2100307 - WJJeeps.com
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1. from premature wear resulting in a non warrantable failure of the transmission 1 Remove fluid using approved Team PSE Automatic Transmission Fluid X changer or equivalent Remove torque converter keep with unit Measure input shaft end play Stand the transmission upright on the converter housing Be sure to use suitable spacers between the bench surface and the converter housing since the input shaft may protrude past the front surface of the housing AON 21 003 07 6 oe Oyo 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Loosen electrical connector guide bushing and remove from transmission housing Remove transmission oil pan Remove oil filter Unscrew Torx socket bolts and remove electrohydraulic unit Place the transmission in PARK to prepare for the removal of the output shaft nut Remove the nut holding the propeller shaft flange to the output shaft and remove the flange Remove the transmission rear oil seal with a suitable slide hammer and screw Remove the transmission output shaft washer Be sure to tag the washer since it is very similar to the geartrain end play shim and they must not be interchanged Remove the transmission rear output shaft bearing retaining ring Position Bearing Remover tool 9082 over the inner race of the output shaft bearing Slide the collar on Bearing Remover tool 9082 downward over the fingers of the tool and remove the output s2. CE Stick with the Specialists 21 003 07 2 2001 2006 JR Sebring Sedan Convertible Stratus Sedan 2007 JS Sebring 1996 2000 JX Sebring Convertible 2007 KA Nitro 2002 2007 KJ Liberty 2002 2005 KJ Cherokee International Markets 1995 2004 LH Concorde Intrepid Vision LHS New Yorker 300M 2005 2007 LX 300 Magnum Charger 2005 2007 LE 300C 300C International Markets 2005 2007 ND Dakota 1996 2000 NS Town amp Country Caravan Voyager 2002 PG Chrysler PT Cruiser International Markets 1995 2005 PL Neon 2001 2007 PT Chrysler PT Cruiser 1997 2002 PR Prowler 2001 2007 RS Town amp Country Caravan Voyager 2001 2007 RG Chrysler Voyager International Markets 1997 2006 TJ Wrangler 2002 2006 VA Sprinter 2007 VB Sprinter 1999 2004 WG Grand Cherokee International Markets 2005 2007 WH Grand Cherokee International Markets 1999 2004 WJ Grand Cherokee 2005 2007 WK Grand Cherokee 2006 2007 XH Commander International Markets 2006 2007 XK Commander 1995 YJ Wrangler 1996 1998 ZG Grand Cherokee International Markets 2004 2007 ZH Crossfire 1996 1998 ZJ Grand Cherokee Grand Wagoneer SPECIAL TOOLS EQUIPMENT REQUIRED C 3339A Set Dial Indicator C 3752 A Puller Set Spring Compressor Alignment 3 21 003 07 8261 Plate Alignment 8266A F
3. NUMBER 21 003 07 es SERVICE GROUP Transmission Jeep BULLETIN DATE February 9 2007 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21 008 06 DATED April 8 2006 WHICH SHOULD BE REMOVED FROM YOUR FILES ALL REVISIONS ARE HIGHLIGHTED WITH ASTERISKS AND INCLUDE AN ADDITIONAL VEHICLES TRANSMISSIONS AND CAUTION STATEMENT SUBJECT Automatic Transmission Diagnostic Tear Down Procedure OVERVIEW This bulletin provides a procedure to determine repair versus replacement of an automatic transmission assembly Follow the proper repair procedure based on the transmission type This procedure is to be used after the transmission has been removed from the vehicle Every replaced transmission assembly returned to DaimlerChrysler must include a properly completed Diagnostic Checksheet This sheet must be attached to the transmission bellhousing Refer to Warranty Bulletin D 06 08 for additional information MODELS 1995 AA Spirit Acclaim LeBaron Sedan 1995 2003 AB Ram Van Wagon 1995 AJ LeBaron Coupe LeBaron Convertible 1997 2004 AN Dakota 1995 2002 BR BE Ram Truck 2004 2007 CS Pacifica 1998 2003 DN Durango 2007 D1 DC Ram Truck 2002 2007 DR DH Ram Truck 1995 2000 FJ Sebring Avenger Talon 1996 2000 GS Chrysler Voyager International Markets 2004 2007 HB Durango 2007 HG Aspen 1995 2000 JA Cirrus Stratus Breeze 2007 JK Wrangler SERVI
4. OTE All parts must be returned with transmission NOTE For detailed information Refer to Tech CONNECT 21 TRANSMISSION AND TRANSFER CASE or the appropriate service manual in Section 21 for specific information regarding disassembly and repair procedures 30RH 30TH 31TH 32RH 36RH 42RE RH 44RE RH 46RE RH 47RE and 48RE Transmissions 1 Remove fluid using approved Team PSE Automatic Transmission Fluid X changer or equivalent Remove torque converter keep with unit Measure input shaft end play Remove pump assembly Loosen front band adjustment screw until link can be removed keep link with unit Rotate front band and remove keep with unit Remove front clutch retainer and rear clutch retainer assembly NO ON 21 003 07 4 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Reassemble transmission by reversing steps 4 through 19 23 24 Remove intermediate shaft snap ring keep with unit Remove front and rear planetary assemblies and drive shell keep with unit Remove low reverse drum snap rings Remove low reverse drum Remove overdrive unit Remove overdrive clutch snap ring Remove overdrive clutch disc and plates Remove overdrive wave spring Remove overdrive snap ring Remove access cover and gasket Expand output shaft bearing snap ring with expanding type snap ring pliers Then push output shaft forward to release shaft bearing from locating ring Remove geartra
5. and hold in place with torque converter retaining bracket from replacement transmission Return any loose items by attaching to bellhousing in plastic bag NOTE All parts must be returned with transmission POLICY Reimbursable within the provisions of the warranty NOTE These labor operation numbers are only to be used when repair exceeds 70 of the cost of transmission assembly replacement 7 21 003 07 NOTE Returned transmissions received missing components are subject to warranty part return chargebacks See Warranty Administration Manual Parts Section Warranty Parts Return pages P1 through P14 for details NOTE Warranty repairs claiming one of the following Labor Operation Numbers must include a completed diagnostic sheet Refer to Warranty Bulletin D 06 08 available in Tech CONNECT under efiles gt Service gt Warranty gt CDJ Bulletins for additional information If the diagnostic sheet is not returned with the transmission assembly the diagnostic tear down time allowance will be charged back NOTE The use of a Diagnostic time allowance and or 00 time in place of one of the below Labor Operation Numbers does not eliminate the requirement to return a properly completed Diagnostic Sheet See Warranty Bulletin D 06 08 for additional information CAUTION The diagnostic sheet is to assist DaimlerChrysler engineering in the analysis of returned units for root cause and corrective actions Your diagnosis and findings ar
6. e important and can assist in this analysis Failure to return a properly completed sheet may result in a chargeback of 75 00 The chargeback for a transmission replaced that should have been repaired can result in complete chargeback of all parts markup and even complete claim chargeback TIME ALLOWANCE ea Micra ven 21 00 21 94 40TE Transaxle 41TE AE Transaxle 62TE Transaxle RG 21 00 21 96 30TH Transmission AA 31TH Transmission AJ NS 21 003 07 8 21 00 27 91 30RH Transmission 32RH Transmission 36RH Transmission 42LE RLE Transmission 21 00 27 92 42RE RH Transmission 44RE RH Transmission 46RE RH Transmission 47RE Transmission 48RE Transmission 21 00 27 93 45RFE Transmission AN 545RFE Transmission DN 68RFE Transmission DR DH D1 DC HB HG EJ KJ ND WG WJ WH WK NAG 1 Transmission
7. haft bearing Remove the geartrain end play shim from the output shaft Be sure to tag the shim since it is very similar to the output shaft washer and they must not be interchanged Remove the bolts holding the transmission housing to the converter housing from inside the converter housing Stand the transmission upright on the converter housing Be sure to use suitable spacers between the bench surface and the converter housing since the input shaft may protrude past the front surface of the housing Remove the remaining bolts holding the transmission housing to the converter housing Remove the transmission housing from the converter housing Remove output shaft with center and rear gear set and clutch K3 Remove thrust needle bearing and thrust washer Remove input shaft with clutch K2 and front gear set Remove clutch K1 Unscrew Torx socket bolts and remove oil pump Screw two opposed bolts into the oil pump housing and press the oil pump out of the converter housing by applying light blows with a plastic hammer If transmission is determined to be greater than 70 failed follow steps 27 through 30 If transmission is determined to be less than 70 failed refer to the service information available in TechCONNECT or the appropriate service manual in Section 21 for detailed repair instructions Place rear seal and thrust washer in transmission pan Reassemble transmission by reversing steps 3 through 25 Install torque converter
8. in assembly If transmission is determined to be greater than 70 failed follow steps 21 through 24 If transmission is determined to be less than 70 failed refer to the service information available in TechCONNECT or the appropriate service manual in Section 21 for detailed repair instructions Drop band adjustment link in pan Return the old torque converter using the same method used to ship to dealer If the service unit was received with the converter in a separate box within the transmission package return the failed unit in this manner Otherwise place converter into trans and install shipping strap and bolts Return any loose items by attaching to bellhousing in plastic bag NOTE All parts must be returned with transmission NOTE For detailed information Refer to Tech CONNECT 21 TRANSMISSION AND TRANSFER CASE or the appropriate service manual in Section 21 for specific information regarding disassembly and repair procedures 45RFE 545RFE and 68RFE Transmissions 1 OONOAR WN 15 16 17 Remove fluid using approved Team PSE Automatic Transmission Fluid X changer or equivalent Remove torque converter keep with unit Remove the transmission oil pan from the transmission case Remove the primary oil filter and the oil cooler return filter Remove the cooler return filter bypass valve Remove the valve body from the transmission case Install Support Stand 8257 onto the transmission case Measure i
9. ixtures End Play 8266 12 Adapter Geartrain End Play REPAIR PROCEDURE NOTE For detailed information Refer to TechCONNECT 21 TRANSMISSION AND TRANSFER CASE or the appropriate service manual in Section 21 for specific information regarding disassembly and repair procedures 40TE 41TE AE 42LE RLE and 62TE Transmissions 1 Remove fluid using approved Team PSE Automatic Transmission Fluid X changer or equivalent Remove torque converter keep with unit Measure input shaft end play Remove input speed sensor Remove pump assembly Remove input clutch assembly Remove front sun gear assembly Remove front carrier rear annulus assembly If transmission is determined to be greater than 70 failed follow steps 10 through 13 If transmission is determined to be less than 70 failed refer to the service information available in TechCONNECT or the appropriate service manual in Section 21 for detailed repair instructions 10 Drop 2 thrust bearing into transmission pan 11 Reassemble transmission by reversing steps 4 through 8 12 Return the old torque converter using the same method used to ship to dealer If the service unit was received with the converter in a separate box within the transmission package return the failed unit in this manner Otherwise place converter into trans and install shipping strap and bolts 13 Return any loose items by attaching to bellhousing in plastic bag 0 00 10 OTe ON N
10. n by reversing steps 3 through 22 25 Return the old torque converter using the same method used to ship to dealer If the service unit was received with the converter in a separate box within the transmission package return the failed unit in this manner Otherwise place converter into trans and install shipping strap and bolts 26 Return any loose items by attaching to bellhousing in plastic bag NOTE All parts must be returned with transmission NOTE For detailed information Refer to TechCONNECT 21 TRANSMISSION AND TRANSFER CASE or the appropriate service manual in Section 21 for specific information regarding disassembly and repair procedures NAG1 Transmissions NOTE Be aware of Sprinter NAG1 characteristics e Automatic Transmission Fluid ATF requires replacement at every second maintenance interval 96 000 km 60 000 mi Special ATF available from Mopar p n 05127382AB Drain plugs in the oil pan as well as in the torque converter Dipstick only use special tool 8863B to determine the fluid level The bell housing has a special geometry fitting OM612 and OM647 engines Several clutch discs are unique for Sprinter The Transmission Control Module is fine tuned for the use of the special ATF based on a commercial vehicle duty cycle e Identification label on the side of the housing has a different placement and format CAUTION Using a non approved ATF may result in shifting concerns and clutch discs may suffer
11. nput shaft end play Remove input speed sensor Remove extension adapter housing from the transmission case Remove front pump cover Remove front pump assembly Hold the input shaft during pump removal to prevent the input clutch thrust bearings from falling out of position Remove input clutch assembly Remove the 4C clutch retainer bulkhead tapered snap ring from the transmission case Remove the 4C clutch retainer bulkhead from the transmission case Remove the front 2C clutch pack snap ring from the transmission case Remove the 2C clutch pack from the transmission case 5 21 003 07 18 Remove the reaction annulus from the reaction planetary carrier 19 Remove the snap ring holding the park sprag gear onto the output shaft 20 Remove the input reverse planetary assembly 21 Remove the snap ring holding the low reverse clutch retainer into the transmission case 22 Remove the low reverse clutch retainer from the transmission case 23 If transmission is determined to be greater than 70 failed follow steps 24 through 26 If transmission is determined to be less than 70 failed refer to the service information available in TechCONNECT or the appropriate service manual in Section 21 for detailed repair instructions Be sure to check input shaft end play during reassembly and if low disassemble the input clutch assembly to check for thrust bearings which may have fallen out of position 24 Reassemble transmissio
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