2003 JEEP GRAND CHEROKEE hub bearing

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 SPRING FORCE IS APPROXI-
MATELY 830 POUNDS. USE SPRING COMPRESSOR
TOOL 6227-1 AND A HYDRAULIC SHOP PRESS
WITH A MINIMUM RAM TRAVEL OF 5-6 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.(1) Mount geartrain assembly in shop press (Fig.
142).
(2) Position Compressor Tool 6227-1 on clutch hub
(Fig. 142). Support output shaft flange with steel
press plates as shown and center assembly under
press ram.
(3) Apply press pressure slowly. Compress hub and
spring far enough to expose clutch hub retaining ring
and relieve spring pressure on clutch pack snap-ring
(Fig. 142).
(4) Remove direct clutch pack snap-ring (Fig. 143).
(5) Remove direct clutch hub retaining ring (Fig.
144).
(6) Release press load slowly and completely (Fig.
145).
(7) Remove Special Tool 6227-1. Then remove
clutch pack from hub (Fig. 145).
GEARTRAIN
(1) Remove direct clutch hub and spring (Fig. 146).
Fig. 140 Removing Gear Case From Geartrain
Assembly
1 - GEARTRAIN ASSEMBLY
2 - GEAR CASE
Fig. 141 Rear Bearing Removal
1 - OUTPUT SHAFT
2 - REAR BEARING
3 - SNAP-RING
Fig. 142 Geartrain Mounted In Shop Press
1 - PRESS RAM
2 - SPECIAL TOOL C-3995-A (OR SIMILAR TOOL)
3 - CLUTCH HUB
4 - PLATES
5 - PRESS BED
6 - SPECIAL TOOL 6227-1
WJAUTOMATIC TRANSMISSION - 42RE 21 - 91
OVERDRIVE UNIT (Continued)

(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 pli-
ers into clutch hub. Expand pliers to grip hub splines
and remove clutch with counterclockwise, twisting
motion.
(4) Remove thrust bearing from overrunning
clutch hub.
Fig. 143 Direct Clutch Pack Snap-Ring Removal
1 - CLUTCH HUB
2 - SPECIAL TOOL 6227-1
3 - DIRECT CLUTCH PACK SNAP-RING
4 - PRESS PLATES
5 - CLUTCH DRUM
Fig. 144 Direct Clutch Hub Retaining Ring Removal
1 - SPECIAL TOOL 6227-1
2 - CLUTCH HUB RETAINING RING
3 - PRESS BED
4 - PRESS PLATES
Fig. 145 Direct Clutch Pack Removal
1 - SPECIAL TOOL 6227-1
2 - DIRECT CLUTCH HUB
3 - DIRECT CLUTCH PACK
Fig. 146 Direct Clutch Hub And Spring Removal
1 - DIRECT CLUTCH SPRING
2 - DIRECT CLUTCH HUB
21 - 92 AUTOMATIC TRANSMISSION - 42REWJ
OVERDRIVE UNIT (Continued)

(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.(7) Remove direct clutch drum rear retaining ring
(Fig. 150).
(8) Remove direct clutch drum outer retaining ring
(Fig. 151).
(9) Mark annulus gear and output shaft for assem-
bly alignment reference (Fig. 152). Use punch or
scriber to mark gear and shaft.
Fig. 147 Removing Sun Gear, Thrust Bearing And
Planetary Gear
1 - PLANETARY GEAR
2 - PLANETARY THRUST BEARING
3 - CLUTCH SPRING PLATE
4 - SPRING PLATE SNAP-RING
5 - SUN GEAR
Fig. 148 Overrunning Clutch
1 - OVERRUNNING CLUTCH
2 - NEEDLE BEARING
Fig. 149 Marking Direct Clutch Drum And Annulus
Gear For Assembly Alignment
1 - DIRECT CLUTCH DRUM
2 - HAMMER
3 - PUNCH
Fig. 150 Clutch Drum Inner Retaining Ring Removal
1 - INNER RETAINING RING
2 - DIRECT CLUTCH DRUM
3 - ANNULUS GEAR
WJAUTOMATIC TRANSMISSION - 42RE 21 - 93
OVERDRIVE UNIT (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)

(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 plate, remove
and reposition bearing.
(14) Install assembled sun gear, spring plate and
thrust bearing (Fig. 164). Be sure sun gear and
thrust bearing are fully seated before proceeding.
Fig. 160 Assembling Overrunning Clutch And Hub
1 - CLUTCH HUB
2 - OVERRUNNING CLUTCH
Fig. 161 Overrunning Clutch Installation
1 - CLUTCH DRUM
2 - OVERRUNNING CLUTCH ASSEMBLY
3 - EXPANDING-TYPE SNAP-RING PLIERS
4 - CLUTCH DRUM
5 - ANNULUS GEAR
6 - OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT
SHAFT
Fig. 162 Planetary Gear Installation
1 - PLANETARY GEAR
2 - ANNULUS GEAR
Fig. 163 Planetary Thrust Bearing Installation
1 - SPRING PLATE
2 - PLANETARY THRUST BEARING
3 - SUN GEAR
WJAUTOMATIC TRANSMISSION - 42RE 21 - 97
OVERDRIVE UNIT (Continued)

(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
case.
(6) Verify that tab ends of rear bearing locating
ring extend into access hole in gear case (Fig. 175).
(7) Support geartrain on Tool 6227-1 (Fig. 176). Be
sure tool is securely seated in clutch hub.
(8) Install overdrive gear case on geartrain (Fig.
176).
(9) Expand front bearing locating ring with snap-
ring pliers (Fig. 177). Then slide case downward until
locating ring locks in bearing groove and release
snap-ring.
(10) Install locating ring access cover and gasket
in overdrive unit case (Fig. 178).
OVERDRIVE CLUTCH
(1) Install overdrive clutch reaction ring first.
Reaction ring is flat with notched ends (Fig. 179).
(2) Install wave spring on top of reaction ring (Fig.
180). Reaction ring and wave ring both fit in same
ring groove. Use screwdriver to seat each ring
securely in groove. Also ensure that the ends of the
two rings are offset from each other.
NOTE: The 42RE transmission has 3 overdrive
clutch discs and 2 plates.
(3) Assemble overdrive clutch pack (Fig. 181).
(4) Install overdrive clutch reaction plate first.
Fig. 173 Reaction Plug Locating Pin And Snap-Ring
1 - REACTION PLUG SNAP-RING (DO NOT OVERCOMPRESS
TO INSTALL)
2 - LOCATING PIN
3 - PARK LOCK REACTION PLUG
Fig. 174 Reaction Plug And Snap-Ring Installation
1 - REACTION PLUG SNAP-RING
2 - SNAP-RING PLIERS
Fig. 175 Correct Rear Bearing Locating Ring
Position
1 - CASE ACCESS HOLE
2 - TAB ENDS OF LOCATING RING
Fig. 176 Overdrive Gear Case Installation
1 - GEARTRAIN ASSEMBLY
2 - GEAR CASE
WJAUTOMATIC TRANSMISSION - 42RE 21 - 101
OVERDRIVE UNIT (Continued)

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 same order.
(6) Install clutch pack pressure plate.
(7) Install clutch pack wire-type retaining ring
(Fig. 182).
INTERMEDIATE SHAFT SPACER 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 to direct clutch hub. Also be sure
output shaft is not loaded and internal components
are moved rearward for accurate measurement.
(2) Determine correct thickness intermediate shaft
spacer as follows:
(a) Insert Special Tool 6312 through sun gear,
planetary gear and into pilot bushing in output
shaft. Be sure tool bottoms against planetary
shoulder.
(b) Position Gauge Tool 6311 across face of over-
drive case (Fig. 183). Then position Dial Caliper
C-4962 over gauge tool.
(c) Extend sliding scale of dial caliper downward
through gauge tool slot until scale contacts end of
Gauge Alignment Tool 6312. Lock scale in place.
Remove dial caliper tool and note distance mea-
sured (Fig. 183).
(d) Select proper thickness end play spacer from
spacer chart based on distance measured (Fig.
184).
(e) Remove Gauge Alignment Tool 6312.
Fig. 177 Seating Locating Ring In Rear Bearing
1 - EXPAND BEARING LOCATING RING WITH SNAP-RING
PLIERS
2 - ACCESS HOLE
Fig. 178 Locating Ring Access Cover And Gasket
Installation
1 - TORX SCREWDRIVER (T25)
2 - ACCESS COVER SCREWS
Fig. 179 Overdrive Clutch Reaction Ring Installation
1 - REACTION RING
2 - CLUTCH HUB
Fig. 180 Overdrive Clutch Wave Spring Installation
1 - WAVE SPRING
21 - 102 AUTOMATIC TRANSMISSION - 42REWJ
OVERDRIVE UNIT (Continued)