2002 JEEP GRAND CHEROKEE tow

PITMAN SHAFT BEARING
REMOVAL
(1) Clean exposed end of pitman shaft and housing
with a wire brush.
(2) Rotate the stub shaft with a wrench (Fig.
5)from stop to stop and count the number of turns.
(3) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(4) Remove pitman shaft cover bolts and remove
the shaft assembly (Fig. 6).
(5) Remove pitman shaft cover o-ring.
(6) Remove pitman shaft dust seal from the hous-
ing with a Puller 7794-A and Slide Hammer C-637
(Fig. 7).
(7) Remove the pitman shaft oil seal retaining ring
with snap ring pliers (Fig. 8).
(8) Remove oil seal metal backup washer then
plastic backup washer from the housing (Fig. 12).
(9)
Remove pitman shaft oil seal from the housing
with a Puller 7794-A and Slide Hammer C-637 (Fig. 7).
(10) Drop Driver 8277 through the top bearing and
align the driver up with the lower bearing. (Fig. 9).
Install Handle C-4171 into the driver and remove the
lower bearing.
(11) Turn the gear over and remover the upper
bearing with Driver 8277 and Handle C-4171.
INSTALLATION
(1) Install upper pitman shaft bearing, with Driver
8294 and Handle C-4171 (Fig. 10). Drive bearing into
housing until the driver bottoms out.NOTE: Install upper pitman shaft bearing with the
part number/letters facing the driver.
(2) Install lower pitman shaft bearing with the
other side Driver 8294 and Handle C-4171 (Fig. 11).
Drive bearing into housing until the bearing shoulder
is seated against the housing.
(3) Coat the oil seal and backup washers withspe-
cial greasesupplied with the new seal.
(4) Install the oil seal with Driver 8294 and Han-
dle C-4171.
(5) Install plastic backup washer.
NOTE: The plastic backup washer has a lip on the
inside diameter that faces down towards the oil
seal.
(6) Install metal backup washer.
(7) Install the retainer ring with snap ring pliers.
(8) Coat the dust seal withspecial greasesup-
plied with the new seal.
(9) Install dust seal with Driver 8294 and Handle
C-4171.
(10) Install new pitman shaft cover o-ring.
(11) Install pitman shaft assembly into the hous-
ing.
(12) Install cover bolts and tighten to 62 N´m (46
ft. lbs.).
(13) Perform over-center rotation torque adjust-
ment.
PITMAN SHAFT SEAL
REMOVAL
(1) Clean exposed end of pitman shaft and housing
with a wire brush.
(2) Rotate the stub shaft with a wrench (Fig.
5)from stop to stop and count the number of turns.
(3) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(4) Remove pitman shaft cover bolts and remove
the shaft assembly (Fig. 6).
(5) Remove pitman shaft cover o-ring.
(6) Remove pitman shaft dust seal from the hous-
ing with a Puller 7794-A and Slide Hammer C-637
(Fig. 7).
(7) Remove the pitman shaft oil seal retaining ring
with snap ring pliers (Fig. 8).
(8) Remove oil seal metal backup washer then
plastic backup washer from the housing (Fig. 12).
Fig. 12 Backup Washers
1 - METAL BACK UP WASHER
2 - PLASTIC BACK UP WASHER
19 - 22 GEARWJ

(9) Remove pitman shaft oil seal from the housing
with a Puller 7794-A and Slide Hammer C-637 (Fig.
7).
(10) Drop Driver 8277 through the top bearing and
align the driver up with the lower bearing. (Fig. 9).
Install Handle C-4171 into the driver and remove the
lower bearing.
(11) Turn the gear over and remover the upper
bearing with Driver 8277 and Handle C-4171.
INSTALLATION
(1) Install upper pitman shaft bearing, with Driver
8294 and Handle C-4171 (Fig. 10). Drive bearing into
housing until the driver bottoms out.
NOTE: Install upper pitman shaft bearing with the
part number/letters facing the driver.
(2) Install lower pitman shaft bearing with the
other side Driver 8294 and Handle C-4171 (Fig. 11).
Drive bearing into housing until the bearing shoulder
is seated against the housing.
(3) Coat the oil seal and backup washers withspe-
cial greasesupplied with the new seal.
(4) Install the oil seal with Driver 8294 and Han-
dle C-4171.
(5) Install plastic backup washer.
NOTE: The plastic backup washer has a lip on the
inside diameter that faces down towards the oil
seal.
(6) Install metal backup washer.
(7) Install the retainer ring with snap ring pliers.
(8) Coat the dust seal withspecial greasesup-
plied with the new seal.
(9) Install dust seal with Driver 8294 and Handle
C-4171.
(10) Install new pitman shaft cover o-ring.
(11) Install pitman shaft assembly into the hous-
ing.
(12) Install cover bolts and tighten to 62 N´m (46
ft. lbs.).
(13) Perform over-center rotation torque adjust-
ment.
RACK PISTON/VALVE
ASSEMBLY
REMOVAL
(1) Remove the steering gear (Refer to 19 -
STEERING/GEAR - REMOVAL).
(2) Clean exposed end of pitman shaft and housing
with a wire brush.
(3) Rotate the stub shaft with a wrench (Fig.
5)from stop to stop and count the number of turns.(4) Center the stub shaft by rotating it from the
stop 1/2 of the total amount of turns.
NOTE: The pitman shaft will not clear the housing if
it is not centered.
(5) Remove pitman shaft cover bolts and remove
the shaft assembly (Fig. 6).
(6) Remove the pitman shaft cover o-ring.
(7) Remove stub shaft housing bolts (Fig. 13).
(8) Remove the housing from the stub shaft (Fig.
14).
Fig. 13 Stub Shaft Housing
1 - STUB SHAFT HOUSING
2 - BOLTS
3 - STUB SHAFT
Fig. 14 Housing Removal
1 - STEERING GEAR
2 - STUB SHAFT HOUSING
WJGEAR 19 - 23
PITMAN SHAFT SEAL (Continued)

(36) Compress rear servo spring retainer about
1/16 inch with Valve Spring Compressor C-3422-B
(Fig. 38).
(37) Remove rear servo spring retainer snap-ring.
Then remove compressor tools and remove rear servo
spring and piston.
(38) Inspect transmission components.
NOTE: To Service the overrunning clutch cam or
overdrive piston retainer, refer to the Overrunning
Clutch Cam service procedure in this section.
CLEANING
Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent.
Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
that all fluid passages are clear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.Lubricate transmission parts with MopartATF +4,
type 9602, transmission fluid during overhaul and
assembly. Use petroleum jelly, MopartDoor Ease, or
Ru-GlydeŸ to prelubricate seals, O-rings, and thrust
washers. Petroleum jelly can also be used to hold
parts in place during reassembly.
INSPECTION
Inspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repaired with Helicoil thread inserts. However, the
case will have to be replaced if it exhibits any type of
damage or wear.
Lubricate the front band adjusting screw threads
with petroleum jelly and thread the screw part-way
into the case. Be sure the screw turns freely.
Inspect the transmission bushings during overhaul.
Bushing condition is important as worn, scored bush-
ings contribute to low pressures, clutch slip and
accelerated wear of other components. However, do
not replace bushings as a matter of course. Replace
bushings only when they are actually worn, or
scored.
Use recommended tools to replace bushings. The
tools are sized and designed to remove, install, and
seat bushings correctly. The bushing replacement
tools are included in Bushing Tool Set C-3887-B.
Pre-sized service bushings are available for
replacement purposes. Only the sun gear bushings
are not serviced.
The use of crocus cloth is permissible where neces-
sary, providing it is used carefully. When used on
shafts, or valves, use extreme care to avoid rounding
off sharp edges. Sharp edges are vital as they pre-
vent foreign matter from getting between the valve
and valve bore.
Do not reuse oil seals, gaskets, seal rings, or
O-rings during overhaul. Replace these parts as a
matter of course. Also do not reuse snap rings or
E-clips that are bent or distorted. Replace these parts
as well.
ASSEMBLY
Do not allow dirt, grease, or foreign material to
enter the case or transmission components during
assembly. Keep the transmission case and compo-
nents clean. Also make sure the tools and workbench
area used for assembly operations are equally clean.
Shop towels used for wiping off tools and hands
must be made fromlint freematerial. Lint will stick
to transmission parts and could interfere with valve
operation, or even restrict fluid passages.
Lubricate the transmission components with
Moparttransmission fluid during reassembly. Use
MopartDoor Ease, or Ru-GlydeŸ on seals and
O-rings to ease installation.
Fig. 38 Compressing Rear Servo Spring
1 - FRONT SERVO SNAP-RING
2 - REAR SERVO SNAP-RING
3 - SPECIAL TOOL
21 - 34 AUTOMATIC TRANSMISSION - 42REWJ
AUTOMATIC TRANSMISSION - 42RE (Continued)

(10) Install thrust plate on intermediate shaft hub
(Fig. 47). Use petroleum jelly to hold thrust plate in
place.
(11) Check seal ring on rear clutch retainer hub
and seal rings on input shaft (Fig. 48). Also verify
that shaft seal rings are installed in sequence shown.
(12) Install rear clutch thrust washer (Fig. 49).
Use additional petroleum jelly to hold washer in
place if necessary.
(13) Align clutch discs in front clutch and install
front clutch on rear clutch (Fig. 50). Rotate front
clutch retainer back and forth until completely
seated on rear clutch retainer.
(14) Coat intermediate shaft thrust washer with
petroleum jelly. Then install washer in rear clutch
hub (Fig. 51). Use enough petroleum jelly to hold
washer in place. Be sure grooved side of washer faces
rearward (toward output shaft) as shown. Also note
that washer only fits one way in clutch hub. Note
thickness of this washer. It is a select fit part and is
used to control transmission end play.
Fig. 46 Installing Planetary Geartrain
1 - PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT
ASSEMBLY
Fig. 47 Installing Intermediate Shaft Thrust Plate
1 - INTERMEDIATE SHAFT HUB
2 - INTERMEDIATE SHAFT THRUST PLATE
Fig. 48 Input Shaft Seal Ring Location
1 - INPUT SHAFT
2 - TEFLON SEAL RING
3 - PLASTIC SEAL RING
4 - REAR CLUTCH RETAINER
Fig. 49 Installing Rear Clutch Thrust Washer
1 - REAR CLUTCH RETAINER
2 - REAR CLUTCH THRUST WASHER (FIBER)
WJAUTOMATIC TRANSMISSION - 42RE 21 - 37
AUTOMATIC TRANSMISSION - 42RE (Continued)

(1) A result of restricted fluid flow through the
main and/or auxiliary cooler. This condition is usu-
ally the result of a faulty or improperly installed
drainback valve, a damaged main cooler, or severe
restrictions in the coolers and lines caused by debris
or kinked lines.
(2) Heavy duty operation with a vehicle not prop-
erly equipped for this type of operation. Trailer tow-
ing or similar high load operation will overheat the
transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary
transmission fluid cooler, a heavy duty cooling sys-
tem, and the engine/axle ratio combination needed to
handle heavy loads.
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION
Transmission fluid contamination is generally a
result of:
²adding incorrect fluid
²failure to clean dipstick and fill tube when
checking level
²engine coolant entering the fluid
²internal failure that generates debris
²overheat that generates sludge (fluid break-
down)
²failure to reverse flush cooler and lines after
repair
²failure to replace contaminated converter after
repair
The use of non-recommended fluids can result in
transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and eventual failure
due to fluid breakdown and sludge formation. Avoid
this condition by using recommended fluids only.
The dipstick cap and fill tube should be wiped
clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall
into the tube if not removed beforehand. Take the
time to wipe the cap and tube clean before withdraw-
ing the dipstick.
Engine coolant in the transmission fluid is gener-
ally caused by a cooler malfunction. The only remedy
is to replace the radiator as the cooler in the radiator
is not a serviceable part. If coolant has circulated
through the transmission, an overhaul is necessary.
The transmission cooler and lines should be
reverse flushed whenever a malfunction generates
sludge and/or debris. The torque converter should
also be replaced at the same time.
Failure to flush the cooler and lines will result in
recontamination. Flushing applies to auxiliary coolers
as well. The torque converter should also be replaced
whenever a failure generates sludge and debris. This
is necessary because normal converter flushing proce-
dures will not remove all contaminants.
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transmssion has too much fluid, the
geartrain churns up foam and cause the same condi-
tions which occur with a low fluid level.
In either case, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transmission vent where it may be mis-
taken for a leak.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
The transmission has a dipstick to check oil level.
It is located on the right side of the engine. Be sure
to wipe all dirt from dipstick handle before removing.
Fluid level is checked with the engine running at
curb idle speed, the transmission in NEUTRAL and
the transmission fluid at normal operating tempera-
ture.The engine should be running at idle
speed for at least one minute, with the vehicle
on level ground.
The transmission fluid level can be checked two
ways.
PROCEDURE ONE
(1) Transmission fluid must be at normal operat-
ing temperature for accurate fluid level check. Drive
vehicle if necessary to bring fluid temperature up to
normal hot operating temperature of 82ÉC (180ÉF).
(2) Position vehicle on level surface.
(3) Start and run engine at curb idle speed.
(4) Apply parking brakes.
(5) Shift transmission momentarily into all gear
ranges. Then shift transmission back to NEUTRAL.
(6) Clean top of filler tube and dipstick to keep
dirt from entering tube.
(7) Remove dipstick (Fig. 87) and check fluid level
as follows:
(a) Correct acceptable level is in crosshatch area.
(b) Correct maximum level is to MAX arrow
mark.
(c) Incorrect level is at or below MIN line.
(d) If fluid is low, add only enough MopartAT F
+4, type 9602, to restore correct level. Do not over-
fill.
21 - 70 AUTOMATIC TRANSMISSION - 42REWJ
FLUID AND FILTER (Continued)

(12) Install new oil seal in pump with Special Tool
C-4193 and Tool Handle C-4171 (Fig. 122). Be sure
seal lip faces inward.
(13) Install new seal ring around pump housing.
Be sure seal is properly seated in groove.
(14) Lubricate lip of pump oil seal and O-ring seal
with transmission fluid.
OUTPUT SHAFT FRONT
BEARING
REMOVAL
(1) Remove overdrive unit from the vehicle.
(2) Remove overdrive geartrain from housing.
(3) Remove snap-ring holding output shaft front
bearing to overdrive geartrain. (Fig. 123).
(4) Pull bearing from output shaft.
INSTALLATION
(1) Place replacement bearing in position on
geartrain with locating retainer groove toward the
rear.
(2) Push bearing onto shaft until the snap-ring
groove is visible.
(3) Install snap-ring to hold bearing onto output
shaft.
(4) Install overdrive geartrain into housing.
(5) Install overdrive unit in vehicle.
OUTPUT SHAFT REAR
BEARING
REMOVAL
(1) Remove overdrive unit from the vehicle. (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC/
OVERDRIVE - REMOVAL)
(2) Remove overdrive geartrain from housing.
(3) Remove snap-ring holding output shaft rear
bearing into overdrive housing (Fig. 124).
(4) Using a suitable driver inserted through the
rear end of housing, drive bearing from housing.
INSTALLATION
(1) Place replacement bearing in position in hous-
ing.
(2) Using a suitable driver, drive bearing into
housing until the snap-ring groove is visible.
(3) Install snap-ring to hold bearing into housing
(Fig. 124).
(4) Install overdrive geartrain into housing.
(5) Install overdrive unit in vehicle.
Fig. 122 Pump Oil Seal Installation
1 - PUMP BODY
2 - PUMP SEAL
3 - SPECIAL TOOL C-4193
Fig. 123 Output Shaft Front Bearing
1 - OUTPUT SHAFT FRONT BEARING
2 - SNAP-RING
3 - OUTPUT SHAFT
4 - GROOVE TO REAR
5 - OVERDRIVE GEARTRAIN
Fig. 124 Output Shaft Rear Bearing
1 - OUTPUT SHAFT REAR BEARING
2 - OVERDRIVE HOUSING
3 - SNAP-RING
WJAUTOMATIC TRANSMISSION - 42RE 21 - 85
OIL PUMP (Continued)

GEAR CASE AND PARK LOCK
(1) Remove locating ring from gear case.
(2) Remove park pawl shaft retaining bolt and
remove shaft, pawl and spring.
(3) Remove reaction plug snap-ring and remove
reaction plug.
(4) Remove output shaft seal.
CLEANING
Clean the geartrain and case components with sol-
vent. Dry all parts except the bearings with com-
pressed air. Allow bearings to air dry.
Do not use shop towels for wiping parts dry unless
the towels are made from a lint-free material. A suf-
ficient quantity of lint (from shop towels, cloths, rags,
etc.) could plug the transmission filter and fluid pas-
sages.
Discard the old case gasket and seals. Do not
attempt to salvage these parts. They are not reus-
able. Replace any of the overdrive unit snap-rings if
distorted or damaged.
Minor nicks or scratches on components can be
smoothed with crocus cloth. However, do not attempt
to reduce severe scoring on any components with
abrasive materials. Replace severely scored compo-
nents; do not try to salvage them.
INSPECTION
Check condition of the park lock components and
the overdrive case.
Check the bushings in the overdrive case. Replace
the bushings if severely scored or worn. Also replace
the case seal if loose, distorted, or damaged.
Examine the overdrive and direct clutch discs and
plates. Replace the discs if the facing is worn,
severely scored, or burned and flaking off. Replace
the clutch plates if worn, heavily scored, or cracked.
Check the lugs on the clutch plates for wear. The
plates should slide freely in the drum. Replace the
plates or drum if binding occurs.
Check condition of the annulus gear, direct clutch
hub, clutch drum and clutch spring. Replace the gear,
hub and drum if worn or damaged. Replace the
spring if collapsed, distorted, or cracked.
Be sure the splines and lugs on the gear, drum and
hub are in good condition. The clutch plates and
discs should slide freely in these components.
Inspect the thrust bearings and spring plate.
Replace the plate if worn or scored. Replace the bear-
ings if rough, noisy, brinnelled, or worn.
Inspect the planetary gear assembly and the sun
gear and bushings. If either the sun gear or the
bushings are damaged, replace the gear and bush-
ings as an assembly. The gear and bushings are not
serviced separately.The planetary carrier and pinions must be in good
condition. Also be sure the pinion pins are secure and
in good condition. Replace the carrier if worn or dam-
aged.
Inspect the overrunning clutch and race. The race
surface should be smooth and free of scores. Replace
the overrunning clutch assembly or the race if either
assembly is worn or damaged in any way.
Replace the shaft pilot bushing and inner bushing
if damaged. Replace either shaft bearing if rough or
noisy. Replace the bearing snap-rings if distorted or
cracked.
Check the machined surfaces on the output shaft.
These surfaces should clean and smooth. Very minor
nicks or scratches can be smoothed with crocus cloth.
Replace the shaft if worn, scored or damaged in any
way.
Inspect the output shaft bushings. The small bush-
ing is the intermediate shaft pilot bushing. The large
bushing is the overrunning clutch hub bushing.
Replace either bushing if scored, pitted, cracked, or
worn.
ASSEMBLY
GEARTRAIN AND DIRECT CLUTCH
(1) Soak direct clutch and overdrive clutch discs in
MopartATF +4, type 9602, transmission fluid. Allow
discs to soak for 10-20 minutes.
(2) Install new pilot bushing and clutch hub bush-
ing in output shaft if necessary (Fig. 155). Lubricate
bushings with petroleum jelly, or transmission fluid.
(3) Install annulus gear on output shaft, if
removed. Then install annulus gear retaining snap-
ring (Fig. 156).
Fig. 155 Output Shaft Pilot Bushing
1 - OUTPUT SHAFT HUB
2 - OVERRUNNING CLUTCH HUB BUSHING
3 - INTERMEDIATE SHAFT PILOT BUSHING
WJAUTOMATIC TRANSMISSION - 42RE 21 - 95
OVERDRIVE UNIT (Continued)

(4) Align and install clutch drum on annulus gear
(Fig. 157). Be sure drum is engaged in annulus gear
lugs.
(5) Install clutch drum outer retaining ring (Fig.
157).
(6) Slide clutch drum forward and install inner
retaining ring (Fig. 158).
(7) Install rear bearing and snap-ring on output
shaft (Fig. 159). Be sure locating ring groove in bear-
ing is toward rear.(8) Install overrunning clutch on hub (Fig. 160).
Note that clutch only fits one-way. Shoulder on clutch
should seat in small recess at edge of hub.
(9) Install thrust bearing on overrunning clutch
hub. Use generous amount of petroleum jelly to hold
bearing in place for installation. Bearing fits one-way
only. Be sure bearing is seated squarely against hub.
Reinstall bearing if it does not seat squarely.
(10) Install overrunning clutch in output shaft
(Fig. 161). Insert snap-ring pliers in hub splines.
Expand pliers to grip hub. Then install assembly
with counterclockwise, twisting motion.
(11) Install planetary gear in annulus gear (Fig.
162). Be sure planetary pinions are fully seated in
annulus gear before proceeding.
(12) Coat planetary thrust bearing and bearing
contact surface of spring plate with generous amount
of petroleum jelly. This will help hold bearing in
place during installation.
Fig. 156 Annulus Gear Installation
1 - SNAP-RING
2 - OUTPUT SHAFT FRONT BEARING
3 - ANNULUS GEAR
Fig. 157 Clutch Drum And Outer Retaining Ring
Installation
1 - ANNULUS GEAR
2 - OUTER SNAP-RING
3 - CLUTCH DRUM
Fig. 158 Clutch Drum Inner Retaining Ring
Installation
1 - ANNULUS GEAR
2 - INNER SNAP-RING
3 - CLUTCH DRUM
Fig. 159 Rear Bearing And Snap-Ring Installation
1 - REAR BEARING
2 - SNAP-RING
21 - 96 AUTOMATIC TRANSMISSION - 42REWJ
OVERDRIVE UNIT (Continued)