Technical Bulletin #321
Transmission: 41TE (A604) and 42LE
Subject: Parts change
Application: Chrysler
Issue Date: 1996
41TE (A604) and 42LE
Parts Change
A change was made in the overdrive clutch hub area in 1996 and later model 41TE and 42LE transaxles
(figure 1). This change was made to keep the shaft section of the hub assembly from cracking or breaking away
from the hub.
Part changes include:
1. The overdrive clutch hub shaft section outer diameter was increased from 1.142" to 1.162". The bottom of the
splines machined into the end of the shaft no longer have a back cut to prevent the shaft from bottoming out in
the splined planet ID (figure 2).
2. The 2-4 sun gear bushings inside diameter was increased from 1.144" to 1.164" (figure 3).
3. The splines cut into the inside diameter of the front planet (figure 4) have been machined to allow the new
O/D clutch hub splines, which now have no back-cut beneath the splines, to engage fully in the planet.
Copyright © 2003 ATRA. All Rights Reserved. ! Page 1 of 3
Technical Bulletin #321
Interchangeability:
A matched early or late set of all
three parts, including the O/D
clutch hub, 2-4 sun gear hub and
the front planet, will fit in any
41TE or 42LE.
The new O/D clutch hub and 2-4
sun gear hub will not individually
interchange with the previous
version of these parts. The earlier
O/D and 2-4 hubs can be used as
a set with the late front planet, but
are weaker than the new hubs and
may fail in operation. The new,
larger hubs can be used as a set
with the earlier front planet, provided that the new set of hubs pass the Planet spline conflict test described
below.
Planet spline conflict test:
A potential problem can exist when using the newer, larger O/D clutch hub and 2-4 sun gear hub described
above with an older version front planet. The earlier planet splines have not been machined in a manner that will
assure no spline conflict between the O/D clutch hub shaft and the splines inside the front planet. Therefore, a
test must be performed to ensure that a conflict does not exist.
Stack the O/D clutch hub and the 2-4 sun gear together on the bench, including both washers that separate them
in place (figure 5). Make sure that the 2-4 sun gear hub washer tabs go through the appropriate holes in the hub
(figure 6).
! Page 2 of 3 Copyright © 2003 ATRA. All Rights Reserved.
Technical Bulletin #321
Lower the front planet in its normal direction onto the
hub splines (figure seven). Press down on the planet with
one hand while turning the 2-4 sun gear hub. The hub
must be a bit harder to turn when pressing down on the
planet, as opposed to when not pressing down on the
planet.
While pressing on the planet, also make certain that
there is absolutely no up and down end play on the 2-4
sun gear hub. It should be solidly held between the
planet and O/D clutch hub, allowing rotation of the sun
gear hub only. Firmly pick up and lower the planet over
the hub splines several times, making certain that the
planet has absolutely no tendency to stick against the sun
gear hub. A solid thunk should be felt whenever the
planet thrust bearing contacts the end of the 2-4 sun gear,
indicating full contact between the gear and bearing.
Copyright © 2003 ATRA. All Rights Reserved. ! Page 3 of 3
