2003 JEEP GRAND CHEROKEE Workshop Manual

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Page 1617 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual (15) Mount assembled output shaft, annulus gear,
and clutch drum in shop press. Direct clutch spring,
hub and clutch pack are easier to install with assem-
bly mounted in press.
(16) Align splines in

Page 1618 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual Fig. 167 42RE Direct Clutch Pack Components
1 - REACTION PLATE 2 - PRESSURE PLATE
Fig. 168 Correct Position Of Direct Clutch Reaction
Plate
1 - REACTION PLATE COUNTERBORE
2 - DIRECT CLUTCH REACTION PL

Page 1619 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual WARNING: THE NEXT STEP IN GEARTRAIN
ASSEMBLY INVOLVES COMPRESSING THE DIRECT
CLUTCH HUB AND SPRING. IT IS EXTREMELY
IMPORTANT THAT PROPER EQUIPMENT BE USED
TO COMPRESS THE SPRING AS SPRING FORCE IS
AP

WARNING: THE NEXT STEP IN GEARTRAIN
ASSEMBLY INVOLVES COMPRESSING THE DIRECT
CLUTCH HUB AND SPRING. IT IS EXTREMELY
IMPORTANT THAT PROPER EQUIPMENT BE USED
TO COMPRESS THE SPRING AS SPRING FORCE IS
APPROXIMATELY 830 POUNDS. USE COMPRES-
SOR TOOL C-6227-1 AND A HYDRAULIC-TYPE
SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 6
INCHES. THE PRESS MUST ALSO HAVE A BED
THAT CAN BE ADJUSTED UP OR DOWN AS
REQUIRED. RELEASE CLUTCH SPRING TENSION
SLOWLY AND COMPLETELY TO AVOID PERSONAL
INJURY.
(20) Position Compressor Tool 6227-1 on clutch
hub.
(21) Compress clutch hub and spring just enough
to place tension on hub and hold it in place.
(22) Slowly compress clutch hub and spring. Com-
press spring and hub only enough to expose ring
grooves for clutch pack snap ring and clutch hub
retaining ring.
(23) Realign clutch pack on hub and seat clutch
discs and plates in clutch drum.
(24) Install direct clutch pack snap-ring (Fig. 171).
Be very sure snap-ring is fully seated in clutch drum
ring groove.
(25) Install clutch hub retaining ring (Fig. 172). Be
very sure retaining ring is fully seated in sun gear
ring groove.
(26) Slowly release press ram, remove compressor
tools and remove geartrain assembly.
GEAR CASE
(1) Position park pawl and spring in case and
install park pawl shaft. Verify that end of spring
with 90É bend is hooked to pawl and straight end of
spring is seated against case.
(2) Install pawl shaft retaining bolt. Tighten bolt
to 27 N´m (20 ft. lbs.) torque.
(3) Install park lock reaction plug. Note that plug
has locating pin at rear (Fig. 173). Be sure pin is
seated in hole in case before installing snap-ring.
(4) Install reaction plug snap-ring (Fig. 174). Com-
press snap ring only enough for installation; do not
distort it.
Fig. 170 Direct Clutch
1 - CLUTCH HUB
2 - DIRECT CLUTCH PACK
3 - CLUTCH DRUM
Fig. 171 Direct Clutch Pack Snap-Ring Installation
1 - SPECIAL TOOL 6227-1
2 - DIRECT CLUTCH PACK SNAP-RING
Fig. 172 Clutch Hub Retaining Ring Installation
1 - SPECIAL TOOL 6227-1
2 - CLUTCH HUB RETAINING RING
21 - 100 AUTOMATIC TRANSMISSION - 42REWJ
OVERDRIVE UNIT (Continued)

Page 1620 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual (5) Install new seal in gear case. On 4x4 gear case,
use Tool Handle C-4171 and Installer C-3860-A to
seat seal in case. On4x2gear case, use same Han-
dle C-4171 and Installer C-3995-A to seat seal in

Page 1621 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual NOTE: The reaction plate is thinner than the pres-
sure plate in a 42RE transmission.
(5) Install first clutch disc followed by first clutch
plate. Then install remaining clutch discs and plates
in sa

Page 1622 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual OD THRUST PLATE SELECTION
(1) Place overdrive unit in vertical position. Mount
it on blocks, or in workbench with appropriate size
mounting hole cut into it. Be sure unit is facing
upward for access t

Page 1623 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual (3) Leave Alignment Tool 6227-2 in place. Tool will
keep planetary and clutch hub splines in alignment
until overdrive unit is ready for installation on trans-
mission.
(4) Transmission speed sensor c

(3) Leave Alignment Tool 6227-2 in place. Tool will
keep planetary and clutch hub splines in alignment
until overdrive unit is ready for installation on trans-
mission.
(4) Transmission speed sensor can be installed at
this time if desired. However, it is recommended that
sensor not be installed until after overdrive unit is
secured to transmission.
OVERDRIVE PISTON
(1) Install new seals on over drive piston.
(2) Stand transmission case upright on bellhous-
ing.
(3) Position Guide Ring 8114-1 on outer edge of
overdrive piston retainer.
(4) Position Seal Guide 8114-2 on inner edge of
overdrive piston retainer.
(5) Install overdrive piston in overdrive piston
retainer by: aligning locating lugs on overdrive piston
to the two mating holes in retainer.
(a) Aligning locating lugs on overdrive piston to
the two mating holes in retainer.(b) Lubricate overdrive piston seals with Mopart
Door Ease, or equivalent.
(c) Install piston over Seal Guide 8114-2 and
inside Guide Ring 8114-1.
(d) Push overdrive piston into position in
retainer.
(e) Verify that the locating lugs entered the lug
bores in the retainer.
(6) Install intermediate shaft spacer on intermedi-
ate shaft.
(7) Install overdrive piston thrust plate on over-
drive piston.
(8) Install overdrive piston thrust bearing on over-
drive piston.
(9) Install transmission speed sensor and O-ring
seal in overdrive case (Fig. 127).
INSTALLATION
(1) Be sure overdrive unit Alignment Tool 6227-2
is fully seated before moving unit. If tool is not
seated and gear splines rotate out of alignment, over-
drive unit will have to be disassembled in order to
realign splines.
(2) If overdrive piston retainer was not removed
during service and original case gasket is no longer
reusable, prepare new gasket by trimming it.
(3) Cut out old case gasket around piston retainer
with razor knife (Fig. 187).
(4) Use old gasket as template and trim new gas-
ket to fit.
(5) Position new gasket over piston retainer and
on transmission case. Use petroleum jelly to hold
gasket in place if necessary. Do not use any type of
sealer to secure gasket. Use petroleum jelly only.
(6) Install selective spacer on intermediate shaft, if
removed. Spacer goes in groove just rearward of
shaft rear splines (Fig. 188).
(7) Install thrust bearing in overdrive unit sliding
hub. Use petroleum jelly to hold bearing in position.
Fig. 184 Intermediate Shaft End Play Spacer
Selection
Fig. 185 Overdrive Piston Thrust Plate Measurement
1 - SPECIAL TOOL 6311
2 - DIRECT CLUTCH HUB THRUST BEARING SEAT
3 - SPECIAL TOOL C-4962
Fig. 186 Overdrive Piston Thrust Plate Selection
21 - 104 AUTOMATIC TRANSMISSION - 42REWJ
OVERDRIVE UNIT (Continued)

Page 1624 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual CAUTION: Be sure the shoulder on the inside diam-
eter of the bearing is facing forward.
(8) Verify that splines in overdrive planetary gear
and overrunning clutch hub are aligned with Align-
ment Too

CAUTION: Be sure the shoulder on the inside diam-
eter of the bearing is facing forward.
(8) Verify that splines in overdrive planetary gear
and overrunning clutch hub are aligned with Align-
ment Tool 6227-2. Overdrive unit cannot be installed
if splines are not aligned. If splines have rotated out
of alignment, unit will have to be disassembled to
realign splines.
(9) Carefully slide Alignment Tool 6227-2 out of
overdrive planetary gear and overrunning clutch
splines.
(10) Raise overdrive unit and carefully slide it
straight onto intermediate shaft. Insert park rod into
park lock reaction plug at same time. Avoid tilting
overdrive during installation as this could cause
planetary gear and overrunning clutch splines to
rotate out of alignment. If this occurs, it will be nec-essary to remove and disassemble overdrive unit to
realign splines.
(11) Work overdrive unit forward on intermediate
shaft until seated against transmission case.
(12) Install bolts attaching overdrive unit to trans-
mission unit. Tighten bolts in diagonal pattern to 34
N´m (25 ft-lbs).
(13) Connect the transmission speed sensor and
overdrive wiring connectors.
(14) Install the transfer case, if equipped.
(15) Align and install rear propeller shaft, if nec-
essary. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
PROPELLER SHAFT/PROPELLER SHAFT -
INSTALLATION)
OVERRUNNING CLUTCH
CAM/OVERDRIVE PISTON
RETAINER
DESCRIPTION
The overrunning clutch (Fig. 189) consists of an
inner race, an outer race (or cam), rollers and
springs, and the spring retainer. The number of roll-
ers and springs depends on what transmission and
which overrunning clutch is being dealt with.
OPERATION
As the inner race is rotated in a clockwise direction
(as viewed from the front of the transmission), the
race causes the rollers to roll toward the springs,
causing them to compress against their retainer. The
compression of the springs increases the clearance
Fig. 187 Trimming Overdrive Case Gasket
1 - GASKET
2 - SHARP KNIFE
Fig. 188 Intermediate Shaft Selective Spacer
Location
1 - SELECTIVE SPACER
2 - SPACER GROOVE
3 - INTERMEDIATE SHAFT
Fig. 189 Overrunning Clutch
1 - OUTER RACE (CAM)
2 - ROLLER
3 - SPRING
4 - SPRING RETAINER
5 - INNER RACE (HUB)
WJAUTOMATIC TRANSMISSION - 42RE 21 - 105
OVERDRIVE UNIT (Continued)

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