLATION .. 134 OVERDRIVE SWITCHDESCRIPTION .. 135 OPERATION .. 135 REMOVAL .. 135 INSTALLATION .. 135 PLANETARY GEARTRAINDESCRIPTION .. 136 OPERATION .. 136 OIL PUMP SEALREMOVAL .. 136 INSTALLATION .. 136 TJAUTOMATICTRANSMISSION-42 RLE21-37 SHIFT MECHANISMDESCRIPTION .. 136 OPERATION .. 136 DIAGNOSIS AND TESTING - SHIFTMECHANISM .. 136 ADJUSTMENTS - SHIFT MECHANISM .. 137 SOLENOIDDESCRIPTION .. 137 OPERATION .. 138 SOLENOID/PRESSURE SWITCH ASSYDESCRIPTION.

4 138 OPERATION .. 139 REMOVAL .. 139 INSTALLATION .. 140 TORQUE CONVERTERDESCRIPTION .. 141 OPERATION .. 145 REMOVAL .. 146 INSTALLATION .. 146 TRANSMISSION CONTROL RELAYDESCRIPTION .. 146 OPERATION .. 147 TRANSMISSION RANGE SENSORDESCRIPTION .. 147 OPERATION .. 147 REMOVAL .. 148 INSTALLATION .. 148 TRANSMISSION TEMPERATURE SENSORDESCRIPTION .. 149 OPERATION .. 149 VALVE BODYDESCRIPTION .. 149 OPERATION .. 150 REMOVAL .. 153 DISASSEMBLY .. 154 ASSEMBLY .. 159 INSTALLATION .. 164 AUTOMATICTRANSMISSION-42 RLEDESCRIPTIONThe42 RLE( )isafour- ,fluidpassages,hydraulicvalves, ,overdrive, :2nd/4 : Threemultiplediscinputclutches Twomultipledischoldingclutches Fourhydraulicaccumulators Twoplanetarygearsets Hydraulicoilpump Valvebody (TCM)portionofthePowertrainControlModule (PCM).

5 TheTCMistheheartoftheelectroniccontrolsy s-temandreliesoninformationfromvariousdi rectandindirectinputs(sensors,switches,e tc.) ,theTCMcancalculateandperformtimelyandqu alityshiftsthroughvari-ousoutputorcontro ldevices(solenoidpack,trans-missioncontr olrelay,etc.).TheTCMalsoperformscertains elf-diagnosticfunctionsandprovidescompre hensiveinformation(sensordata,DTC s,etc.) 1 42 RLE AUTOMATIC TransmissionTJAUTOMATICTRANSMISSION-42 RLE21-39 AUTOMATICTRANSMISSION-42 RLE(Continued) (10),dateofmanufacture(4,5),manufacturin gorigin(2),assemblylineidentifier(6),bui ldsequencenumber(7),etc.( ).Ifthetagisnotlegibleorismissing,the PK number,whichisstampedintotheleftrearflan geofthetransmissioncase, ,buildcode, : : : : : 11 - DRIVEPLATE6 - REVERSE CLUTCH11 - STUB SHAFT2 - TORQUE CONVERTER7 - FRONT PLANET CARRIER12 - LOW/REVERSE CLUTCH3 - INPUT SHAFT8 - REAR PLANET CARRIER13 - 2/4 CLUTCH4 - UNDERDRIVE CLUTCH9 - OUTPUT SHAFT14 - OIL PUMP5 - OVERDRIVE CLUTCH10 - SNAP RINGFig.

6 2 Identification Label Breakdown1 - T=TRACEABILITY2 - SUPPLIER CODE (PK=KOKOMO)3 - COMPONENT CODE (TK=KOKOMO TRANSMISSION )4 - BUILD DAY (350=DEC. 15)5 - BUILD YEAR (1=2001)6 - ASSEMBLY LINE CODE7 - BUILD SEQUENCE NUMBER8 - LAST THREE OF P/N9 - CHANGE LEVEL10 - TRANSMISSION PART NUMBER11 - P=PART NUMBER21-40 AUTOMATICTRANSMISSION-42 RLETJAUTOMATICTRANSMISSION-42 RLE(Continued)FIRSTGEARPOWERFLOWI nfirstgearrange,torqueinputisthroughtheu nderdriveclutch(1)( ) , (2) 3 First Gear Powerflow1 - UNDERDRIVE CLUTCH APPLIED (Turns Rear Sun)2 - LOW-REVERSE CLUTCH APPLIED (Holds Rear Annulus/FrontCarrier)TJAUTOMATICTRANSMIS SION-42 RLE21-41 AUTOMATICTRANSMISSION-42 RLE(Continued)SECONDGEARPOWERFLOWS econdgearisachievedbyhavingbothplanetary gearsets( ) ,torqueinputisthroughtheunder-driveclutc h(1) (2) , 4 Second Gear Powerflow1 - UNDERDRIVE CLUTCH APPLIED (Turns Rear Sun)

7 2 - 2-4 CLUTCH APPLIED (Holds Front Sun)21-42 AUTOMATICTRANSMISSION-42 RLETJAUTOMATICTRANSMISSION-42 RLE(Continued)THIRDGEARPOWERFLOWI nthirdgear,twoinputclutchesareappliedtop ro-videtorqueinput:theunderdriveclutch(1 )( )andoverdriveclutch(2).Theunderdriveclut chrotatestherearsungear, (rearsungearandrearannulusgear) 5 Third Gear Powerflow1 - UNDERDRIVE CLUTCH APPLIED (Turns Rear Sun)2 - OVERDRIVE CLUTCH APPLIED (Turns Front Carrier/RearAnnulus)TJAUTOMATICTRANSMISS ION-42 RLE21-43 AUTOMATICTRANSMISSION-42 RLE(Continued)FOURTHGEARPOWERFLOWI nfourthgearinputtorqueisthroughtheover-d riveclutch(1)( ) (2) , , 6 Fourth Gear Powerflow1 - OVERDRIVE CLUTCH APPLIED (Turns Rear Sun)2 - 2-4 CLUTCH APPLIED (Holds Front Sun)21-44 AUTOMATICTRANSMISSION-42 RLETJAUTOMATICTRANSMISSION-42 RLE(Continued)REVERSEGEARPOWERFLOWI nreverse,input( )poweristhroughthereverseclutch(1).

8 Whenapplied, (2) ,inreverse, 7 Reverse Gear Powerflow1 - LOW-REVERSE CLUTCH APPLIED (Holds Rear Annulus FrontCarrier)2 - REVERSE CLUTCH APPLIED (Turns Front Sun)TJAUTOMATICTRANSMISSION-42 RLE21-45 AUTOMATICTRANSMISSION-42 RLE(Continued)DIAGNOSISANDTESTINGDIAGNOS ISANDTESTING-AUTOMATICTRANSMISSIONCAUTIO N: Before attempting any repair on the42 RLE Four Speed AUTOMATIC TRANSMISSION , alwayscheck for proper shift cable adjustment. Also checkfor diagnostic trouble codes with the DRBT scantool and the 42 RLE TRANSMISSION Diagnostic Proce-dure : Poorengineperformance Improperadjustments Hydraulicmalfunctions Mechanicalmalfunctions : Temperatureatoccurrence(cold,hot,both) Dynamicconditions(acceleration,decelerat ion,upshift,cornering) Elementsinusewhenconditionoccurs(whatgea ristransmissioninduringcondition) Roadandweatherconditions ,checktheeasilyacces-siblevariables.

9 Fluidlevelandcondition Shiftcableadjustment , ,verifythatthefluidlevel,fluidcondition, , ,buthaspooracceleration, ,buthighthrottleopeningisneededtomaintai nhighwayspeeds, ElementsinUse (Continued)ELEMENTSINUSEATEACHPOSITIONOF SELECTORLEVERS hift LeverPositionINPUT CLUTCHESHOLDING CLUTCHESU nderdriveOverdriveReverse2/4 Low/ReverseP - PARKXR - REVERSEXXN - NEUTRALXOD -OVERDRIVEF irstXXSecondXXDirectXXOverdriveXXD - DRIVE*FirstXXSecondXXDirectXXL - LOW*FirstXXSecondXXDirectXX* Vehicle upshift and downshift speeds are increased when in these selector , ,becertainthatfluidlevelandcondition, (150to200degreesF.).Installanenginetacho meter,raisevehicleonhoistwhichallowsthew heelstoturn, ,attach300psigauge(s)C-3293 SPtotheport(s) ( )Fig. 8 Pressure Taps1 - TORQUE CONVERTER CLUTCH OFF2 - REVERSE3 - LOW/REVERSE4 - 2/45 - UNDERDRIVE6 - TORQUE CONVERTER CLUTCH ON7 - OVERDRIVETJAUTOMATICTRANSMISSION-42 RLE21-47 AUTOMATICTRANSMISSION-42 RLE(Continued)TESTONE-SELECTORINMANUAL1( 1stGear)NOTE: This test checks pump output, pressure reg-ulation and condition of the low/reverse clutchhydraulic circuit and shift schedule.

10 (1)Attachpressuregaugetothelow/reversecl utchtap.(2)MoveselectorlevertotheMANUAL1 position.(3)Allowvehiclewheelstoturnandi ncreasethrottleopeningtoachieveanindicat edvehiclespeedto20mph.(4) (SecondGear)NOTE: This test checks the underdrive clutchhydraulic circuit as well as the shift schedule.(1)Attachgaugetotheunderdrivecl utchtap.(2)MoveselectorlevertotheMANUAL2 position.(3)Allowvehiclewheelstoturnandi ncreasethrottleopeningtoachieveanindicat edvehiclespeedof30mph.(4) (ODON-FourthGear)NOTE: This test checks the underdrive clutchhydraulic circuit as well as the shift schedule.(1)Attachgaugetotheunderdrivecl utchtap.(2) (3)Allowwheelstorotatefreelyandincreaset hrottleopeningtoachieveanindicatedspeedo f40mph.(4) , (ODOFF-ThirdandSecondGear)NOTE: This test checks the overdrive clutchhydraulic circuit as well as the shift schedule.

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