Dodge Durango (DN). Manual - part 49

parking brake, and leave engine running at curb idle
speed.

(6) Remove funnel, insert dipstick and check fluid

level. If level is low, add fluid to bring level to
MIN mark on dipstick. Check to see if the oil level
is equal on both sides of the dipstick. If one side is
noticably higher than the other, the dipstick has
picked up some oil from the dipstick tube. Allow the
oil to drain down the dipstick tube and re-check.

(7) Drive vehicle until transmission fluid is at nor-

mal operating temperature.

(8) With the engine running at curb idle speed, the

gear selector in NEUTRAL, and the parking brake
applied, check the transmission fluid level.

CAUTION: Do not overfill transmission, fluid foam-
ing and shifting problems can result.

(9) Add fluid to bring level up to MAX arrow

mark.

When fluid level is correct, shut engine off, release

park brake, remove funnel, and install dipstick in fill
tube.

CONVERTER DRAINBACK CHECK VALVE
SERVICE

The converter drainback check valve is located in

the cooler outlet (pressure) line near the radiator
tank. The valve prevents fluid drainback when the
vehicle is parked for lengthy periods. The valve check
ball is spring loaded and has an opening pressure of
approximately 2 psi.

The valve is serviced as an assembly; it is not

repairable. Do not clean the valve if restricted, or
contaminated by sludge, or debris. If the valve fails,
or if a transmission malfunction occurs that gener-
ates significant amounts of sludge and/or clutch par-
ticles

and

metal

shavings,

the

valve

must

replaced.

The valve must be removed whenever the cooler

and lines are reverse flushed. The valve can be flow
tested when necessary. The procedure is exactly the
same as for flow testing a cooler.

If the valve is restricted, installed backwards, or in

the wrong line, it will cause an overheating condition
and possible transmission failure.

CAUTION: The drainback valve is a one-way flow
device. It must be properly oriented in terms of flow
direction for the cooler to function properly. The
valve must be installed in the pressure line. Other-
wise flow will be blocked and would cause an over-
heating condition and eventual transmission failure.

OIL PUMP VOLUME CHECK

Measuring the oil pump output volume will deter-

mine if sufficient oil flow to the transmission oil
cooler exists, and whether or not an internal trans-
mission failure is present.

Verify that the transmission fluid is at the proper

level. Refer to the Fluid Level Check procedure in
this section. If necessary, fill the transmission to the
proper level with Mopar

t ATF+3, type 7176, Auto-

matic Transmission Fluid.

(1) Disconnect the To cooler line at the cooler

inlet and place a collecting container under the dis-
connected line.

CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.

(2) Run the engine at curb idle speed, with the

shift selector in neutral.

(3) If one quart of transmission fluid is collected in

the container in 20 seconds or less, oil pump flow vol-
ume is within acceptable limits. If fluid flow is inter-
mittent, or it takes more than 20 seconds to collect
one quart of fluid, refer to the Hydraulic Pressure
tests in this section for further diagnosis.

(4) Re-connect the To cooler line to the transmis-

sion cooler inlet.

(5) Refill the transmission to proper level.

FLUSHING COOLERS AND TUBES

When a transmission failure has contaminated the

fluid, the oil cooler(s) must be flushed. The torque
converter must also be replaced. This will insure that
metal particles or sludged oil are not later trans-
ferred back into the reconditioned (or replaced) trans-
mission.

The only recommended procedure for flushing cool-

ers and lines is to use Tool 6906A Cooler Flusher.

WARNING: WEAR PROTECTIVE EYEWEAR THAT
MEETS THE REQUIREMENTS OF OSHA AND ANSI
Z87.1–1968. WEAR STANDARD INDUSTRIAL RUB-
BER GLOVES.

KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,

AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
EXTINGUISHER

THE

AREA

WHERE

THE

FLUSHER WILL BE USED.

KEEP THE AREA WELL VENTILATED.
DO NOT LET FLUSHING SOLVENT COME IN CON-

TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
INATION OCCURS, FLUSH EYES WITH WATER FOR
15 TO 20 SECONDS. REMOVE CONTAMINATED
CLOTHING AND WASH AFFECTED SKIN WITH
SOAP AND WATER. SEEK MEDICAL ATTENTION.

21 - 62

42/44RE AUTOMATIC TRANSMISSION

SERVICE PROCEDURES (Continued)

COOLER FLUSH USING TOOL 6906A

(1) Remove cover plate filler plug on Tool 6906A.

Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
Flushing solvents are petroleum based solutions gen-
erally used to clean automatic transmission compo-
nents. DO NOT use solvents containing acids, water,
gasoline, or any other corrosive liquids.

(2) Reinstall filler plug on Tool 6906A.
(3) Verify pump power switch is turned OFF. Con-

nect red alligator clip to positive (+) battery post.
Connect black (-) alligator clip to a good ground.

(4) Disconnect the cooler lines at the transmission.

NOTE: When

flushing

transmission

cooler

and

lines, ALWAYS reverse flush.

NOTE: The converter drainback valve must be
removed and an appropriate replacement hose
installed to bridge the space between the transmis-
sion cooler line and the cooler fitting. Failure to
remove the drainback valve will prevent reverse
flushing the system. A suitable replacement hose
can be found in the adapter kit supplied with the
flushing tool.

(5) Connect the BLUE pressure line to the OUT-

LET (From) cooler line.

(6) Connect the CLEAR return line to the INLET

(To) cooler line

(7) Turn pump ON for two to three minutes to

flush cooler(s) and lines.

(8) Turn pump OFF.
(9) Disconnect CLEAR suction line from reservoir

at cover plate. Disconnect CLEAR return line at
cover plate, and place it in a drain pan.

(10) Turn pump ON for 30 seconds to purge flush-

ing solution from cooler and lines. Turn pump OFF.

(11) Place CLEAR suction line into a one quart

container of Mopar

t ATF Plus 3, type 7176 automatic

transmission fluid.

(12) Turn pump ON until all transmission fluid is

removed from the one quart container and lines. This
purges any residual cleaning solvent from the trans-
mission cooler and lines. Turn pump OFF.

(13) Disconnect alligator clips from battery. Recon-

nect flusher lines to cover plate, and remove flushing
adapters from cooler lines.

ALUMINUM THREAD REPAIR

Damaged or worn threads in the aluminum trans-

mission case and valve body can be repaired by the
use of Heli-Coils, or equivalent. This repair consists
of drilling out the worn-out damaged threads. Then
tap the hole with a special Heli-Coil tap, or equiva-
lent, and installing a Heli-Coil insert, or equivalent,

into the hole. This brings the hole back to its original
thread size.

Heli-Coil, or equivalent, tools and inserts are

readily available from most automotive parts suppli-
ers.

REMOVAL AND INSTALLATION

TRANSMISSION

The overdrive unit can be removed and serviced

separately. It is not necessary to remove the entire
transmission assembly to perform overdrive unit
repairs.

CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo-
nent damage. The converter drive plate, pump
bushing, or oil seal can be damaged if the con-
verter is left attached to the driveplate during
removal.

REMOVAL

(1) Disconnect battery negative cable.
(2) Hoist and support vehicle.
(3) Remove skid plate, if equipped.
(4) Remove skid plate support crossmember, if

equipped.

(5) Disconnect and lower or remove necessary

exhaust components.

(6) Remove starter motor.
(7) Support engine with suitable support stand

and wood block.

(8) Remove bolts attaching engine-to-transmission

brackets to transmission.

(9) Remove bolt and nut attaching each engine-to-

transmission bracket to the motor mounts.

(10) Remove bolts holding the engine-to-transmis-

sion brackets to the front axle, if equipped.

(11) Loosen bolts attaching engine-to-transmission

brackets to each side of the engine block.

(12) Raise engine slightly.
(13) Remove torque converter access cover.
(14) Tighten bolts attaching engine-to-transmis-

sion brackets to each side of the engine block.

(15) Lower engine.
(16) Disconnect fluid cooler lines at transmission.
(17) If transmission is being removed for overhaul,

remove transmission oil pan, drain fluid and reinstall
pan.

(18) Remove fill tube bracket bolts and pull tube

out of transmission. Retain fill tube seal. On 4 x 4
models, it will also be necessary to remove bolt
attaching transfer case vent tube to converter hous-
ing (Fig. 73).

42/44RE AUTOMATIC TRANSMISSION

21 - 63

SERVICE PROCEDURES (Continued)

(19) Rotate crankshaft in clockwise direction until

converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.

(20) Mark propeller shaft and axle companion

flanges for assembly alignment. Then disconnect and
remove propeller shaft.

(21) Disconnect wires from park/neutral position

switch and transmission solenoid.

(22) Disconnect throttle valve cable from transmis-

sion bracket and throttle valve lever.

(23) On 4 x 4 models, disconnect shift rod from

transfer case shift lever. Or remove shift lever from
transfer case and tie rod and lever to chassis compo-
nent with wire.

(24) Raise transmission slightly with service jack

to relieve load on crossmember and supports.

(25) Remove bolts securing rear support and cush-

ion to transmission and crossmember. Raise trans-
mission slightly, slide exhaust hanger arm from
bracket (Fig. 74) and remove rear support.

(26) Remove bolts attaching crossmember to frame

and remove crossmember.

(27) On 4 x 4 models, disconnect vent hose from

transfer case. Then remove transfer case with trans-
mission jack or aid of helper.

(28) Remove all converter housing bolts.
(29) Carefully work transmission and torque con-

verter assembly rearward off engine block dowels.

(30) Lower transmission and remove assembly

from under the vehicle.

INSTALLATION

(1) Check torque converter hub and hub drive

notches for sharp edges burrs, scratches, or nicks.
Polish the hub and notches with 320/400 grit paper
and crocus cloth if necessary. The hub must be
smooth to avoid damaging pump seal at installation.

(2) Lubricate oil pump seal lip with transmission

fluid.

(3) Lubricate converter pilot hub pocket in the rear

of the crankshaft with a light coating of Mopar

t High

Temp Grease.

(4) Align and install converter in oil pump.
(5) Carefully insert converter in oil pump. Then

rotate converter back and forth until fully seated in
pump gears.

(6) Check converter seating with steel scale and

straightedge (Fig. 75). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con-
verter is fully seated.

(7) Temporarily secure converter with wedge tool

or C-clamp.

(8) Position transmission on jack and secure it

with chains.

(9) Check

condition

converter

driveplate.

Replace the plate if cracked, distorted or damaged.
Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
held transmission in alignment.

(10) Raise transmission and align converter with

drive plate and converter housing with engine block.

(11) Move transmission forward. Then raise, lower

or tilt transmission to align converter housing with
engine block dowels.

Fig. 73 Fill Tube Attachment

1 – TRANSFER CASE VENT TUBE
2 – FILL TUBE (V8)
3 – TUBE SEAL
4 – FILL TUBE (V6)

Fig. 74 Rear Support Cushion

1 – EXHAUST PIPE ARM AND BRACKET
2 – CROSSMEMBER
3 – REAR SUPPORT AND CUSHION

21 - 64

42/44RE AUTOMATIC TRANSMISSION

REMOVAL AND INSTALLATION (Continued)

(12) Carefully work transmission forward and over

engine block dowels until converter hub is seated in
crankshaft.

(13) Install bolts attaching converter housing to

engine.

(14) Install rear support. Then lower transmission

onto crossmember and install bolts attaching trans-
mission mount to crossmember.

(15) Install new plastic retainer grommet on any

shift linkage rod or lever that was disconnected.
Grommets should not be reused.

(16) Connect gearshift and throttle cable to trans-

mission.

(17) Connect wires to park/neutral position switch,

transmission solenoid(s) and oxygen sensor. Be sure
transmission harnesses are properly routed.

CAUTION: It is essential that correct length bolts
be used to attach the converter to the driveplate.
Bolts that are too long will damage the clutch sur-
face inside the converter.

(18) Install torque converter-to-driveplate bolts.

Tighten bolts to 31 N·m (270 in. lbs.).

(19) Raise engine slightly.
(20) Loosen bolts attaching engine-to-transmission

brackets to each side of the engine block.

(21) Install converter housing access cover.
(22) Install bolts attaching engine-to-transmission

brackets to transmission.

(23) Tighten bolts attaching engine-to-transmis-

sion brackets to each side of the engine block.

(24) Lower engine.
(25) Install bolt and nut attaching each engine-to-

transmission bracket to the motor mounts.

(26) Remove engine support.
(27) Install bolts to hold engine-to-transmission

brackets to the front axle, if equipped.

(28) Install starter motor and cooler line bracket.
(29) Connect cooler lines to transmission.
(30) Install transmission fill tube. Install new seal

on tube before installation.

(31) Install exhaust components.
(32) Install transfer case, if necessary.
(33) Align and connect propeller shaft(s).
(34) Install rear skid plate, if equipped.
(35) Adjust gearshift linkage and throttle valve

cable if necessary.

(36) Install front skid plate, if equipped.
(37) Lower vehicle.
(38) Fill transmission with Mopar

t ATF Plus 3,

Type 7176 fluid.

TORQUE CONVERTER

REMOVAL

(1) Remove transmission and torque converter

from vehicle.

(2) Place a suitable drain pan under the converter

housing end of the transmission.

CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.

The torque converter is a heavy unit. Use caution

when separating the torque converter from the
transmission.

(3) Pull the torque converter forward until the cen-

ter hub clears the oil pump seal.

(4) Separate the torque converter from the trans-

mission.

INSTALLATION

Check converter hub and drive notches for sharp

edges, burrs, scratches, or nicks. Polish the hub and
notches with 320/400 grit paper or crocus cloth if nec-
essary. The hub must be smooth to avoid damaging
the pump seal at installation.

(1) Lubricate oil pump seal lip with transmission

fluid.

(2) Place torque converter in position on transmis-

sion.

CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.

Fig. 75 Typical Method Of Checking Converter

Seating

1 – SCALE
2 – STRAIGHTEDGE

42/44RE AUTOMATIC TRANSMISSION

21 - 65

REMOVAL AND INSTALLATION (Continued)

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