2001 DODGE RAM engine

GEARTRAIN
(1) Install input shaft into Support Stand 8246.
(2) Install fifth gear friction cone onto the input
shaft.
(3) Install fifth gear blocker ring onto the fifth
gear friction cone.
(4) Install output shaft into the input shaft (Fig.
79).
(5) Install countershaft into the Support Stand
8246 and verify that all gears are meshed with their
mates on the mainshaft (Fig. 80).
(6) Install Fixture 8232 to the output shaft and
the countershaft.
(7) Install Holding Tool 8242 onto the 5-6 synchro
and tighten the screw to hold the 5±6 synchro
together during the remainder of the installation pro-
cedure.(8) Attach and engine crane or equivalent to Fix-
ture 8232 and move the geartrain from the Support
Stand 8246 to the clutch housing (Fig. 81).
(9) Install shift forks and rails onto the geartrain
(Fig. 82).
NOTE: The closest shift arm to the geartrain is for
Reverse. The next is 5-6, then 3-4 and then 1-2
when moving out from the geartrain.
(10) Install geartrain and shift rails into the clutch
housing. Lower the geartrain and rails into the hous-
ing slowly while guiding input shaft through input
shaft seal. Avoid any binds on the shift rails, forks
and synchros as the rails enter their bushings.
CAUTION: Do not damage input shaft seal with the
input shaft splines.
Fig. 79 Install Output Shaft to Input Shaft
1 - OUTPUT SHAFT
2 - INPUT SHAFT
3 - SUPPORT STAND 8246
Fig. 80 Countershaft to Mainshaft
1 - COUNTERSHAFT
2 - OUTPUT SHAFT
3 - SUPPORT STAND 8246
BR/BEMANUAL - NV5600 21 - 119
MANUAL - NV5600 (Continued)

(11) With the geartrain approximately 1/4 in. from
the clutch housing, remove Holding Tool 8242 from
the 5-6 synchro (Fig. 83).
(12) Install 5-6 crossover bracket and arm to the
shift rails and the clutch housing.(13) Lower geartrain the remainder of the way
into the clutch housing.
(14) Install the 5-6 crossover bracket bolts (Fig.
84).
(15) Remove engine crane and Fixture 8232 from
the output shaft and the countershaft.
Fig. 81 Lift Geartrain with Engine Crane
1 - FIXTURE 8232
2 - SUPPORT STAND 8246
Fig. 82 Install Shift Rails
1 - SHIFT RAILS
Fig. 83 Holding Tool 8242
1 - HOLDING TOOL 8242
2 - 5-6 SYNCHRO
Fig. 84 5-6 Crossover Bracket Bolts
1 - 5-6 CROSSOVER BRACKET
21 - 120 MANUAL - NV5600BR/BE
MANUAL - NV5600 (Continued)

TRANSMISSION GEAR CASE
(1) Install rear output shaft bearing race into the
transmission gear case with Installer C-4308 and
Handle C-4171.
(2) Install rear countershaft bearing race into the
transmission gear case with Installer 8153 and Han-
dle C-4171.
(3) Install Fixture 8232 to the transmission gear
case.
NOTE: Shift socket must be loose on the shift shaft
and is rotated a minimum of 90É from its normal
position. This will ensure enough clearance to
install the transmission gear case.
(4) Attach an engine crane or equivalent to Fixture
8232 and install the transmission gear case onto the
clutch housing (Fig. 85).
(5) Install clutch housing bolts and tighten to 48
N´m (35 ft.lbs.).
(6) Install shift socket roll pin with a suitable
6mm (7/32 inch) punch and hammer.MAINSHAFT AND COUNTERSHAFT ENDPLAY
(1) With transmission in vertical position, use
Socket 6993 to rotate the shafts and seat the bear-
ings.
(2) Measure mainshaft endplay with Dial Indicator
Set C-3339 and Extension Rod 8161 installed onto
the rear of the transmission gear case (Fig. 86).
(3) Measure countershaft end-play with Dial Indi-
cator Set C-3339 and Extension Rod 8161 installed
onto the rear of the transmission gear case (Fig. 87).
(4) Rotate transmission into a horizontal position
and remove the input shaft retainer.
(5) Install shims necessary to achieve an end-play
of 0.051-0.15 mm (0.002-0.006 in.) for the mainshaft
and countershaft.
NOTE: Countershaft shims go between the bearing
race and spacer. Mainshaft shims go into the input
shaft retainer.
Fig. 85 Transmission Gear Case
1 - FIXTURE 8232
2 - TRANSMISSION CASE
Fig. 86 Measure Mainshaft End-Play
1 - DIAL INDICATOR C-3339
2 - EXTENSION ROD 8161
3 - MAIN SHAFT
BR/BEMANUAL - NV5600 21 - 121
MANUAL - NV5600 (Continued)

(18) Install crossover detent plunger, spring and
plug into the extension/adapter housing. Tighten the
plug to 47.5 N´m (35 ft.lbs.) (Fig. 97).
(19) Apply sealer to the surface of the transmis-
sion case.
(20) Install extension/adapter housing onto the
transmission case.
(21) Install bolts to hold the extension/adapter
housing onto the transmission gear case. Tighten
bolts to 48 N´m (35 ft.lbs.).
(22) Install shift rail blocker bolt and tighten bolt
to 55 N´m (41 ft.lbs.).
(23) Install primary shift rail detent plunger,
spring and plug into the transmission case. Tighten
detent plug to 47.5 N´m (35 ft.lbs.).(24) Install shift tower onto the transmission case
and tighten bolts to 9 N´m (7 ft.lbs.).
INSTALLATION
NOTE: If a new transmission is being installed, be
sure to use all components supplied with the new
transmission. For example, if a new shift tower is
supplied with the new transmission, do not re-use
the original shift tower.
NOTE: Use a heavy duty scissors style transmis-
sion jack to install the transmission.
Before installation apply light coat of Mopar high
temperature bearing grease to contact surfaces of fol-
lowing components:
²input shaft splines.
²release bearing slide surface of front retainer.
²release bearing bore.
²release fork.
²release fork ball stud.
²propeller shaft slip yoke.
(1) Apply sealer to threads of bottom PTO cover
bolt and install bolt in case.
(2) Mount transmission on jack and position trans-
mission under vehicle.
(3) Raise transmission until input shaft is centered
in clutch disc hub.
(4) Move transmission forward and start input
shaft in clutch disc and pilot bushing/bearing.
(5) Work transmission forward until seated against
engine block. Do not allow transmission to remain
unsupported after input shaft has entered clutch
disc.
(6) Install and tighten transmission-to-engine
block bolts.
(7) Install clutch slave cylinder.
(8) Connect backup light switch wires.
(9) Fill transmission with recommended lubricant.
Correct fill level is bottom edge of fill plug hole.
(10) Position transmission harness wires in clips
on transmission.
(11) Install transmission mount on transmission or
rear crossmember.
(12) Install rear crossmember.
(13) Remove transmission jack and engine support
fixture.
TWO WHEEL DRIVE
(1) Install propeller shaft with referece marks
aligned.
(2) Install exhaust system components.
(3) Remove support and lower vehicle.
(4) Shift transmission into third gear.
Fig. 96 Crossover Cam
1 - CROSSOVER CAM
2 - BOLT
3 - EXTENSION HOUSING
Fig. 97 Crossover Cam Detent Plug
1 - DETENT PLUG
2 - EXTENSION HOUSING
BR/BEMANUAL - NV5600 21 - 125
MANUAL - NV5600 (Continued)

OVERRUNNING CLUTCH CAM/OVERDRIVE
PISTON RETAINER
DESCRIPTION..........................235
OPERATION............................235
DISASSEMBLY..........................235
CLEANING.............................236
INSPECTION...........................236
ASSEMBLY............................236
PARK/NEUTRAL POSITION SWITCH
DIAGNOSIS AND TESTING................237
PARK/NEUTRAL POSITION SWITCH.......237
REMOVAL.............................238
INSTALLATION..........................238
PISTONS
DESCRIPTION..........................238
OPERATION............................238
PLANETARY GEARTRAIN/OUTPUT SHAFT
DESCRIPTION..........................240
OPERATION............................240
DISASSEMBLY..........................240
INSPECTION...........................241
ASSEMBLY............................241
REAR CLUTCH
DESCRIPTION..........................246
OPERATION............................246
DISASSEMBLY..........................247
CLEANING.............................247
INSPECTION...........................248
ASSEMBLY............................248
REAR SERVO
DESCRIPTION..........................250
OPERATION............................250
DISASSEMBLY..........................251
CLEANING.............................251
ASSEMBLY............................251
SHIFT MECHANISM
DESCRIPTION..........................251OPERATION............................251
ADJUSTMENTS.........................252
SOLENOID
DESCRIPTION..........................252
OPERATION............................253
SPEED SENSOR
DESCRIPTION..........................253
OPERATION............................253
THROTTLE VALVE CABLE
DESCRIPTION..........................253
ADJUSTMENTS.........................254
TORQUE CONVERTER
DESCRIPTION..........................256
OPERATION............................260
REMOVAL.............................261
INSTALLATION..........................261
TORQUE CONVERTER DRAINBACK VALVE
DESCRIPTION..........................262
OPERATION............................262
STANDARD PROCEDURE.................262
TORQUE CONVERTER DRAINBACK VALVE . 262
TRANSMISSION TEMPERATURE SENSOR
DESCRIPTION..........................262
OPERATION............................262
VALVE BODY
DESCRIPTION..........................263
OPERATION............................267
REMOVAL.............................281
DISASSEMBLY..........................282
CLEANING.............................293
INSPECTION...........................293
ASSEMBLY............................294
INSTALLATION..........................303
ADJUSTMENTS.........................304
AUTOMATIC TRANSMISSION -
42RE
DESCRIPTION
The 42RE is a four speed fully automatic transmis-
sion (Fig. 1) with an electronic governor. The 42RE is
equipped with a lock-up clutch in the torque con-
verter. First through third gear ranges are provided
by the clutches, bands, overrunning clutch, and plan-
etary gear sets in the transmission. Fourth gear
range is provided by the overdrive unit that contains
an overdrive clutch, direct clutch, planetary gear set,
and overrunning clutch.
The transmission contains a front, rear, and direct
clutch which function as the input driving compo-
nents. It also contains the kickdown (front) and thelow/reverse (rear) bands which, along with the over-
running clutch and overdrive clutch, serve as the
holding components. The driving and holding compo-
nents combine to select the necessary planetary gear
components, in the front, rear, or overdrive planetary
gear set, transfer the engine power from the input
shaft through to the output shaft.
The valve body is mounted to the lower side of the
transmission and contains the valves to control pres-
sure regulation, fluid flow control, and clutch/band
application. The oil pump is mounted at the front of
the transmission and is driven by the torque con-
verter hub. The pump supplies the oil pressure nec-
essary for clutch/band actuation and transmission
lubrication.
BR/BEAUTOMATIC TRANSMISSION - 42RE 21 - 135

IDENTIFICATION
Transmission identification numbers are stamped
on the left side of the case just above the oil pan gas-
ket surface (Fig. 2). Refer to this information when
ordering replacement parts.
GEAR RATIOS The 42RE gear ratios are:
1st.................................2.74:1
2nd................................1.54:1
3rd.................................1.00:1
4th.................................0.69:1
Rev.................................2.21:1
OPERATION
The application of each driving or holding compo-
nent is controlled by the valve body based upon the
manual lever position, throttle pressure, and gover-
nor pressure. The governor pressure is a variable
pressure input to the valve body and is one of the
signals that a shift is necessary. First through fourth
gear are obtained by selectively applying and releas-
ing the different clutches and bands. Engine power is
thereby routed to the various planetary gear assem-
blies which combine with the overrunning clutch
assemblies to generate the different gear ratios. The
torque converter clutch is hydraulically applied and
is released when fluid is vented from the hydraulic
circuit by the torque converter control (TCC) solenoid
on the valve body. The torque converter clutch is con-
trolled by the Powertrain Control Module (PCM). The
torque converter clutch engages in fourth gear, and
in third gear under various conditions, such as when
the O/D switch is OFF, when the vehicle is cruising
on a level surface after the vehicle has warmed up.
The torque converter clutch will disengage momen-
tarily when an increase in engine load is sensed by
the PCM, such as when the vehicle begins to go
uphill or the throttle pressure is increased. The
torque converter clutch feature increases fuel econ-
omy and reduces the transmission fluid temperature.
Since the overdrive clutch is applied in fourth gear
only and the direct clutch is applied in all ranges
except fourth gear, the transmission operation for
park, neutral, and first through third gear will be
described first. Once these powerflows are described,
the third to fourth shift sequence will be described.
1 - CONVERTER CLUTCH 15 - HOUSING
2 - TORQUE CONVERTER 16 - REAR BEARING
3 - OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY 17 - OUTPUT SHAFT
4 - FRONT BAND 18 - SEAL
5 - FRONT CLUTCH 19 - OVERDRIVE OVERRUNNING CLUTCH
6 - DRIVING SHELL 20 - OVERDRIVE PLANETARY GEAR
7 - REAR BAND 21 - DIRECT CLUTCH SPRING
8 - TRANSMISSION OVERRUNNING CLUTCH 22 - OVERDRIVE CLUTCH PISTON
9 - OVERDRIVE UNIT 23 - VALVE BODY ASSEMBLY
10 - PISTON RETAINER 24 - FILTER
11 - OVERDRIVE CLUTCH 25 - FRONT PLANETARY GEAR
12 - DIRECT CLUTCH 26 - REAR CLUTCH
13 - INTERMEDIATE SHAFT 27 - TRANSMISSION
14 - FRONT BEARING 28 - REAR PLANETARY GEAR
Fig. 2 Transmission Part And Serial Number
Location
1 - PART NUMBER
2 - BUILD DATE
3 - SERIAL NUMBER
BR/BEAUTOMATIC TRANSMISSION - 42RE 21 - 137
AUTOMATIC TRANSMISSION - 42RE (Continued)

PARK POWERFLOW
As the engine is running and the crankshaft is
rotating, the flexplate and torque converter, which
are also bolted to it, are all rotating in a clockwise
direction as viewed from the front of the engine. The
notched hub of the torque converter is connected to
the oil pump's internal gear, supplying the transmis-
sion with oil pressure. As the converter turns, it
turns the input shaft in a clockwise direction. As the
input shaft is rotating, the front clutch hub-rear
clutch retainer and all their associated parts are also
rotating, all being directly connected to the input
shaft. The power flow from the engine through the
front clutch hub and rear clutch retainer stops at the
rear clutch retainer. Therefore, no power flow to the
output shaft occurs because no clutches are applied.
The only mechanism in use at this time is the park-
ing sprag (Fig. 3), which locks the parking gear on
the output shaft to the transmission case.
NEUTRAL POWERFLOW
With the gear selector in the NEUTRAL position
(Fig. 4), the power flow of the transmission is essen-
tially the same as in the park position. The only
operational difference is that the parking sprag has
been disengaged, unlocking the output shaft from the
transmission case and allowing it to move freely.
Fig. 3 Park Powerflow
1 - PAWL ENGAGED FOR PARK
2 - PARK SPRAG
3 - OUTPUT SHAFT
Fig. 4 Neutral Powerflow
1 - PAWL DISENGAGED FOR NEUTRAL
2 - PARK SPRAG
3 - OUTPUT SHAFT
4 - CAM
5-PAWL
21 - 138 AUTOMATIC TRANSMISSION - 42REBR/BE
AUTOMATIC TRANSMISSION - 42RE (Continued)

REVERSE POWERFLOW
When the gear selector is moved into the
REVERSE position (Fig. 5), the front clutch and the
rear band are applied. With the application of the
front clutch, engine torque is applied to the sun gear,
turning it in a clockwise direction. The clockwise
rotation of the sun gear causes the rear planet pin-
ions to rotate against engine rotation in a counter-
clockwise direction. The rear band is holding the low
reverse drum, which is splined to the rear carrier.
Since the rear carrier is being held, the torque fromthe planet pinions is transferred to the rear annulus
gear, which is splined to the output shaft. The output
shaft in turn rotates with the annulus gear in a
counterclockwise direction giving a reverse gear out-
put. The entire transmission of torque is applied to
the rear planetary gearset only. Although there is
torque input to the front gearset through the sun
gear, no other member of the gearset is being held.
During the entire reverse stage of operation, the
front planetary gears are in an idling condition.
Fig. 5 Reverse Powerflow
1 - FRONT CLUTCH ENGAGED 5 - OUTPUT SHAFT
2 - OUTPUT SHAFT 6 - INPUT SHAFT
3 - LOW/REVERSE BAND APPLIED 7 - FRONT CLUTCH ENGAGED
4 - INPUT SHAFT 8 - LOW/REVERSE BAND APPLIED
BR/BEAUTOMATIC TRANSMISSION - 42RE 21 - 139
AUTOMATIC TRANSMISSION - 42RE (Continued)