2002 JEEP GRAND CHEROKEE Workshop Manual

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Page 1609 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual OVERDRIVE GEARTRAIN
(1) Remove overdrive clutch wave spring (Fig.
135).
(2) Remove overdrive clutch reaction snap-ring
(Fig. 136). Note that snap-ring is located in same
groove as wave spring.
(3) Rem

Page 1610 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual DIRECT CLUTCH, HUB AND SPRING
WARNING: THE NEXT STEP IN DISASSEMBLY
INVOLVES COMPRESSING THE DIRECT CLUTCH
SPRING. IT IS EXTREMELY IMPORTANT THAT
PROPER EQUIPMENT BE USED TO COMPRESS
THE SPRING AS SPR

Page 1611 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual (2) Remove sun gear and spring plate. Then
remove planetary thrust bearing and planetary gear
(Fig. 147).
(3) Remove overrunning clutch assembly with
expanding type snap-ring pliers (Fig. 148). Insert

Page 1612 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual (5) Remove overrunning clutch from hub.
(6) Mark position of annulus gear and direct clutch
drum for assembly alignment reference (Fig. 149).
Use small center punch or scriber to make alignment
marks.

Page 1613 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual (10) Remove snap-ring that secures annulus gear
on output shaft (Fig. 153). Use two screwdrivers to
unseat and work snap-ring out of groove as shown.(11) Remove annulus gear from output shaft (Fig.
15

Page 1614 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual 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 plu

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)

Page 1615 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual (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 i

Page 1616 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual (13) Install planetary thrust bearing on sun gear
(Fig. 163). Slide bearing onto gear and seat it against
spring plate as shown. Bearing fits one-way only. If it
does not seat squarely against spring

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