2003 JEEP GRAND CHEROKEE Prop

(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)

DIAGNOSIS AND TESTING - OVERDRIVE
ELECTRICAL CONTROLS
The overdrive off switch, valve body solenoid, case
connectors and related wiring can all be tested with
a 12 volt test lamp or a volt/ohmmeter. Check conti-
nuity of each component when diagnosis indicates
this is necessary.
Switch and solenoid continuity should be checked
whenever the transmission fails to shift into fourth
gear range.
OVERDRIVE UNIT
REMOVAL
(1) Shift transmission into PARK.
(2) Raise vehicle.
(3) Remove transfer case, if equipped.
(4) Mark propeller shaft universal joint(s) and axle
pinion yoke, or the companion flange and flange
yoke, for alignment reference at installation, if necc-
esary.
(5) Disconnect and remove the rear propeller shaft,
if necessary. (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(6) Remove transmission oil pan, remove gasket,
drain oil and reinstall pan.
(7) If overdrive unit had malfunctioned, or if fluid
is contaminated, remove entire transmission. If diag-
nosis indicated overdrive problems only, remove just
the overdrive unit.
(8) Support transmission with transmission jack.
(9) Remove bolts attaching overdrive unit to trans-
mission (Fig. 126).
CAUTION: Support the overdrive unit with a jack
before moving it rearward. This is necessary to pre-
vent damaging the intermediate shaft. Do not allow
the shaft to support the entire weight of the over-
drive unit.(10) Carefully work overdrive unit off intermediate
shaft. Do not tilt unit during removal. Keep it as
level as possible.
(11) If overdrive unit does not require service,
immediately insert Alignment Tool 6227-2 in splines
of planetary gear and overrunning clutch to prevent
splines from rotating out of alignment. If misalign-
ment occurs, overdrive unit will have to be disassem-
bled in order to realign splines.
(12) Remove and retain overdrive piston thrust
bearing. Bearing may remain on piston or in clutch
hub during removal.
(13) Position drain pan on workbench.
(14) Place overdrive unit over drain pan. Tilt unit
to drain residual fluid from case.
(15) Examine fluid for clutch material or metal
fragments. If fluid contains these items, overhaul will
be necessary.
(16) If overdrive unit does not require any service,
leave alignment tool in position. Tool will prevent
accidental misalignment of planetary gear and over-
running clutch splines.Fig. 126 Overdrive Unit Bolts
1 - OVERDRIVE UNIT
2 - ATTACHING BOLTS (7)
WJAUTOMATIC TRANSMISSION - 42RE 21 - 87
OVERDRIVE OFF SWITCH (Continued)

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)

(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 hubs of planetary gear and
overrunning clutch with Alignment tool 6227-2 (Fig.
165). Insert tool through sun gear and into splines of
both hubs. Be sure alignment tool is fully seated
before proceeding.
(17) Install direct clutch spring (Fig. 166). Be sure
spring is properly seated on spring plate.
NOTE: The 42RE transmission has 6 direct clutch
discs and 5 clutch plates.
(18) Assemble and install direct clutch pack on
hub as follows:
(a) Assemble clutch pack components (Fig. 167).
(b) Install direct clutch reaction plate on clutch
hub first. Note that one side of reaction plate is
counterbored. Be sure this side faces rearward.
Splines at rear of hub are raised slightly. Counter-
bore in plate fits over raised splines. Plate should
be flush with this end of hub (Fig. 168).
(c) Install first clutch disc followed by a steel
plate until all discs and plates have been installed.
(d) Install pressure plate. This is last clutch
pack item to be installed. Be sure plate is installed
with shoulder side facing upward (Fig. 169).
(19) Install clutch hub and clutch pack on direct
clutch spring (Fig. 170). Be sure hub is started on
sun gear splines before proceeding.
Fig. 164 Sun Gear Installation
1 - SUN GEAR AND SPRING PLATE ASSEMBLY
Fig. 165 Alignment Tool Installation
1 - SPECIAL TOOL 6227-2
2 - PRESS PLATES
3 - ASSEMBLED DRUM AND ANNULUS GEAR
4 - SUN GEAR
Fig. 166 Direct Clutch Spring Installation
1 - SPECIAL TOOL 6227-2
2 - DIRECT CLUTCH SPRING
3 - CLUTCH HUB
4 - PRESS PLATES
21 - 98 AUTOMATIC TRANSMISSION - 42REWJ
OVERDRIVE UNIT (Continued)

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)

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)

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 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 overdrive piston
thrust plate as follows:(a) Position Gauge Tool 6311 across face of over-
drive case. Then position Dial Caliper C-4962 over
gauge tool (Fig. 185).
(b) Measure distance to clutch hub thrust bear-
ing seat at four points 90É apart. Then average
measurements by adding them and dividing by 4.
(c) Select and install required thrust plate from
information in thrust plate chart (Fig. 186).
Fig. 181 42RE Overdrive Clutch Components
1 - REACTION PLATE 2 - PRESSURE PLATE
Fig. 182 Overdrive Clutch Pack Retaining Ring
Installation
1 - OVERDRIVE CLUTCH PACK RETAINING RING
Fig. 183 Shaft End Play Measurement
1 - SPECIAL TOOL 6312
2 - SPECIAL TOOL 6311
3 - SPECIAL TOOL C-4962
WJAUTOMATIC TRANSMISSION - 42RE 21 - 103
OVERDRIVE UNIT (Continued)

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)