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42re automatic transmission

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1. NI 9019297135 110 NOLIVOIHSITI n 21012 1NOHd un 3nouoL 3A TVA ONIMILL 2 Tn R pum S n 7 U 1 t9 15008 22 308 11 LO 3ATVA 1 6 v E d I 8 2 5 INTIVA JILLOHHL E T TV NVIN J UE 1 9nd HONH3AOS 7 3TLIOHHL 3ATVA HONH3AOD YOLVINANDSY 75 3AIHQU3AO YyOLYINANIDV O 1 54 OAH3S LNOtid HO1fY1O LNOH4 ZU 6 4 HOLN13 HV3H 1 J GION310S LES q L OAH3S 21 167 42RE AUTOMATIC TRANSMISSION WJ inued SCHEMATICS AND DIAGRAMS Cont ATILLOYHL 14 4 Hva3o 1544 SAIC NI H3A31 HOLO3 13S nonn 154914 3AIHG NI f NOLLVOIHSITI H21fr19 LNOu3 isd s 0 NOILVOIHS TI OL M g3unssaud Til
2. MANUAL VALVE The manual valve is a relay valve The purpose of the manual valve is to direct fluid to the correct cir cuit needed for a specific gear or driving range The manual valve as the name implies is manually oper 80c072f1 ated by the driver with a lever located on the top of the valve body The valve is connected mechanically Fig 15 Check Ball Locations by a cable to the gearshift mechanism The valve is held in each of its positions by a roller detent spring Fig 16 that engages the roostercomb of the TRS selector plate LOW REVERSE SWITCH VALVE Allows the low reverse clutch to be operated by either the LR CC solenoid or the MS solenoid 21 192 45RFE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued TRS SELECTOR CLUTCH PASSAGE O lt gt 80c072f3 Fig 16 TRS Selector Plate and Detent Spring PISTONS DESCRIPTION There are several sizes and types of pistons used in an automatic transmission Some pistons are used to apply clutches while others are used to apply bands They all have in common the fac that they are round or circular in shape located within a smooth walled cylinder which is closed at one
3. 5v oc Ale bz RE 1 19 02 3SH3AdH MOT H1 99 di z 254 uv39 45RFE AUTOMATIC TRANSMISSION SCHEMATICS AND DIAGRAMS Continued 21 260 JILVIMSHOS 3ddSr Wau 059 3346551 3NH isd saunssaud 08 38 xA Je Or Sd ly 14 14 ov ov Ov Oc 2 2 i Em TROL A I E ee ee ew 4 1 HOSN3S Sdud HVA SdA IlO3T3S LEIQATSIN TO H31H3ANOO OO HOL YTIO HOLN19 6 HOlv in9dg dorm er IN3A A MO HHJAO Q3JVA3T3 7X 39HOd HVA SdA HOLIMS SdHd Sd dVL lt 54 1 dO1VT0W nOOV OV IO asuaAad od 5 MO T d1 SOWA uva 5 dari US e n CORE TINO gt Tats 29 21 261 45RFE AUTOMATIC TRANSMISSION SCHEMATICS AND DIAGRAMS Continued WJ 5 354957 08 0081 1Y NO 29 440929 ann SW 99 81 og jesunseaua 0652 891 56 QIazioH3N3 SdION310S ee m x Z 1 H A T F d Barre Sd mmm H A HA IV
4. 219 SHIFTER et ex 221 BRAKE TRANSMISSION SHIFT 222 DISASSEMBLY AND ASSEMBLY 223 VALVE BODY 233 sac peed pian 235 INPUT CLUTCH 5 238 4 RETAINER BULKHEAD 242 PLANETARY GEAR SET 244 LOW REVERSE 245 CLEANING AND INSPECTION VALVE 247 5 248 LOW REVERSE CLUTCH ASSEMBLY 249 249 OIL PUMP AND REACTION SHAFT SUPPORT 249 PLANETARY GEARTRAIN 249 ADJUSTMENTS BRAKE TRANSMISSION SHIFT 249 GEARSHIFT 250 SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS 252 SPECIFICATIONS 5 271 SPECIAL TOOLS 45RFE 271 21 182 45RFE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION 45RFE AUTOMATIC TRANSMISSION DESCRIPTION The 45RFE automatic transmission is a sophisti cated multi range electronically controlled transmis sion which combines optimized gear ratios for responsive performance state of the art efficiency features and low NVH Other featur
5. TENA 3 4 TIMING VALVE 4 SHIFT VALVE m ni OVERDRV SOL 80c07150 Fig 37 3 4 Timing Valve Allowing 3 2 Shift 773 4 QUICK FILL VALVE 1 3 4 TIMING VALVE e 80 0714 Fig 36 3 4 Timing Valve Allowing 4 3 Shift WJ DESCRIPTION AND OPERATION Continued 3 4 QUICK FILL VALVE The 3 4 quick fill valve provides faster engagement of the overdrive clutch during 3 4 upshifts The valve temporarily bypasses the clutch piston feed orifice at the start of a 3 4 upshift Fig 39 This exposes a larger passage into the piston retainer resulting in a much faster clutch fill and apply sequence The quick fill valve does not bypass the regular clutch feed ori fice throughout the 3 4 upshift Instead once a pre determined pressure develops within the clutch the valve closes the bypass Clutch fill is then completed through the regular feed orifice OVERDRIVE CLUTCH 3 4 ACCUMULATOR ee A 3 4 QUICK FILL VALVE 9 u Eu L 80c07153 Fig 38 3 4 Quick Fill Valve Before
6. TRANSMISSION AND TRANSFER CASE 21 1 TRANSMISSION AND TRANSFER CASE TABLE OF CONTENTS page page 42RE AUTOMATIC TRANSMISSION 1 NV242 TRANSFER 275 45RFE AUTOMATIC TRANSMISSION 181 NV247 TRANSFER 5 308 42RE AUTOMATIC TRANSMISSION TABLE OF CONTENTS page page DESCRIPTION AND OPERATION ANALYZING ROAD 5 55 42RE AUTOMATIC TRANSMISSION 2 HYDRAULIC PRESSURE TEST 55 RECOMMENDED FLUID 10 AIR TESTING TRANSMISSION CLUTCH AND FLUID Cee ee 10 BAND 57 TORQUE CONVERTER 11 CONVERTER HOUSING FLUID LEAK OIL PUMP cen sar pusa 16 DIAGNOSIS 58 VALVE BODY ost ged ee e 17 DIAGNOSIS TABLES AND CHARTS RE 38 59 PISTONS ci fr Q uqu HER Eg 39 SERVICE PROCEDURES FRONT CLUTCH 42 FLUID LEVEL 72 REAR 43 FLUID AND FILTER REPLACEMENT 72 OVERDRIVE CLUTCH 44 TRANSMISSION FILL PROCEDURE 73 OVERRUNNING CLUTCH 45 CONVERTER DRAINBACK CHECK VALVE PLANETARY 5 45 SERVICE esse eae ey eae ee eee
7. IMIWA JILLOHHL JILLOYHL YHONHSAOD YOLVINNNDDV v HOLfYTIO HOLN19 OAu3S 21019 3AIHQH3AO GION31OS HONH3AOD uorivininoov OAH3S LNOHJ 21 165 42RE AUTOMATIC TRANSMISSION WJ SCHEMATICS AND DIAGRAMS Continued NOILLONS isd g9 zs 3HnsS3Hd gan uald3ANOO isd 59 16 3unssaud 3NI1 31LLOHHL 038079 NI H3A31 1 lt NI NOLLVOIHS TI 21119 LNOH3 106 H31H3ANOO 105 E cu 3ATVA t V d A AATWA IHS 2 1 LJ 3ATVA IOHLNOO LdIHS
8. C TRANSMISSION 21 27 TT When governor pressure builds to a point where it can overcome the combined force of the spring and throttle pressure on the other side of the valve the valve will begin to move over to the right As the valve moves to the right the middle land of the valve will close off the circuit supplying the throttle pres 1 2 SHIFT CONTROL VALVE BOO LB J H 80 07144 Fig 29 1 2 Shift Valve Before Shift e t allows the shift e When in a manual hydraulically blocked i occur sure to the right side of the valve When the throttle pressure is closed off the valve will move even far ther to the right allowing line pressure to enter another circuit and energize the front servo applying the front band Fig 30 r LIMIT VALVE THROTTLE PLUG I n umm mm TLI The governor plug serves a dual purpose valves to move either left or right allowing both upshifts and downshifts selection position it will be nto position so no upshift can 2 E re eave F ri l i gt sss CONTROL VALVE 80 07145 Fig 30 1 2 Shift Valve After Shift 21 28 42 AUTOMATIC TRA
9. GION3 1OS U anouol uai 710 H3l1H3ANOO Naauos 105 to E isd 7 8 3unss3ud SAYA TVnNVH m i o ter isd op 01 d3unssaud IMYA TIH JONO v e JILLOHYHL dd isd 0 3unssaud HONH3AO9 isd 8 0 3unssaud INIT 9 6 H LNTO uoivinnoov OAH3S J eme E i ond H afr HONHJAOD H H I E A ES ENSIS LAS Ond 5 3ATVA 5 6 2 STLLOYHL x NUS IMYA LIANE lt oo Ae Nd 311LOHH L Orid L WUONHZJAOD 5 oS A Ot N jo HOLfYIO LNOHJ i HOLN19 OAH3S HV3H GION310S HONH3AO9 42RE AUTOMATIC TRANSMISSION SCHEMATICS AND DIAGRAMS Continued 21
10. Es eriam erm m Nanay R s Sd PETE am prm beIIIIIIIIIIIIIIIIIIIID 4 Hd 14 ov HOSN3S S3Hd HvA SdA 7108 30404 ui 1 5 HOLIMS S3tid Sd 14 H31H3ANOO 29 HOLWINNINDOW 0 HOLNTO 10 an HO1fT10 2 MOT H1 GNOO3S 45RFE AUTOMATIC TRANSMISSION SCHEMATICS AND DIAGRAMS Continued 21 270 641220908 OrTOVHGAH 3ddSr NO29 330221 pelo 6 lt 5 08 51 811 55 991 96 14 AN3A A MOTHH3AO G31VA31 HOSN3S SdHd HVA SdA 10S 3OHOd HVA 199195 01 8 HOLIMS S3Hd SHNSSaud 9 SJA 5 Ld H31H3ANO27902 YOLVINNNDOV 9V up Ov JIoasuaA3u oud an HOLNTO Puz Oc 3Sua Aau 4 51 uvao aNooas N N N N N N N N N N N e RR XI COOLER T o o gt WJ SPECIFICATIONS TRANSMISSION GENERAL Component Metric inch Output Shaft End Play 0 is 78 er 031 Input Shaft End Play 0 79 1 0
11. 0994068 Ln SVE ca rz T Id LNSA A G a1VA313 A ovi uosNas saud uvA sdA 7108 30HOd uvA S3 103 3S LEIIW SIA HOLIMS S3Hd Sd H dVL 3 nSS3tid Ld H31H3ANOO 00 uo vnWnoov ov H Le HOLITTO 19 3Su3A3H 0H on 29 Aloo 276 1 HOLNTO Puz 0z 3su3Adu MOT H1 uvao aWidd 5 45RFE AUTOMATIC TRANSMISSION SCHEMATICS AND DIAGRAMS Continued 21 262 JILVISHOS Or T VHGAH 3ddSr 9655 T aao SS 3NH ce 0 991 96 Leo ies rr Fn A 5 6 LI 4 EE fa A t nai 14 IN3A A G31VA313 x HOSN3S HVA SdA 10S 3OHOd HVA SJA 109135 071 8 HOLIMS S3Hd Sd dV 553 4214 19 HALYAANOD 99 YHOLVINNNDOV 9V M HOLNT9 Ulp t 712 ASHAAAY 9Y 3AIHaH3AO dO0 3AIdagaaun an HO L TIO 3Sud ddH M01541 GNOOAS 21 263 45RFE AUTOMATIC TRANSMISSION WJ SCHEMATICS AND DIAGRAMS Continued 11620208 OrTOVHGAH 3ddSr 00 NO29 330221 sa S3unsssua 08 01 811 68 P ITZ H fo H r 1 AINSA A
12. L4IHS t ss pev TVA JILLOYHL B YOLVINAINDOY H E LE ENSE 1 195 3AIHQH3AO LU LIIHS 6 1 L3IHS g t 9nd 3ATVA 9nd JILLOHHL i HONH3AOD NL e 12 M and JILLOYHL OAu3S LNOHJ 1 19 1 5 HONH3AOD u vdd GION3 10S HONH3AOS 42RE AUTOMATIC TRANSMISSION SCHEMATICS AND DIAGRAMS Continued 21 174 68 isd 6 0 3unssaud NOILONS 189 29 9 3unssaud ASN 134 5 9 3unssaud HONHSAOS isd lt lt 2 5 ZL isd 59 55 3unssaud INIT 245 DITINVYCAH J3T1LLOHHI 0350719 HV39 0948 H3A31 193145 NOILLVDIHSfI1 LNOYS 4 HOLIMS NN df 4901 s ua GION3108 H3lH3ANOO
13. Rete 306 SPECIAL TOOLS 2 2 ead REG RE RS 306 drive sprocket on the mainshaft The drive sprocket is engaged disengaged by the mode fork which oper ates the mode sleeve and hub The sleeve and hub are not equipped with a synchro mechanism for shift ing The geartrain is mounted in two aluminum case halves attached with bolts The mainshaft front and rear bearings are mounted in aluminum retainer housings bolted to the case halves TRANSFER CASE IDENTIFICATION Two versions of the NV242 are used in the WJ vehicles NV242LD and NV242HD The two transfer cases can be distinguished from one another by the rear output shaft retainer The NV242LD uses a rub ber boot to cover the rear output shaft while the NV242HD uses a cast aluminum housing Other than this difference the two transfer cases are serviced the same A circular ID tag is attached to the rear case of each transfer case Fig 2 The ID tag provides the transfer case model number assembly number serial number and low range ratio The transfer case serial number also represents the date of build OPERATING RANGES NV242 operating ranges are 2WD 2 wheel drive 4x4 part time 4x4 full time and 4 Lo The 2WD and 4x4 full time ranges can be used at any time and on any road surface The 4x4 part time and 4 Lo ranges are for off road use only The only time these ranges can be used on hard surface roads is when the surface is covered with sn
14. VALVE El OVERDRIVE LOW REVERSE ACCUMULATOR ACCUMULATOR UNDERDRIVE PE ACCUMULATOR 2ND CLUTCH J z ACCUMULATOR 80b9a599 Fig 102 Valve Body Components ASSEM BLY 1 Lubricate valves springs and the housing valve bores with clean transmission fluid 2 Install solenoid switch valve manual valve and the low reverse switch valve into the valve body 3 Install the retainers to hold each valve into the valve body 4 Install the valve body check balls into their proper locations 5 Position the transfer plate onto the valve body 45RFE AUTOMATIC TRANSMISSION 21 235 6 Install the screws to hold the transfer plate to the valve body Tighten the screws to 4 5 40 Ibs 7 Install the accumulator pistons and springs into the valve body in the location from which they were removed Note that all accumulators except the overdrive have two springs The overdrive accumula tor piston has only one spring 8 Position the accumulator cover onto the valve body 9 Install the screws to hold the accumulator cover onto the valve body Tighten the screws to 4 5 N m 40 in Ibs 10 Install the TRS selector plate onto the valve body and the manual valve 11 Install the solenoid and pressure switch assembly onto the valve body 12 Install the screws to hold the solenoid and pressure switch assembly onto the valve body Tighten the screws to 5 7 N m 50 in 165 Tighten the scr
15. ATF Plus 3 to transmission a If only fluid and filter were changed add 10 pints 5 quarts of ATF Plus 3 to transmission b If transmission was completely overhauled torque converter was replaced or drained and cooler was flushed add 24 pints 12 quarts of ATF Plus 3 to transmission 3 Refer to the Fluid Level Check information in this group for the proper fill procedures OIL PUMP VOLUME CHECK Measuring the oil pump output volume will deter mine if sufficient oil flow to the transmission oil cooler exists and whether or not an internal trans mission failure is present Verify that the transmission fluid is at the proper level Refer to the Fluid Level Check procedure in this section If necessary fill the transmission to the proper level with ATF 43 type 7176 Auto matic Transmission Fluid 1 Disconnec the To cooler line at the cooler inlet and place a collecting container under the dis connected line CAUTION With the fluid set at the proper level fluid collection should not exceed 1 quart or inter nal damage to the transmission may occur 2 Run the engine at curb idle speed with the shift selector in neutral 3 one quart of transmission fluid is collected in the container in 20 seconds or less oil pump flow vol ume is within acceptable limits If fluid flow is inter mittent or it takes more than 20 seconds to collec one quart of fluid refer to the Hydraulic Pressure
16. Plus 3 type 7176 fluid 12 Check and adjust gearshift cable if necessary 45RFE AUTOMATIC TRANSMISSION 21 215 SOLENOID AND PRESSURE SWITCH ASSEMBLY REM OVAL 1 Remove the valve body from the transmission Fig 42 8 VALVE BODY TO CASE BOLT 6 N Fig 42 Valve Body Bolts 2 Remove the screws holding the solenoid and pressure switch assembly onto the valve body Fig 43 3 Separate the solenoid and pressure switch assembly from the valve body SOLENOID PACK BOLTS 15 80c07445 Fig 43 Solenoid and Pressure Switch Assembly Screws INSTALLATION 1 Place TRS selector plate in the PARK position 21 216 45RFE AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION Continued 2 Position the solenoid and pressure switch assembly onto the valve body Be sure that both alignment dowels are fully seated in the valve body and that the TRS switch contacts are properly posi tioned in the selector plate 3 Install the screws to hold the solenoid and pressure switch assembly onto the valve body 4 Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first Tighten the screws to 5 7 N m 50 in Ibs 5 Tighten the remainder of the solenoid assembly screws to 5 7 N m 50 in Ibs 6 Install the valve body into the transmission TRANSMISSION CAUTION The transmission and torque converte
17. 5 Align and position differential top case on bot tom case Fig 72 Align using scribe marks made at disassembly WJ 242 TRANSFER CASE 21 295 DISASSEMBLY AND ASSEMBLY Continued 6 While holding differential case halves together invert the differential and start the differential case bolts 7 Tighten differential case bolts to specified torque J8921 214 Fig 73 Low Range And Input Gear Assembly 1 THRUST WASHERS 2 LOW RANGE GEAR 3 GEAR 4 RETAINER 2 18921 281 Fig 72 Differential Case Assembly 1 TOP CASE 2 BOTTOM CASE 3 CASE ALIGNMENT MARKS INPUT GEAR LOW RANGE ASSEMBLY 1 Assemble low range gear input gear thrust washers input gear and input gear retainer Fig 73 2 Install low range gear snap ring Fig 74 3 Lubricate input gear and low range gears with automatic transmission fluid 4 Start input gear shaft into front case bearing 5 Press input gear shaft into front bearing 6 Install new input gear snap ring Fig 75 7 Apply 3 mm 1 8 in wide bead of Mopar gas ket maker or silicone adhesive sealer to seal surface of front bearing retainer 8 Install front bearing retainer Fig 76 Tighten retainer bolts to 16 ft Ibs 21 N m torque Fig 74 Install Low Range Gear Snap Ring 1 LOW RANGE GEAR SNAP RING J8921 269 21 296 NV242 TRANSFER CASE DISASSEMBLY AND
18. TRANSMISSION TEMPERATURE SENSOR SOLENOIDS 45222 Rr ace gs SOLENOID SWITCH VALVE DIAGNOSIS AND TESTING EFFECTS OF INCORRECT FLUID LEVEL CAUSES OF BURNT FLUID FLUID CONTAMINATION 45RFE AUTOMATIC TRANSMISSION GENERAL DIAGNOSIS PRELIMINARY DIAGNOSIS BRAKE TRANSMISSION SHIFT INTERLOCK GEARSHIFT ROAD HYDRAULIC PRESSURE TEST AIR TESTING TRANSMISSION CLUTCH OPERATION ciei sia dria ara i ua aa CONVERTER HOUSING FLUID LEAK DIAGNOSIS epee rine SERVICE PROCEDURES FLUID LEVEL CHECK page page FLUID AND FILTER REPLACEMENT 211 TRANSMISSION FILL PROCEDURE 212 OIL PUMP VOLUME 212 FLUSHING COOLERS AND TUBES 212 TRANSMISSION QUICK LEARN PROCEDURE RP ake ey 213 ALUMINUM THREAD REPAIR 213 REMOVAL AND INSTALLATION INPUT SPEED 5 213 OUTPUT SPEED SENSOR 214 LINE PRESSURE SENSOR 214 VALVE 214 SOLENOID AND PRESSURE SWITCH ASSEMBLY uu 215 5 216 TORQUE CONVERTER 218 OIL PUMP FRONT SEAL 219 ADAPTER HOUSING SEAL 219 GEARSHIFT
19. AVE BEARING NUMBER 3 OD HUB SHAFT HUB SHAFT d OD BEARING NUMBER 2 SOT SNAP RING TAPER UD OD SNAP RING REACTION PLATE FLAT SELECT 80c07014 Fig 22 Input Clutch Assembly Part 2 OVERDRIVE CLUTCH REVERSE CLUTCH The overdrive clutch is hydraulically applied in The reverse clutch is hydraulically applied in third direct and overdrive gears by pressurized fluid reverse gear by pressurized fluid against the over against the overdrive reverse piston When the over drive reverse piston When the reverse clutch is drive clutch is applied the overdrive hub drives the applied the reaction annulus gear is driven reverse carrier input annulus assembly 21 196 45RFE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued 2C PISTON SEAL sc 4 RETAINER BULKHEAD SEAL 4C PISTON E SNAP RING ae BELLEVILLE SPRING DISC SNAP RING SELECT REACTION PLATE RETURN SPRING 80c07032 Fig 23 2C and 4C Clutches HOLDING CLUTCHES DESCRIPTION Three hydraulically applied multi disc clutches are used to hold planetary geartrain components station ary while the input dutches drive others The 2C 4C and Low Reverse dutches are considered holding dutches The 2C and 4C dutches are located in the 4C retainer bulkhead Fig 23 while the Low Re verse clutch is located at the rear of the transmission case Fig 24 OPERATION 2C CLUTCH
20. Fig 240 Installing Driving Shell Front Thrust Plate On Sun Gear 1 SPACER 2 SUN GEAR 3 THRUST PLATE 9 Hold sun gear in place and install thrust plate over sun gear at rear of driving shell Fig 241 10 Position wood block on bench and support sun gear on block Fig 242 This makes it easier to align and install sun gear lock ring Keep wood block handy as it will also be used for geartrain end play check 11 Align rear thrust plate on driving shell and install sun gear lock ring Be sure ring is fully seated in sun gear ring groove Fig 243 12 Install assembled driving shell and sun gear on output shaft Fig 244 13 Install rear thrust washer on front planetary gear Fig 245 Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated J9121 162 Fig 241 Installing Driving Shell Rear Thrust Plate 1 DRIVING SHELL 2 SUN GEAR 3 REAR THRUST PLATE 2 AUTOMATIC TRANSMISSION 21 135 DISASSEMBLY AND ASSEMBLY Continued J9121 163 J9121 165 Fig 244 Installing Assembled Sun Gear And Driving Fig 242 W Block i ee Sun Gear On Wood Bloc Shell On Output Shaft 2 DRIVING SHELL 1 SUN GEAR DRIVING SHELL ASSEMBLY 2 OUTPUT SHAFT 3 WOOD BLOCK J9121 166 J9121 164 Fig 245 Installing Rear Thrust Washer On Front Fig 243 Installing Sun Gear Lock Ring 1
21. GION310S 105 3ATVA 5 t 3ATVA ONIINLL 7 6 YOLVINANIOV 9 6 Lu 1 12 3AIHQH3AO HOLVINWNDOV NOILVOINEM H LNTO LNOtid NOLLVOINSNT OL 3NIVA HOLIMS 3NVA 15008 NMOQXODI 3ATVA 2111081 AS 3A1VA T1OHLINOO 14IHS 2 1 JAVA 3 1LLOHS Sfi ld STLLOYHL 3NTVA HOLN1D 1NOtHd OAYAS LNOYS OAH3S uviu 110 3nO0HOL 1N33HOS 3AVA LAIHS 2 1 AS 3AT1VA L3IHS lt 2 211112 HV3H GION310S HONHJAOD 21 171 42RE AUTOMATIC TRANSMISSION WJ SCHEMATICS AND DIAGRAMS Continued 98 4808 isd 9 8 auns 38nrH3183ANO NOILONS 001 0 3unssaHd 31110HHL isd 09 0 3HnsSdHd HONH3AOD isd 061 96 3unssaud 0311997 LON H LNT H3183ANOO 3AIHG 3320 INn HV39 3AIHQE3AO H3A31 40193173S df1 420 df12 201 GION3 10S d 14201 108 Audd34o 3ATVA IIHS t 3A1VA SNINIL 7 6 AATVA TI AINO HE p YOLVINANSSY HOLN1D uoIvnnno2v NOILVOIHSTI LNOtdid NOLLVOINSNT OL 15004 NANOQDIODI TM SATA TILLOHHL i 3ATVA JILLNHS Sn
22. DIFFERENTIAL 2 MAINSHAFT 8921 282 Fig 80 Installing Mainshaft Bearing Rollers and Spacers 1 MAINSHAFT BEARING ROLLERS 18221526 2 BEARING SPACERS Fig 82 Installing Differential Snap Ring 1 DIFFERENTIAL SNAP RING 8 Install remaining bearing spacer on mainshaft Fig 80 Do nct displace any bearings while install 12 Install clutch shaft thrust washer Fig 84 Ing Spacer 13 Install clutch shaft snap ring Fig 85 21 298 NV242 TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued J8921 260 Fig 83 Installing Intermediate Clutch Shaft 1 INTERMEDIATE CLUTCH SHAFT J8921 258 Fig 85 Installing Clutch Shaft Snap Ring 1 SNAP RING 2 INTERMEDIATE CLUTCH SHAFT 14 Inspect mode fork assembly Fig 86 Replace pads and bushing if necessary Replace fork tube if bushings inside tube are worn or damaged Also check springs and slider bracket Fig 86 Replace worn damaged components ml T 1 vy Fig 84 Installing Clutch Shaft Thrust Washer 1 CLUTCH SHAFT THRUST RING J8921 259 J8921 284 Fig 86 Mode Fork Assembly Inspection 1 SLIDER 2 MODE FORK 3 BUSHING SPRING 4 TUBE 5 PADS 15 Install mode sleeve in mode fork Fig 87 Then install assembled sleeve and fork on mainshaft Be sure mode sleeve splines are engaged in differen tial splines WJ DISASSEMBLY AND ASSEMBLY
23. INTERMEDIATE SHAFT THRUST PLATE Fig 170 Removing Planetary Geartrain And x 1 Intermediate Shaft Assembly 1 PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT L Y Te ASSEMBLY Fig 169 Front Band Removal Installation 1 DRIVING SHELL 2 FRONT BAND J9121 351 Fig 171 Removing Low Reverse Drum Snap Ring 1 LOW REVERSE DRUM 2 HUB OF OVERDRIVE PISTON RETAINER 3 LOW REVERSE DRUM SNAP RING WJ DISASSEMBLY AND ASSEMBLY Continued 31 Remove low reverse drum and reverse band 32 Remove overrunning clutch roller and spring assembly as a unit Fig 172 33 Compress front servo rod guide about 1 8 inch with Valve Spring Compressor C 3422 B Fig 173 34 Remove front servo rod guide snap ring Exercise caution when removing snap ring Servo bore can be scratched or nicked if care is not exercised 35 Remove compressor tools and remove front servo rod guide spring and servo piston J9121 222 Fig 172 Overrunning Clutch Assembly Removal 1 OVERRUNNING CLUTCH CAM 2 REAR BAND REACTION PIN 3 OVERRUNNING CLUTCH ASSEMBLY 80be44b7 Fig 178 Compressing Front Servo Rod Guide 1 SPRING COMPRESSOR TOOL C 3422 B 2 ROD GUIDE SNAP RING 42RE AUTOMATIC TRANSMISSION 21 113 36 Compress rear servo spring retainer about 1 16 inch with Valve Spring Compressor C 3422 B Fig 172 37 Remove rear servo spring retainer snap ring Then remove compressor tools and remo
24. Q31VA3 T37x Ls OVE uosNas SaHd HVA SdA 7106 39HOd HVA SJA 1o313s LEInW SMW HOLIMS S3Hd Sd SUNSSAHd 1d e oai H31H3ANO2709 m up asuqAati 5u d ou an 55 H 6 H LNTO 02 3S43434 MOT H1 uvao 45RFE AUTOMATIC TRANSMISSION SCHEMATICS AND DIAGRAMS Continued 21 264 09612908 354957 0 NO9O 44099 0851 giise 991 65 ULL inoad 55 1 SENS E C a i s CITI AEE EEE EEE EELS 4 a 4 H 4 gt Lai RTT In z zx gt kkxzxxxx 4 5 4 1 4 ld IN3A A MO IHJH3AO Q31VA3T37 HOSN3S S3tid HVA SdA 7106 39HOd HVA SHA 1931435 6 HOLIMS 5 5 dV SHNSSAYd 1d 19 H31H3ANOO 25 HOLVINNINDOW O0V 19 41 95 10 3suaA3u ou an HO1fT10 Puz oz 3SH3AdH MOT H1 4 611 uvao 103uia 21 265 45RFE AUTOMATIC TRANSMISSION WJ SCHEMATICS AND DIAGRAMS Continued JILVISHOS 3ddSr 81620208
25. TEES TEES 21119 3AIHQH3AO HolvinWnoov NOILVOIHS TI 1 19 LNOH4 NOILVOIHSITI OL NINOOMOM R S T ATA 3ILLOBHL LA KS 3ATVA 1OH1NOO LIHS 2 3111nHS 31LLOHHL 3ATVA H LNT 1 OAua3S OAH3S 1 uarin 110 H31H3ANOO 3no0HOL Ni3H0S HOLVINDAY 3AT1VA 3ATVA 13IHS 2 ond HONH3AOS HONHHAOD 1 19 uvau GION310S HONHJAOO 21 176 42RE AUTOMATIC TRANSMISSION SPECIFICATIONS TRANSMISSION GENERAL Planetary end play 0 127 1 22 0 005 0 048 mm in Input shaft end play 0 56 2 31 0 022 0 091 mm in Clutch pack clearance 1 70 3 40 0 067 0 134 Front mm in Clutch pack clearance 0 559 0 914 0 022 0 036 Rear mm in Direct clutch 42RE Band adjustment from 72 in lbs Front band Back off 3 turns Rear band Back off 4 turns Recommended fluid Plus 3 type 7176 GEAR RATIOS 15 GEAR 2 74 2ND GEAR 1 54 3RD GEAR 1 00 4TH GEAR 0 69 REV GEAR 2 21 WJ TORQUE DESCRIPTION TORQUE Fitting cooler line at trans 18 13 ft Ibs Bolt torque convertor 31 N m 23 ft Ibs Bolt nut crossmember 68 N m 50 ft Ibs Bolt driveplate to crankshaft 75 N m 55 ft Ibs Plug front band reaction 17 N m 13 ft Ibs Locknut front band adj 34 N m 25 ft Ibs Sw
26. 37 Position new oil pan gasket on case and install oil pan Tighten pan bolts to 17 N m 13 ft Ibs 38 Install new valve body manual shaft seal in case Fig 196 Lubricate seal lip and manual shaft with petroleum jelly Start seal over shaft and into case Seat seal with 15 16 inch deep well socket 39 Install throttle valve and shift selector levers on valve body manual lever shaft OVERRUNNING CLUTCH CAM OVERDRIVE PISTON RETAINER DISASSEMBLY NOTE TO SERVICE THE OVERRUNNING CLUTCH CAM AND THE OVERDRIVE PISTON RETAINER THE TRANSMISSION GEARTRAIN AND OVERDRIVE UNIT MUST BE REMOVED FROM THE TRANSMIS SION 1 Remove the overdrive piston Fig 197 2 Remove the overdrive piston retainer bolts 3 Remove overdrive piston retainer 4 Remove case gasket 5 Mark the position of the overrunning clutch cam in the case Fig 198 6 Remove the overrunning clutch cam bolts 7 Remove the overrunning clutch cam 19121 20 Fig 197 Overdrive Piston Removal 1 OVERDRIVE CLUTCH PISTON 2 INTERMEDIATE SHAFT 3 SELECTIVE SPACER 4 PISTON RETAINER ASSEMBLY 1 Examine bolt holes in overrunning dutch cam Note that one hole is not threaded Fig 199 This hole must align with blank area in dutch cam bolt Fig 200 Mark hole location on dutch cam and blank area in case with grease pencil paint stripe or scribe mark for assembly reference WJ DISASSEMBLY AND ASSEMBLY C
27. 80c07014 Fig 107 Input Clutch Assembly Part I 20 Separate OD reverse piston from input dutch hub retainer Fig 109 21 Remove all seals and o rings from the input shaft and input hub The o rings on the input hub are color coded Be sure to make note of which o ring belongs in which location ASSEM BLY 1 Install all new seals and o rings onto the input shaft and input hub The o rings on the input hub are color coded Be sure to install the correct o ring in the correct location 2 Lubricate all seals with ATF 43 type 7176 prior to installation 3 Assemble the OD reverse piston onto the input dutch hub Fig 109 4 Assemble the input dutch retainer onto the input clutch hub 5 Install the input dutch retainer tapered snap ring with tapered side up onto the input dutch hub 6 Install Piston Guides 8504 into the input clutch retainer Fig 110 and onto the input clutch hub to guide the inner and outer underdrive piston seals into position 7 Install the underdrive piston into the input dutch retainer and over the input clutch hub Fig 109 8 Install the UD OD balance piston return spring pack into the input dutch retainer 9 Install Piston Guide 8252 into the input clutch retainer Fig 111 to guide the UD OD balance piston seal into position inside the underdrive piston 10 Install the UD OD balance piston into the input dutch retainer and the underdrive piston 21 240 4
28. 9 Install thrust bearing on overrunning dutch 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 2 J9121 322 Fig 285 Assembling Overrunning Clutch And Hub 1 CLUTCH HUB 2 OVERRUNNING CLUTCH 10 Install overrunning dutch in output shaft Fig 286 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 287 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 13 Install planetary thrust bearing on sun gear Fig 288 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 289 Be sure sun gear and thrust bearing are fully seated before proceeding 15 Mount assembled output shaft annulus gear and clutch drum in shop press Direct dutch spring hub and dutch pack are easier to install with assem bly mounted in press D J9121 314 Fig
29. CLUTCH PLATES 3 15 RETAINER SEAL RING 16 SHAFT REAR SEAL RING PLASTIC 17 SHAFT FRONT SEAL RING TEFLON Clearance should be 1 70 to 3 40 mm 0 067 to 0 134 in If dearance is incorrect dutch discs plates pressure plates and snap ring may have to be changed REAR CLUTCH DISASSEMBLY 1 Remove fiber thrust washer from forward side of dutch retainer 2 Remove input shaft front rear seal rings 3 Remove selective dutch pack snap ring Fig 224 4 Remove top pressure plate dutch discs steel plates bottom pressure plate and wave snap ring and wave spring Fig 224 5 Remove dutch piston with rotating motion 6 Remove and discard piston seals 7 Remove input shaft snap ring Fig 225 It may be necessary to press the input shaft in slightly to relieve tension on the snap ring 8 Press input shaft out of retainer with shop press and suitable size press tool Use a suitably sized press tool to support the retainer as close to the input shaft as possible 21 130 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued 39121 149 Fig 225 Removing Installing Input Shaft Snap Ring 1 REAR CLUTCH RETAINER 2 INPUT SHAFT SNAP RING 3 SNAP RING PLIERS ASSEM BLY 1 Soak dutch discs in transmission fluid while assembling other dutch parts 2 Install new seal rings on dutch retainer hub and input shaft if necessary Fig 226 a Be sure dutch hub seal
30. 74 BANDS race l 45 OIL PUMP VOLUME CHECK 74 SERVOS 25 RR wa eu dum add unu 46 FLUSHING COOLERS AND 5 74 GEARSHIFT 5 47 ALUMINUM THREAD REPAIR 75 CONVERTER DRAINBACK VALVE 47 REMOVAL AND INSTALLATION POWERTRAIN CONTROL MODULE POM 47 5 75 ELECTRONIC GOVERNOR 49 TORQUE CONVERTER 79 GOVERNOR PRESSURE CURVES 50 PARK NEUTRAL POSITION SWITCH 79 OVERDRIVE OFF SWITCH 51 GEARSHIFT 79 BRAKE TRANSMISSION SHIFT INTERLOCK SHIE TER n t ec Rt a RO e ede e e 81 51 BRAKE TRANSMISSION SHIFT INTERLOCK 83 DIAGNOSIS AND TESTING GOVERNOR SOLENOID AND PRESSURE AUTOMATIC TRANSMISSION DIAGNOSIS 51 SENSOR 5 idv egies EFFECTS INCORRECT FLUID LEVEL 51 VALVE BODY RR RE ERI A REGE CAUSES OF BURNT FLUID 52 OVERDRIVE FLUID CONTAMINATION 52 OVERDRIVE HOUSING PRELIMINARY DIAGNOSIS 53 OUTPUT SHAFT REAR BEARING PARK NEUTRAL POSITION SWITCH 53 OUTPUT SHAFT FRONT BEARING OVERDRIVE ELECTRICAL CONTROLS 53 DISASSEMBLY AND ASSEMBLY BRAKE TRANSMISSION SHI
31. FOA NZS Lu d S NYA 42RE AUTOMATIC TRANSMISSION 21 9 2 FRONT AND REAR PLANETARY 80c070ab Fig 8 Direct Drive Powerflow 1 FRONT CLUTCH APPLIED 2 OVER RUNNING CLUTCH FREE WHEELING 3 OUTPUT SHAFT 4 REAR CLUTCH APPLIED 5 OUTPUT SHAFT 6 INPUT SHAFT 7 OVER RUNNING CLUTCH FREE WHEELING 8 REAR CLUTCH APPLIED 9 FRONT CLUTCH APPLIED 10 INPUT SHAFT DIRECT DRIVE POWERFLOW The vehicle has accelerated and reached the shift point for the 2 3 upshift into direct drive Fig 8 When the shift takes place the front band is released and the front dutch is applied The rear dutch stays applied as it has been in all the forward gears With the front clutch now applied engine torque is now on the front dutch retainer which is locked to the sun gear driving shell This means that the sun gear is now turning in engine rotation dock wise and at engine speed The rear clutch is still applied so engine torque is also still on the front annulus gear If two members of the same planetary set are driven direct drive results Therefore when two members are rotating at the same speed and in the same direction it is the same as being locked up The rear planetary set is also locked up given the sun gear is still the input and the rear annulus gear must turn with the output shaft Both gears are turning in the same direction and at the sa
32. LOCK RING GROOVE Planetary Gear 2 SUN GEAR LOCK RING 1 FRONT PLANETARY GEAR 2 REAR TABBED THRUST WASHER 3 DRIVING SHELL 4 REAR THRUST PLATE 21 136 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued 14 Install front planetary gear on output shaft and in driving shell Fig 246 15 Install front thrust washer on front planetary gear Use enough petroleum jelly to hold washer in place and be sure all four washer tabs are seated 16 Assemble front annulus gear and support if necessary Be sure support snap ring is seated 17 Install front annulus on front planetary Fig 246 18 Position thrust plate on front annulus gear support Fig 247 Note that plate has two tabs on it These tabs fit in notches of annulus hub 19 Install thrust washer in front annulus Fig 248 Align flat on washer with flat on planetary hub Also be sure washer tab is facing up 20 Install front annulus snap ring Fig 249 Use snap ring pliers to avoid distorting ring during installation Also be sure ring is fully seated 21 Install planetary selective snap ring with snap ring pliers Fig 250 Be sure ring is fully seated 22 Turn planetary geartrain assembly over so driving shell is fadng workbench Then support geartrain on wood block positioned under forward end of output shaft This allows geartrain compo nents to move forward for accurate end play check 23 Check planetary geart
33. NOOO ce 0 991 66 0091 IV ISd s3unssaud dOlvinoagad deer morer CNN T 14 IN3A A MO TI3H3AO Q3IVA3 37x HOSN3S Suud HVA SdA 106 39H04 HVA SJA 19313S LETTQIA SIN HOLIMS Sd3Hd Sd 390553 10 H31H3ANO2 20 Holv1nWnoov ov 1 19 UW Ob 10 9 ou HO1n19 puz 2z lt 1 Be u 2 2 1 1 45RFE AUTOMATIC TRANSMISSION SCHEMATICS AND DIAGRAMS Continued 21 266 93220208 354957 an sw oora r G3zIDu3N3 541083105 pem e 0051 lv ISd s3unssaud 59 44099 08 61 eti se 591 56 Up HOSNAS SHHd HVA SdA LOFTAS ILINW ESW 79 YALYSANOO 99 H LNTO ur Puc oc 6 2 2 1 9999994 IN3A A MO TJHJAO Q3JVA3 T3473 7105 39HOH HVA SdA HOLIMS SdHd Sd dufnissdud ld YHOLVINANDOV OV TO 3Su3A3d 9H 3Su3A3Hd MO T d 1 21 267 45RFE AUTOMATIC TRANSMISSION WJ SCHEMATICS AND DIAGRAMS Continued 446409208 5 354957 0081 LY NO 44099 I
34. OL 3nouol IMIYA 4 4201 02 7 HN33H9S 3ATVA 15008 3ATVA HOlvno3u 105 J SATIVA LdIHS t tU ATA S1LIOHHL 3ATVA NIMDODIODI aul 3ATVA 1 WE 1 6 Z L 3ATVA LAIHS 2 1 i 3ATVA TI 32100 H E 3NTVA 1031409 LIIHS 1 JAVA LAIHS 5 6 _ SATVA 9119 JILLOHHL oS HONH3AOS 7 6 H LNT LNOHH HOLNTO GION310S HONH3AOD OAd3S HO1n12 3AIHQH3AO Ho1vinWnoov OAH3S LNOH4 21 175 42RE AUTOMATIC TRANSMISSION WJ SCHEMATICS AND DIAGRAMS Continued 0 isd 9 0 3unssSatd 7115 dud NOLLONS 150 25 6 aunssaud 38 yH3183ANOO 25 0 3ufiSS3ud HONH3AO5 139 0 8 TOHINOO 14lHS 2 1 isd t6 0 3ufiSS3ud 31LLOHHL isd 3ufiSS3ud 3NI1 uV35 DNISSVd LJ3IHSNMOG 2 6 31LLOHHL TINA MOTA 3 1LLOUHL 1103 dvao QNOO3S JAYA NI H3A31 HOL23 13S 3A1VA 201 3ATVA dfr201 GION310S dr43201 p 105 Audd3AO L3IHS t 3ATVA 7 6 CLE 3AT1VA 2 v e i YOLVINANIDOV v
35. ing surfaces carefully for evidence of wear or dam NV247 TRANSFER CASE 21 329 age Replace the shaft if necessary do not attempt to salvage it if damaged The shift rail and range fork are an assembly Replace both parts if either is damaged However the nylon pads in the fork can be replaced if worn or cracked Inspect the transfer case snap rings closely Do not attempt to salvage a distorted snap ring by straight ening or reshaping it Replace any snap ring that is distorted or worn Inspect the low range gear input gear and the gear thrust washers retainer and snap ring The low range gear is serviced as an assembly only Replace the gear if the case or pinions are damaged During inspection also make sure the seal surface of the input gear is in good condition Minor nicks on this surface can be reduced with crocus cloth How ever replace the gear if the seal surface is severely scored or worn OIL PUMP AND PROGRESSIVE COUPLING The oil pump and progressive coupling are not ser viceable components Replace the coupling as an assembly if it is leaking or damaged Replace the oil pump as an assembly if the gear teeth are worn or if the pump has become damaged BEARINGS AND SEALS The transfer case seals should be replaced during overhaul Use new seals in the input gear bearing retainer front case and rear retainer Also replace the yoke seal washer and the detent plug O ring Check condition of each transfer
36. 1 OIL PUMP AND REACTION SHAFT SUPPORT DISASSEMBLY 5 1 Remove seal ring from housing and reaction 6 shaft support Fig 206 2 Mark pump housing and support assembly for 2 F alignment reference D 3 Remove bolts attaching pump body to support Y Fig 207 9 P ud 80315881 Fig 204 Front Servo 1 PISTON RINGS 2 SERVO PISTON 3 O RING J9321 211 4 SNAP RING 5 PISTON ROD GUIDE Fig 206 Removing Pump Seal Ring 6 SEAL RING 1 PUMP HOUSING SEAL RING 7 SNAP RING 8 SERVO SPRING 9 WASHER 10 SPRING 11 PISTON ROD 0 7 6 19121 64 Fig 205 Rear Servo Components 80 483 7 1 SNAP RING Fig 207 Pump Support Bolts 2 PISTON SEAL 1 REACTION SHAFT SUPPORT 3 PISTON PLUG 2 PUMP 4 SPRING RETAINER 5 SNAP RING 6 PISTON SPRING 7 CUSHION SPRING 8 PISTON 21 124 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued 4 Separate support from pump housing Fig 208 5 Remove inner and outer gears from reaction shaft support Fig 209 If pump seal was not removed during transmis sion disassembly remove seal with punch and ham mer 7 Remove front clutch thrust washer from sup port hub Fig 210 J9321 213 Fig 208 Separating Pump Housing From Reaction Shaft Support 1 REACTION SHAFT SUPPORT 2 PUMP HOUSING
37. 286 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 287 Planetary Gear Installation 1 PLANETARY GEAR 2 ANNULUS GEAR 2 2 AUTOMATIC TRANSMISSION 21 147 DISASSEMBLY AND ASSEMBLY Continued 19121 326 Fig 288 Planetary Thrust Bearing Installation 1 SPRING PLATE 2 PLANETARY THRUST BEARING 3 SUN GEAR J9321 395 Fig 290 Alignment Tool Installation 1 SPECIAL TOOL 6227 2 2 PRESS PLATES 3 ASSEMBLED DRUM AND ANNULUS GEAR 4 SUN GEAR J9121 327 Fig 289 Sun Gear Installation 1 SUN GEAR AND SPRING PLATE ASSEMBLY 16 Align splines in hubs of planetary gear and overrunning clutch with Alignment tool 6227 2 Fig 290 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 291 Be sure spring is properly seated on spring plate 22 J9321 396 NOTE The 42RE transmission has 6 direct clutch discs and gt clutch plates Fig 291 Direct Clutch Spring Installation 1 SPECIAL TOOL 6227 2 2 DIRECT CLUTCH SPRING 3 CLUTCH HUB 4 PRESS PLATES 21 148 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Cont
38. 80 79 2 Fig 61 Brake Transmission Shift Interlock 4 STEERING COLUMN ASSEMBLY 5 INTERLOCK CABLE 1 SHIFT MECHANISM 2 SHIFTER BTSI LEVER 3 ADJUSTMENT CLIP 10 Install the center console and related trim Refer to Group 23 Body for proper procedures 11 Test the BTSI cable operation DISASSEMBLY AND ASSEMBLY TRANSMISSION DISASSEMBLY 1 Drain fluid from transmission 2 Clean exterior of transmission with suitable solvent or pressure washer 3 Remove the torque converter from the trans mission 4 Remove the manual shift lever from the trans mission 5 Remove the input output and line pressure sensors from the transmission case Fig 62 6 Inspec the ends of the sensors for debris which may indicate the nature of the transmission failure 7 Install Support Stand 8257 onto the transmis sion case Fig 63 OUTPUT SPEED SENSOR LINE PRESSURE INPUT SPEED SENSOR SENSOR 80c07350 Fig 62 Remove Input Output and Line Pressure Sensors 8 Using Adapter 8266 1 from End Play Tool Set 8266 and Dial Indicator C 3339 measure and record the input shaft end play Fig 64 21 224 45 AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued 80c07351 Fig 63 Install Support Stand Tool 8257 80c07352 Fig 64 Measure Input Shaft End Play NOTE When measuring the input shaft end play two stops will be felt When the input shaft is pushed i
39. 9 Se Qr End Play Set 8266 Filter Wrench 8321 a Spring Compressor 8285 Piston Installer 8504 NV242 TRANSFER CASE TABLE OF CONTENTS page DESCRIPTION AND OPERATION NV242 TRANSFER 275 LUBRICANT AND FILL LEVEL 276 DIAGNOSIS AND TESTING NV242 DIAGNOSIS 276 REMOVAL AND INSTALLATION TRANSFER CASE 277 FRONT OUTPUT SHAFT SEAL 278 NV242HD REAR RETAINER BUSHING AND SEAL oie rae ena 278 DESCRIPTION AND OPERATION NV242 TRANSFER CASE DESCRIPTION The NV242 is a full transfer case Fig 1 It pro vides full time 2 wheel or 4 wheel drive operation A differential in the transfer case is used to control torque transfer to the front and rear axles A low range gear provides increased low speed torque capa bility for off road operation The low range provides a 2 72 1 reduction ratio 18921 243 Fig 1 NV242 Transfer Case The input gear is splined to the transmission out put shaft It drives the mainshaft through the plan etary gear and range hub The front output shaft is operated by a drive chain that connects the shaft to a NV242 TRANSFER CASE 21 275 page TRANSFER CASE SHIFT CABLE 279 DISASSEMBLY AND ASSEMBLY NV242 TRANSFER 280 CLEANING AND INSPECTION NV242 TRANSFER 303 SPECIFICATIONS
40. At low speeds both pumps supply fluid to the transmission As the speed of the torque converter increases the pressure output of both pumps increases until the primary pump pressure reaches the point where it can close off the check valve located between the two pumps When the check valve is closed the secondary pump is shut down and the primary pump supplies all the fluid to the trans mission CONVERTER CLUTCH SWITCH VALVE The converter clutch switch valve is used to control the hydraulic pressure supplied to the front OFF side of the torque converter clutch CONVERTER CLUTCH REGULATOR VALVE The converter clutch regulator valve is used to con trol the hydraulic pressure supplied to the back ON side of the torque converter clutch TORQUE CONVERTER LIMIT VALVE The torque converter limit valve serves to limit the available line pressure to the torque converter clutch to approximately 120 psi 21 190 45RFE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued 80c07011 Fig 13 Oil Pump Reaction Shaft and Seal VALVE BODY DESCRIPTION The valve body consists of a cast aluminum valve body a separator plate and a transfer plate The valve body contains valves and check balls that con trol fluid delivery to the torque converter clutch bands and frictional clutches The valve body con tains the following components Fig 14 and Fig 15 Solenoid switch valve Manual valve Low reverse switch valve 5 Ac
41. Clean all chips from shaft after bushing removal 4 Lightly grip old bushing in vise or with pliers and back remover tool out of bushing 5 Assemble Bushing Installer Tools C 4171 and SP 5325 Fig 213 6 Slide new bushing onto Installer Tool SP 5325 7 Position reaction shaft support upright on a clean smooth surface 8 Align bushing in bore Then tap bushing into place until Bushing Installer SP 5325 bottoms 9 Clean reaction shaft support thoroughly after installing bushing ASSEMBLY 1 Lubricate gear bore in pump housing with transmission fluid 2 Lubricate pump gears with transmission fluid 3 Support pump housing on wood blocks Fig 214 4 Install outer gear in pump housing Fig 214 Gear can be installed either way it is not a one way fit 5 Install pump inner gear Fig 215 42RE AUTOMATIC TRANSMISSION 21 125 BUSHING REMOVAL BUSHING INSTALLATION 5 19221 243 Fig 213 Replacing Reaction Shaft Support Bushing 1 SPECIAL TOOL SP 1191 2 SPECIAL TOOL SP 3633 3 SPECIAL TOOL C 4171 4 SPECIAL TOOL SP 5325 5 REACTION SHAFT 6 SPECIAL TOOL SP 5324 7 BUSHING CAUTION The pump inner gear is a one way fit The bore on one side of the gear inside diameter 1 0 is chamfered Be sure the chamfered side faces forward to front of pump J9321 219 Fig 214 Supporting Pump And Installing Outer Gear 1 OUTER GEAR 2 PUMP H
42. Continued 4 Install overdrive geartrain into housing 5 Install overdrive unit in vehicle 80315860 Fig 107 Output Shaft Rear Bearing 1 OUTPUT SHAFT REAR BEARING 2 OVERDRIVE HOUSING 3 SNAP RING OUTPUT SHAFT FRONT BEARING REMOVAL 1 Remove overdrive unit from the vehide 2 Remove overdrive geartrain from housing 3 Remove snap ring holding output shaft front bearing to overdrive geartrain Fig 108 4 Pull bearing from output shaft INSTALLATION 1 Place replacement bearing in position 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 Fig 108 4 Install overdrive geartrain into housing 5 Install overdrive unit in vehide DISASSEMBLY AND ASSEMBLY VALVE BODY Remove the valve body from the transmission refer to Removal and Installation procedures section in this group DISASSEMBLY CAUTION Do not clamp any valve body compo nent in a vise This practice can damage the com ponent resulting in unsatisfactory operation after 42RE AUTOMATIC TRANSMISSION 21 89 80315861 Fig 108 Output Shaft Front Bearing 1 OUTPUT SHAFT FRONT BEARING 2 SNAP RING 3 OUTPUT SHAFT 4 GROOVE TO REAR 5 OVERDRIVE GEARTRAIN assembly and installation Do not use pliers to remove any of the valves plugs or springs and do not forc
43. Disconnect cable at shift lever and shifter assembly bracket Fig 12 NV242 TRANSFER CASE 21 279 WY She TRANSFER CASE SHIFT LEVER 4 em S SIS D A DP BO S TRANSFER CASE SHIFT CABLE 80ba79c6 Fig 11 Transfer Case Shift Cable at Transfer Case 8 Remove the nuts holding the shift cable seal plate to the floor pan Fig 13 9 Pull cable through floor panel opening b AR sS ERE NE nv Ed EN lt ns 80ba79cd Fig 12 Transfer Case Shift Cable at Shifter 1 CLIP 2 SHIFTER 3 TRANSFER CASE SHIFT LEVER PIN 4 TRANSFER CASE SHIFT CABLE 10 Remove transfer case shift cable from vehicle INSTALLATION 1 Route cable through hole in floor pan 2 Install seal plate to studs in floor pan 3 Install nuts to hold seal plate to floor pan Fig 13 Tighten nuts to 7 N m 65 in Ibs 4 Install the transfer case shift cable to the shifter assembly bracket Seat cable in bracket and install dip Fig 12 5 Verify the transfer case shift lever at console is in the NEUTRAL position 21 280 242 TRANSFER CASE REMOVAL AND INSTALLATION Continued 80ba79cc Fig 13 Shift Cables at Floor Pan 1 SEAL PLATES 2 TRANSMISSION SHIFT CABLE 3 TRANSFER CASE SHIFT CABLE 6 Snap the cable onto the shift lever pin Fig 12 7 Raise the vehicle 8 Install the shift cable to t
44. FRONT CLUTCH RETAINER 1 RETAINER SEAL 2 CLUTCH PISTON 3 PISTON SPRING 4 SPRING RETAINER SNAP RING 5 CLUTCH DISCS 6 PRESSURE PLATE FRONT CLUTCH DESCRIPTION The front clutch assembly Fig 54 is composed of the front clutch retainer pressure plate four clutch plates four driving discs piston piston return spring return spring retainer and snap rings The front clutch is the forwardmost component in the transmission geartrain and is directly behind the oil pump and is considered a driving component NOTE The number of discs and plates may vary with each engine and vehicle combination OPERATION To apply the clutch pressure is applied between the clutch retainer and piston The fluid pressure is provided by the oil pump transferred through the control valves and passageways and enters the clutch through the hub of the reaction shaft support With pressure applied between the clutch retainer and piston the piston moves away from the clutch retainer and compresses the clutch pack This action applies the clutch pack allowing torque to flow through the input shaft into the driving discs and into the clutch plates and pressure plate that are lugged to the clutch retainer The waved snap ring is used to cushion the application of the clutch pack In some transmissions the snap ring is selective and used to adjust clutch pack clearance When pressure is released from the piston the
45. Fig 15 Torque Converter Fluid Operation 1 APPLY PRESSURE 2 THE PISTON MOVES SLIGHTLY FORWARD 3 RELEASE PRESSURE 4 THE PISTON MOVES SLIGHTLY REARWARD TURBINE As the fluid that was put into motion by the impel ler blades strikes the blades of the turbine some of the energy and rotational force is transferred into the turbine and the input shaft This causes both of them turbine and input shaft to rotate in a dockwise direction following the impeller As the fluid is leav ing the trailing edges of the turbine s blades it con tinues in a hindering direction back toward the impeller If the fluid is not redirected before it strikes the impeller it will strike the impeller in such a direction that it would tend to slow it down STATOR Torque multiplication is achieved by locking the stator s over running clutch to its shaft Fig 16 Under stall conditions the turbine is stationary the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counter dockwise direction When this happens the over run ning dutch of the stator locks and holds the stator from rotating With the stator locked the oil strikes the stator blades and is redirected into a helping direction before it enters the impeller This circula tion of oil from impeller to turbine turbine to stator and stator to impeller can produce a maximum torque multiplication of about 2 4 1 As the turbine be
46. Install remaining thrust washer in low range gear and on top of input gear Be sure washer tabs are properly aligned in gear notches 5 Install retainer on input gear and install snap ring 19321 60 Fig 52 Input Low Range Gear Components 1 SNAP RING 2 RETAINER PLATE 3 GEAR 4 LOW RANGE GEAR 5 THRUST WASHERS INPUT GEAR LOW RANGE INSTALLATION 1 Align and install low range input gear assem bly in front case Fig 53 Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing 2 Install snap ring to hold input low range gear into front bearing Fig 54 3 Clean gasket sealer residue from retainer and inspect retainer for cracks or other damage 4 Apply a 3 mm 1 8 in bead of Mopar gasket maker or silicone adhesive to sealing surface of retainer 5 Align cavity in seal retainer with fluid return hole in front of case CAUTION Do not block fluid return cavity on seal ing surface of retainer when applying Mopar gas 21 323 NV247 TRANSFER CASE J9321 61 Fig 53 Input Low Range Gear Installation 1 ANNULUS GEAR 2 INPUT LOW RANGE GEAR 19321 28 Fig 54 Install Snap Ring 1 GEAR 2 SNAP RING ket maker or silicone adhesive sealer Seal failure and fluid leak can result 6 Install bolts to hold retainer to transfer case Fig 55 Tighten to 21
47. Install the 4C retainer bulkhead tapered snap ring into the transmission case Make sure that the open ends of the snap ring are located in the case opening toward the valve body area 15 Using a feeler gauge through the opening in the rear of the transmission case measure the 2C dutch pack dearance between the 2C reaction plate and the transmission case at four different points The average of these measurements is the 2C clutch pack dearance Adjust the dearance as necessary The correct dutch dearance is 0 533 1 27 mm 0 021 0 050 in The reaction plate is selective Install the chosen reaction plate and re measure the dutch dearance to verify the selection 16 Remove the 4C retainer bulkhead and all of the 2C dutch components from the transmission case 17 Install the low reverse dutch assembly Fig 81 Make sure that the oil feed hole points toward the valve body area and that the bleed orifice is aligned with the notch in the rear of the transmis sion case 18 Install the snap ring to hold the low reverse dutch retainer into the transmission case Fig 81 The snap ring is tapered and must be installed with the tapered side forward Once installed verify that the snap ring is fully seated in the snap ring groove SEAL WJ DISASSEMBLY AND ASSEMBLY Continued LOW REVERSE OVERRUNNING CLUTCH ASSEMBLY SNAP RING 80c07411 Fig 81 Install Low Reverse Clutch Retainer
48. J9121 321 Fig 280 Ouiput Shaft Pilot Bushing 1 OUTPUT SHAFT HUB 2 OVERRUNNING CLUTCH HUB BUSHING 3 INTERMEDIATE SHAFT PILOT BUSHING 3 Install annulus gear on output shaft if removed Then install annulus gear retaining snap ring Fig 281 4 Align and install clutch drum on annulus gear Fig 282 Be sure drum is engaged in annulus gear lugs 5 Install dutch drum outer retaining ring Fig 282 WJ DISASSEMBLY AND ASSEMBLY Continued J9021 89 Fig 281 Annulus Gear Installation 1 SNAP RING 2 OUTPUT SHAFT FRONT BEARING 3 ANNULUS GEAR J9321 393 Fig 282 Clutch Drum And Outer Retaining Ring Installation 1 ANNULUS GEAR 2 OUTER SNAP RING 3 CLUTCH DRUM 42RE TRANSMISSION 21 145 6 Slide clutch drum forward and install inner retaining ring Fig 283 7 Install rear bearing and snap ring on output shaft Fig 284 Be sure locating ring groove in bear ing is toward rear J9321 394 Fig 283 Clutch Drum Inner Retaining Ring Installation 1 ANNULUS GEAR 2 INNER SNAP RING 3 CLUTCH DRUM J9321 370 Fig 284 Rear Bearing And Snap Ring Installation 1 REAR BEARING 2 SNAP RING 21 146 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued 8 Install overrunning clutch on hub Fig 285 Note that clutch only fits one way Shoulder on clutch should seat in small recess at edge of hub
49. SHUTTLE VALVE COVER 2 RETAINER 9 SHUTTLE VALVE 3 BOOST VALVE 10 SHUTTLE VALVE PRIMARY SPRING 4 BOOST VALVE PLUG 11 GOVERNOR PLUG COVER 5 SPRING GUIDES 12 THROTTLE PLUG 6 E CLIP 13 UPPER HOUSING 7 SHUTTLE VALVE SECONDARY SPRING 14 BOOST VALVE COVER 2 AUTOMATIC TRANSMISSION 21 19 DESCRIPTION AND OPERATION Continued J9321 157 Fig 20 Upper Housing Shift Valve and Pressure Plug Locations 1 UPPER HOUSING 8 RETAINER 2 1 2 SHIFT VALVE AND SPRING 9 1 2 SHIFT CONTROL VALVE AND SPRING 3 2 3 SHIFT VALVE AND SPRING 10 PRESSURE PLUG COVER 4 2 3 THROTTLE PLUG 11 LINE PRESSURE PLUG 5 LIMIT VALVE HOUSING 12 PLUG SLEEVE 6 LIMIT VALVE COVER 13 THROTTLE PRESSURE SPRING AND PLUG 7 LIMIT VALVE AND SPRING 21 20 42RE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued 80607265 Fig 21 Lower Housing Shift Valves and Springs 1 3 4 ACCUMULATOR HOUSING 11 TIMING VALVE COVER 2 8 4 SHIFT VALVE AND SPRING 12 PLUG 3 PLUG 13 3 4 TIMING VALVE AND SPRING 4 SPRING RETAINER 14 LOWER HOUSING 5 CONVERTER CLUTCH VALVE AND SPRING 15 ACCUMULATOR END PLATE 6 CONVERTER CLUTCH TIMING VALVE AND SPRING 16 3 4 ACCUMULATOR PISTON AND SPRING 7 OVERDRIVE SEPARATOR PLATE 17 E CLIP 8 CASE CONNECTOR 18 3 4 QUICK FILL SPRING AND VALVE 9 CONVERTER CLUTCH SOLEN
50. SOLENOID HARNESS CASE CONNECTOR 2 8 4 ACCUMULATOR HOUSING go A Z E AO J J9321 458 Fig 110 Unhooking Solenoid Harness From Accumulator Cover Plate 1 OVERDRIVE CONVERTER SOLENOID WIRE HARNESS 2 3 4 ACCUMULATOR COVER PLATE 80c072b3 Fig 111 Solenoid Assembly Screws 1 OVERDRIVE CONVERTER CLUTCH SOLENOID ASSEMBLY 2 HARNESS 80c072b4 Fig 112 Solenoid Assembly 1 GOVERNOR SOLENOID WIRES 2 CONVERTER CLUTCH SOLENOID 3 SOLENOID SCREWS 4 GOVERNOR SENSOR WIRES 5 OVERDRIVE SOLENOID 6 HARNESS 7 CASE CONNECTOR WJ J9321 467 Fig 113 Boost Valve Cover Location 1 BOOST VALVE HOUSING AND COVER 2 BOOST VALVE TUBE T P xe To gt gt AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued J9321 468 Fig 114 Boost Valve Components 1 SPRING AND VALVE RETAINER 2 COVER SCREWS 3 BOOST VALVE COVER 4 BOOST VALVE PLUG 5 BOOST VALVE 6 BOOST VALVE SPRING 21 91 17 Position pencil magnet next to detent housing to catch detent ball and spring Then carefully remove Retainer Tool 6583 and remove detent ball and spring Fig 119 18 Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate Fig 120 Hold bracket firmly against spring tension while removing last screw J9521 178 Fig 115 Detent Ball And Spring 1 SPECIA
51. The over drive dutch discs are attached to the overdrive clutch hub while the overdrive clutch plates reaction plate and pressure plate are lugged to the overdrive hous ing This allows the intermediate shaft to transfer the engine torque to the planetary gear and overrun ning dutch This drives the planetary gear inside the annulus which is attached to the overdrive clutch drum and output shaft creating the desired gear ratio The waved snap ring is used to cushion the application of the clutch pack WJ DESCRIPTION AND OPERATION Continued OVERRUNNING CLUTCH DESCRIPTION The overrunning clutch Fig 57 consists of an inner outer race or 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 LOCKED 4 FREE WHEELING 80be45f8 Fig 57 Overrunning Clutch 1 OUTER RACE CAM 2 ROLLER 3 SPRING 4 SPRING RETAINER 5 INNER RACE HUB 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 between the rollers and cam This increased clear ance between the rollers and cam results in a free wheeling condition When the inner race attempts to rotate counte
52. Worn Pump Incorrect Control to determine cause Pressure Adjustments Valve Body Warpage or Malfunction Sticking Leaking Seal Rings Clutch Seals Leaking Servo Leaks Clogged Filter or Cooler Lines 7 Rear Clutch Malfunction Leaking 7 Air pressure check clutch servo operation Seals or Worn Plates and repair as required 8 Overrunning Clutch Worn Not 8 Replace Clutch Holding Slips in 1 Only SLIPS IN LOW GEAR Overrunning Clutch Faulty Replace overrunning clutch ONLY BUT NO IN 1 POSITION GROWLING GRATING OR 1 Drive Plate Broken 1 Replace SCRAPING NOISES 2 Torque Converter Bolts Hitting 2 Dust shield bent Replace or repair Dust Shield 3 Planetary Gear Set Broken 3 Check for debris in oil pan and repair as Seized required 4 Overrunning Clutch Worn Broken 4 Inspect and check for debris in oil pan Repair as required 5 Oil Pump Components Scored 5 Remove inspect and repair as required Binding 6 Output Shaft Bearing or Bushing 6 Remove inspect and repair as required Damaged 7 Clutch Operation Faulty 7 Perform air pressure check and repair as required 8 Front and Rear Bands 8 Adjust bands Misadjusted 2 AUTOMATIC TRANSMISSION 21 67 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION DRAGS OR LOCKS UP 1 Fluid Level Low 1 Check and adjust level 2 Clutch Dragging Failed 2 Air pressure check clutch operat
53. Z BEAD REAR RETAINER AND OIL PUMP REMOVAL 2 1 Remove rear retainer bolts Fig 14 Qe W X 2 Remove rear bearing locating ring access plug SS Fig 15 lt D S3 N 80ba7a34 Fig 16 Loosening Rear Retainer PARALLEL 0 SNAP RING AV U gt PLIERS REAR ETAINER RETAINER S 9 Z 9 80ba7a35 A E Z Fig 14 Rear Retainer Bolt Removal Se N lt E 3 Loosen rear retainer with pry tool to break DNS S y gt sealer bead Pry only against retainer boss as shown Fig 16 4 80ba7a36 4 Remove rear retainer as follows a Spread rear bearing locating ring with snap ring pliers Fig 17 Fig 17 Disengaging Rear Bearing Locating Ring 5 Remove rear bearing snap ring WJ DISASSEMBLY AND ASSEMBLY Continued REAR CASE REAR RETAINER 80ba7a37 Fig 18 Rear Retainer Removal 6 Remove rear bearing Note position of bearing locating ring groove for assembly reference 7 Disengage oil pickup tube from oil pump and remove oil pump assembly Fig 19 8 Remove pick up tube o ring from oil pump Fig 20 if necessary Do not disassemble the oil pump it is not serviceable OIL PUMP TUBE O RING OIL e PICKUP TUBE 80ba7a38 Fig 19 Rear Bearing and Oil Pump Removal PROGRESSIVE COUPLING REM OVAL 1 Remove oil pump locating snap ring and pro gressive coupling snap ring fr
54. efficiency of the torque converter that is lost to the slippage of the fluid coupling Although the fluid cou pling provides smooth shock free power transfer it is natural for all fluid couplings to slip If the impel ler and turbine were mechanically locked together a zero slippage condition could be obtained A hydraulic piston was added to the turbine and a friction mate rial was added to the inside of the front cover to pro vide this mechanical lock up OPERATION The converter impeller Fig 15 driving member which is integral to the converter housing and bolted to the engine drive plate rotates at engine speed The converter turbine driven member which reacts from fluid pressure generated by the impeller rotates and turns the transmission input shaft 80bfe26f Fig 14 Torque Converter Clutch TCC 1 IMPELLER FRONT COVER 2 THRUST WASHER ASSEMBLY 3 IMPELLER 4 STATOR 5 TURBINE 6 FRICTION DISC WJ DESCRIPTION AND OPERATION Continued TORQUE CONVERTER CLUTCH RELEASED 42RE AUTOMATIC TRANSMISSION 21 15 VENTED 2 TORQUE CONVERTER CLUTCH APPLIED 800 276
55. past the piston There must be a resistance to flow in order to create pres sure Piston sealing is extremely important in hydraulic operation Several kinds of seals are used to accomplish this within a transmission These indude but are not limited to O rings D rings lip seals sealing rings or extremely dose tolerances between the piston and the cylinder wall The force exerted is downward gravity however the principle remains the same no matter which direction is taken The pressure created in the fluid is equal to the force applied divided by the piston area If the force is 100 lbs and the piston area is 10 sq in then the pres sure created equals 10 PSI Another interpretation of Pascal s Law is that regardless of container shape or size the pressure will be maintained throughout as long as the fluid is confined In other words the pressure in the fluid is the same everywhere within the container FORCE MULTIPLICATION Using the 10 PSI example used in the illustration Fig 19 a force of 1000 Ibs can be moved with force of only 100 Ibs The secret of force multiplica tion in hydraulic systems is the total fluid contact area employed The illustration Fig 19 shows an area that is ten times larger than the original area The pressure created with the smaller 100 input is 10 PSI The concept pressure is the same every WJ DESCRIPTION AND OPERATION Continued WHEN FLUID PRESSURE IS CREATED IS
56. selector lever in PARK and NEUTRAL positions only The outer terminals on the switch are for the backup lamp circuit SWITCH TEST To test the switch remove the wiring connector Test for continuity between the center terminal and the transmission case Continuity should exist only when the transmission is in PARK or NEUTRAL Shift the transmission into REVERSE and test continuity at the switch outer terminals Continuity should exist only when the transmission is in REVERSE Continuity should not exist between the outer terminals and the case Check gearshift linkage adjustment before replac ing a switch that tests faulty 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 Refer to Group 8W Wiring Dia grams for component locations and circuit informa tion Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range BRAKE TRANSMISSION SHIFT INTERLOCK 1 Verify that the key can only be removed in the PARK position 2 When the shift lever is in PARK And the shift handle pushbutton is in the OU T position the igni tion key cylinder should rotate freely from OFF to LOCK When the shifter is in any other gear or neu tral position the ignition key cylinder should
57. spring returns the piston to its fully released position and disengages the clutch The release spring also helps to cushion the application of the clutch assem bly When the clutch is in the process of being released by the release spring fluid flows through a vent and one way ball check valve located in the clutch retainer The check valve is needed to elimi nate the possibility of plate drag caused by centrifu gal force acting on the residual fluid trapped in the clutch piston retainer WJ DESCRIPTION AND OPERATION Continued 42RE AUTOMATIC TRANSMISSION 21 43 80c070a4 Fig 55 Rear Clutch 1 PISTON SPRING 2 REAR CLUTCH PISTON 3 CLUTCH PISTON SEALS 4 OUTPUT SHAFT THRUST WASHER METAL 5 INPUT SHAFT SNAP RING 6 REAR CLUTCH RETAINER 7 INPUT SHAFT 8 REAR CLUTCH THRUST WASHER FIBER 9 CLUTCH PACK SNAP RING SELECTIVE 10 TOP PRESSURE PLATE 11 CLUTCH DISCS 4 12 BOTTOM PRESSURE PLATE 13 WAVE SPRING 14 CLUTCH PLATES 3 15 RETAINER SEAL RING 16 SHAFT REAR SEAL RING PLASTIC 17 SHAFT FRONT SEAL RING TEFLON REAR CLUTCH DESCRIPTION The rear dutch assembly Fig 55 is composed of the rear clutch retainer pressure plate three clutch plates four driving discs piston Belleville spring and snap rings The Belleville spring acts as a lever to multiply the force applied on to it by the apply pis ton The increased apply force
58. 10 F and 36 F Oil temperature 40 F and 80 F Park Reverse Neutral and 1st and 3rd gear only in D position 2nd gear only in Manual 2 or L Delayed 2 3 upshift Delayed 3 4 upshift Early 4 3 coastdown shift High speed 4 2 3 2 2 1 kickdown shifts are prevented Shifts at high throttle openings willl be early No EMCC Shift schedule is the same as Super Cold except that the 2 3 upshifts are not delayed Normal operation upshift kickdowns and coastdowns No EMCC Normal operation upshift kickdowns and coastdowns Normal EMCC operation Delayed 2 3 upshift Delayed 3 4 upshift 3rd gear from 30 48 mph 3rd gear PEMCC above 35 mph Above 25 mph the torque converter will not unlock unless the throttle is closed or if a wide open throttle 2nd PEMCC to 1 kickdown is made WJ DESCRIPTION AND OPERATION Continued SOLENOID AND PRESSURE SWITCH ASSEMBLY DESCRIPTION The solenoid and pressure switch assembly is internal to the transmission and mounted on the valve body assembly Fig 30 The assembly consists of six solenoids that control hydraulic pressure to the six friction elements transmission clutches and the torque converter dutch The pressure control sole noid is located on the side of the solenoid and pres sure switch assembly The solenoid assembly also contains five pressure switches that feed informa
59. 12 Verify that plunger is properly engaged in sec tor FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION 1 Lubricate front output shaft sprocket assembly drive chain and drive sprocket with transmission fluid 2 Assemble drive chain drive sprocket and front output shaft Fig 60 3 Start drive sprocket on mainshaft 4 Guide front shaft into bearing and drive sprocket onto mainshaft drive gear Fig 60 5 Install drive sprocket snap ring Fig 61 6 Install roller bearings if removed 7 Install progressive coupling Fig 62 8 Install oil pickup tube in rear case Be sure tube is seated in case notch as shown Fig 63 9 Install magnet in front case pocket Fig 64 WJ DISASSEMBLY AND ASSEMBLY Continued DETENT PLUNGER J9321 22 Huu B 9321 72 Fig 60 Installing Drive Chain Front Output Shaft And Drive Sprocket 1 FRONT OUTPUT SHAFT 2 DRIVE CHAIN 3 MAINSHAFT 4 DRIVE SPROCKET 10 Clean sealing flanges of front case and rear case with a wax and grease remover 11 Apply mm 1 8 in wide bead of gasket maker or silicone adhesive sealer to mounting flange of front case Work sealer bead around bolt holes as shown Fig 65 12 Align and install rear case on front case Fig 66 NV247 TRANSFER CASE 21 325 DRIVE SPROCKET SNAP RING SNAP RING GAS Fig 61 Installing Drive Sp
60. 19 Air check the low reverse clutch and verify correct overrunning clutch operation 20 Install the reverse input planetary assembly through the low reverse dutch assembly Fig 82 21 Install the number 12 bearing over the output shaft of the rear planetary gear set and onto the low reverse dutch assembly The flat side of the bearing goes toward the clutch assembly INPUT REVERSE PLANETARY ASSEMBLY BEARING NUMBER 12 BEARING NUMBER 9 80c07410 Fig 82 Install Input Reverse Planetary Assembly 22 Install the park sprag onto the output shaft Fig 83 23 Install the snap ring to hold the park sprag onto the output shaft Fig 84 24 Install the 2C reaction plate into the trans mission case Fig 85 The reaction plate is selective 45RFE AUTOMATIC TRANSMISSION 21 229 PARK SPRAG GEAR 80c07413 80c07412 Fig 84 Install Park Sprag Snap Ring and directional The plate must be installed with the flat side toward the front 25 Install the 2C dutch pack into the transmis sion case Fig 85 26 Install the number 8 bearing inside the tion carrier with the round side against the plane tary carrier 27 Install the reaction planetary gear set and the number 9 bearing into the transmission case Fig 86 28 Install the flat 2C dutch snap ring into the transmission case Fig 85 29 Install the reaction sun gear into the reaction planetary gear set with the small should
61. 2 i JILLNHS ond J uolvinWnoov H91019 OAH3S LNOHH i Y S f ond HONH3AOS 42RE AUTOMATIC TRANSMISSION SCHEMATICS AND DIAGRAMS Continued 21 166 NOLLONS isd 061 96 3unssaud AEN TH3183ANOO isd 001 05 3HATVA OL 3unss3ud 3NI1 isd 0 lt 2 1 L4IHS 2 1 isd v6 0 a3unssaud JILLOYHL isd 0 2 091 3unssaud INNT 3SH3A3H
62. 5 N m 40 in 165 9 Verify that the oil pump gears rotate freely and smocthl y 10 Position the reaction shaft support into the oil pump Fig 103 11 Install and torque the bolts to hold the tion shaft support to the oil pump Fig 103 The cor rect torque is 12 N m 105 in 165 21 238 45RFE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued T C REGULATOR OIL PUMP VALVE BODY gt Fig 105 Oil Pump Valve Body RETAINER REGULATOR VALVE 80c07422 T C SWITCH OIL PUMP VALVE BODY 80c07421 Fig 106 T C Switch Valve INPUT CLUTCH ASSEMBLY DISASSEMBLY 1 Remove the reverse reaction plate selective snap ring from the input dutch retainer Fig 107 2 Remove the reverse reaction plate from the input dutch retainer 3 Remove the reverse hub and reverse clutch pack from the input clutch retainer 4 Remove the number 4 bearing from the over drive hub 5 Remove the overdrive hub from the input dutch retainer Fig 107 6 Remove the number 3 bearing from the under drive hub 7 Remove the OD reverse reaction plate snap ring from the input clutch retainer 8 Remove the underdrive hub overdrive dutch and overdrive reaction plate from the input clutch retainer Fig 107 NOTE The overdrive friction discs and steel discs are thicker than the matching components in the underdrive and reverse clutches 9 Remove the number 2 bearing fro
63. AND INSPECTION Continued Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth Position the crocus cloth on a surface plate sheet of plate glass or equally flat sur face If distortion is severe or any surfaces are heavily scored the valve body will have to be replaced CAUTION Many of the valves and plugs such as the throttle valve shuttle valve plug 1 2 shift valve and 1 2 governor plug are made of coated alumi num Aluminum components are identified by the dark color of the special coating applied to the sur face or by testing with a magnet Do not sand alu minum valves or plugs under circumstances This practice could damage the special coating causing the valves plugs to stick and bind Inspec the valves and plugs for scratches burrs nicks or scores Minor surface scratches on steel valves and plugs can be removed with crocus doth but do not round off the edges of the valve or plug lands Maintaining sharpness of these edges is vitally important The edges prevent foreign matter from lodging between the valves and plugs and the bore Inspect all the valve and plug bores in the valve body Use a penlight to view the bore interiors Replace the valve body if any bores are distorted or scored Inspect all of the valve body springs The springs must be free of distortion warpage or broken coils Check the two separator plates for distortion or d
64. CONDITION POSSIBLE CAUSES CORRECTION NO 3 4 UPSHIFT 1 Dash O D Switch In OFF Position 1 Turn control switch to ON position 2 Overdrive Circuit Fuse Blown 2 Replace fuse Determine why fuse failed and repair as necessary i e shorts or grounds in circuit 3 O D Switch Wire Shorted Open 3 Check wires connections with 12V test Cut lamp and voltmeter Repair damaged or loose wire connection as necessary 4 Distance or Coolant Sensor 4 Check with DRB scan tool and repair or Malfunction replace as necessary 5 TPS Malfunction 5 Check with DRB scan tool and replace if necessary 6 Neutral Switch to PCM Wire 6 Test switch as described in service Shorted Cut section and replace if necessary Engine no start 7 Malfunction 7 Check with DRB scan tool and replace if necessary 8 Overdrive Solenoid Shorted Open 8 Replace solenoid if shorted or open and repair loose or damaged wires DRB scan tool 9 Solenoid Feed Orifice in Valve 9 Remove disassemble and clean valve Body Blocked body thoroughly Check feed orifice 10 Overdrive Clutch Failed 10 Disassemble overdrive and repair as needed 11 Hydraulic Pressure Low 11 Pressure test transmission to determine cause 12 Valve Body Valve Stuck 12 Repair stuck 3 4 shift valve 3 4 timing valve 13 O D Piston Incorrect Spacer 13 Remove unit check end play and install correct spacer 14 Overdrive Piston Seal Failure 14 Replace both s
65. Clutch Pack Snap Ring Installation 1 SPECIAL TOOL 6227 1 2 DIRECT CLUTCH PACK SNAP RING J9321 401 Fig 297 Clutch Hub Retaining Ring Installation 1 SPECIAL TOOL 6227 1 2 CLUTCH HUB RETAINING RING 2 J9121 338 Fig 298 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 GEAR CASE ASSEMBLY 1 Position park pawl and spring in case and install park pawl shaft Verify that end of spring with 90 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 Ibs torque 3 Install park lock reaction plug Note that plug has locating pin at rear Fig 298 Be sure pin is seated in hole in case before installing snap ring 4 Install reaction plug snap ring Fig 299 Com press snap ring only enough for installation do not distort it 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 On 4 x 2 gear case use same Han dle C 4171 and Installer C 3995 A to seat seal in case 8921 240 Fig 299 Reaction Plug And Snap Ring Installation 1 REACTION PLUG SNAP RING 2 SNAP RING PLIERS WJ DISASSEMBLY AND ASSEMBLY Continued 6 Verify that tab ends of rear bearing locating ring extend into access hole in gear case Fig 3
66. Continued 21 254 lt 908 3ddSr 95 99 92 0 SLi ocz cb 0091 LV ISd s3unssa3ud HOlV In 5dH oor morer d daria 14 14 MO 3H3AO Q31VA313 x H HOSN3S S3Hd HVA SdA 7105 HVA SJA ov LOd1aS ILINW SW HOLIMS S3Hd Sd 3 5534 14 YHALYAANOD 99 HOLfTIO uiv Ot 19 JSHHAHH O2H Ou mE HO1fT19 Puz oz 5 MOT H1 3SH3A3H 21 255 45RFE AUTOMATIC TRANSMISSION WJ SCHEMATICS AND DIAGRAMS Continued 92622908 OrTOVHGAH 354957 0081 Iv NO 99 44099 3NIT Sd s3unssaud 97 5 error osc ov vini N d i N a Ll d I a 14 MO TIJH3AO G31VA313 x HOSN3S SdHd HVA SdA 7105 30HOd HVA SJA Ov 419474S ILINW SA HOLIMS Sa3tld Sd dVL 3HfisS3Hd 1d 7 19 H31H3ANOO 700 uolvinWnoov ov HOLN19 10 3suaA3u ou oo dn HOLNTO Puz oe 3SH3A3H MOT H1 9 Ala o c c 8 H3AO OL LJIHS 2 5018 3suaAad 45RFE AUTOMATIC TRANSMISSION SCHEMATICS AND DIAGRAMS Continued 21 256 ZP6Zeq08 JILVASHO
67. DRB readings and the gauge reading to make a determi nation regarding the accuracy of the feedback con trols In order to access any other pressure tap locations the transmission oil pan must be removed the pres sure port plugs removed and Valve Body Pressure Tap Adapter 8258 Fig 34 installed The extensions supplied with Adapter 8258 will allow the installa tion of pressure gauges to the valve body Refer to Fig 32 for correct pressure tap location identifica tion 80ba79d1 Fig 32 Pressure Tap Locations WJ DIAGNOSIS AND TESTING Continued A ES m ES h e 80 07215 Fig 33 Line Pressure Adapter 8259 80c072fa Fig 34 Valve Body Pressure Tap Adapter 8258 TEST PROCEDURE pressure readings should be taken with the transmission fluid level full transmission oil at the normal operating temperature and the engine at 1500 rpm Check the transmission for proper opera tion in each gear position that is in question or if a specific element is in question check the pressure readings in at least two gear positions that employs that element Refer to the Hydraulic Schematics at 45RFE AUTOMATIC TRANSMISSION 21 209 the rear of this section to determine the correct pres sures for each element in a given gear position NOTE The 45RFE utilizes closed loop control of pump line pressure The pressure readings may therefore vary greatly
68. Engine starts must not be possible in any other gate posi tions other than park or neutral 9 With shifter lever handle push button not depressed and lever detent in e PARK POSITION apply forward force on center of handle and remove pressure Engine start must be possible e PARK POSITION apply rearward force on cen ter of handle and remove pressure Engine start must be possible e NEUTRAL POSITION engine start must be possible e NEUTRAL POSITION ENGINE RUNNING AND BRAKES APPLIED Apply forward force on center of shift handle Transmission should not be able to shift into reverse detent TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT The transmission throttle valve is operated by a cam on the throttle lever The throttle lever is oper 21 160 42RE AUTOMATIC TRANSMISSION ADJ USTMENTS Continued 80ba79c2 Fig 316 Brake Transmission Shift Interlock Cable 4 STEERING COLUMN ASSEMBLY 5 INTERLOCK CABLE 1 SHIFT MECHANISM 2 SHIFTER BTSI LEVER 3 ADJUSTMENT CLIP ated by an adjustable cable Fig 317 The cable is attached to an arm mounted on the throttle lever shaft A retaining clip at the engine end of the cable is removed to provide for cable adjustment The retaining dip is then installed back onto the throttle valve cable to lock in the adjustment A correctly adjusted throttle valve cable will cause the throttle lever on the transmission to move simul taneously with the throttle
69. Fig 107 Low Range Annulus Gear 1 FRONT SLINGER PART OF YOKE 1 FRONT CASE 2 SEAL CONTACT SURFACE MUST BE CLEAN AND SMOOTH 2 LOW RANGE ANNULUS GEAR be repaired with a thread chaser or tap if necessary Or the threads can be repaired with Helicoil stainless pickup parts Replace the pump if any part appears to be worn or damaged Do 21 306 NV242 TRANSFER CASE CLEANING AND INSPECTION Continued not disassemble the pump as individual parts are not available The pump is only available as a complete assembly The pickup screen hose and tube are the only serviceable parts and are available separately SPECIFICATIONS TORQUE DESCRIPTION TORQUE Plug Detent 16 24 N m 12 18 ft 165 Bolt Diff Case 17 27 N m 15 24 ft Ibs Plug Drain Fill 20 25 N m 15 25 ft Ibs Bolt Front Brg Retainer 16 27 12 20 ft Ibs Bolt Case Half 35 46 N m 26 34 ft Ibs Nut Front Yoke 122 176 N m 90 130 ft Ibs Screw Oil Pump 1 2 1 8 N m 12 15 in 16 Nut RangeLever 27 34 20 25 ft Ibs Bolt Rear Retainer 35 46 26 34 ft Ibs Nuts Mounting 35 N m 26 ft Ibs Bolts 0 oint 19 N m 17 ft Ibs SPECIAL TOOLS NV242 Installer C 4076 B Handle Universal C 4171 Remover C 4210 Puller Slinger MD 998056 A Installer MD 998323 Installer Bearing 5064 I
70. HV39 GHIHL JAHA NI HOLOATAS 3ATVA dr1001 3N1VA GION310S LJIHS T 3AT1VA 6 JAYA TI MOIDO H E LL B 7 6 1 19 3AIHQH3AO NOILVOIBSfT HOL1n D LNOYS JAVA HOLIMS M amva 16008 OL 5 3ATVA 3NIVA TILLOHHL 103444095 LAIHS 6 3ATVA 31LLOHS 3 T1LLOUHL HOLN1D 1NOtd OAYAS LNOtid uaria 10 H31H83ANOCO 3nouor 1 Na3828 SATIVA 19 1 9944 3BATVA 1 6 2 1 HONd3A09 VS 3ATVA L3IHS 6 2 HONH3AOD SN1d J1LLOHHL NC o o GION3 IOS HONH3AOS OAu3S uVau 42RE AUTOMATIC TRANSMISSION SCHEMATICS AND DIAGRAMS Continued 21 170 58 9 08 isd 6 0 3unssaud NOILO3S sd 16 6 3unssaud aan JH31H3ANOO isd v6 0 3uHnssdHd 5 159 6 6 3unssaud INIT a3r1ddV H LNT H31H3ANOO HY39 3AIHG NI MOTA aaxoo1un HV39 JAHA NI HOLO3 13S 3AT1VA dr1901 3AT1VA
71. Install shift lever bezel and any console parts removed for access to transfer case shift cable FRONT OUTPUT SHAFT SEAL REM OVAL 1 Raise vehicle on hoist 2 Remove front propeller shaft Refer to Group 3 Differential and Driveline for proper procedure 3 Remove front output shaft companion shaft 4 Remove seal from front case with pry tool Fig 9 INSTALLATION 1 Install new front output seal in front case with Installer Tool 6952 A as follows a Place new seal on tool Garter spring on seal goes toward interior of case b Start seal in bore with light taps from ham mer Fig 10 Once seal is started continue tap ping seal into bore until installer tool seats against case WJ REMOVAL AND INSTALLATION Continued QU x 2222 e 80a1108b Fig 9 Remove Front Output Shaft Seal 1 OUTPUT SHAFT SEAL 2 PRYBAR 80a98363 Fig 10 Front Output Seal Installation 1 INSTALLER 6952 A 2 TRANSFER CASE 2 Install companion flange and torque nut to 122 176 N m 90 130 ft Ibs 3 Install front propeller shaft Refer to Group 3 Differential and Driveline for proper procedures and torque specifications REAR RETAINER BUSHING AND SEAL REMOVAL 1 Raise vehicle on hoist 2 Remove rear propeller shaft Refer to Group 3 Differential and Driveline for proper procedure 3 Using a suitable pry tool or slide hammer mounted screw remove the rear
72. J9321 214 Fig 209 Pump Gear Removal 1 REACTION SHAFT SUPPORT 2 INNER GEAR 3 OUTER GEAR 80 483 8 Fig 210 Support Hub Thrust Washer 1 BUSHING 2 REACTION SHAFT SUPPORT 3 THRUST WASHER 4 HUB OIL PUMP BUSHING REPLACEMENT 1 Remove pump bushing with Tool Handle C 4171 and Bushing Remover SP 3551 from Tool Set 3887 Fig 211 2 Install new pump bushing with Tool Handle C 4171 and Bushing Installer SP 5117 Fig 211 Bushing should be flush with pump housing bore 3 Stake new pump bushing in two places with blunt punch Fig 212 Remove burrs from stake points with knife blade afterward J9221 242 Fig 211 Removing Oil Pump Bushing 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL SP 3551 3 BUSHING 4 SPECIAL TOOL SP 5117 5 BUSHING 6 SPECIAL TOOL C 4171 7 PUMP HOUSING REACTION SHAFT SUPPORT BUSHING REMOVAL 1 Assemble Bushing Remover Tools SP 1191 3633 and 5324 Fig 213 Do not clamp any part of reaction shaft or support in vise WJ DISASSEMBLY AND ASSEMBLY Continued Fig 212 Staking Oil Pump Bushing 1 NARROW BLADE 2 BLUNT PUNCH 3 TWO STAKES 2 Hold Cup Tool SP 3633 firmly against reaction shaft and thread remover SP 5324 into bushing as far as possible by hand Then thread remover tool 3 4 additional turns into bushing with a wrench 3 Turn remover tool nut down against remover cup to pull bushing from shaft
73. N m 16 ft Ibs of torque SHIFT FORKS AND M AINSHAFT INSTALLATION 1 Install new sector shaft O ring and bushing Fig 56 2 Install shift sector Fig 57 3 Install locking dutch spring locking dutch blockout spring and range dutch sleeve to main shaft as shown in Fig 58 Install snap ring 4 Install drive sprocket hub to mainshaft and manually load the needle bearings 5 Install new pads on range fork if necessary 21 324 NV247 TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued Fig 55 Install Front Bearing Retainer 1 FRONT BEARING RETAINER Fig 56 Sector O Ring And Bushing Installation 1 SECTOR BUSHING 2 O RING 6 Install range shift fork to range dutch sleeve Install mainshaft range shift fork assembly into transfer case and input planetary assembly Rotate fork until it engages with slot in shift sector 7 Install shift rail to shift range fork and trans fer case housing 8 Rotate shift sector to Neutral position 9 Install new O ring on detent plug Fig 59 10 Lubricate detent plunger with transmission fluid or light coat of petroleum jelly AA 9323 Fig 57 Shift Sector Installation LOCKING BLOCKOUT CLUTCH SPRING SPRING SNAP RING XN N RANGE SPROCKET LOCKING CLUTCH HUB CLUTCH SLEEVE BOba7a52 Fig 58 Range Clutch Sleeve Blockout Spring Locking Clutch and Spring 11 Install detent plunger spring and plug Fig 59
74. NOT CONFINED WITHA THERE IS CONFINED FLUID NO PRESSURE CREATED 80bfe273 Fig 18 Pressure on a Confined Fluid where means that the pressure underneath the larger piston is also 10 PSI Pressure is equal to the force applied divided by the contact area Therefore by means of simple algebra the output force may be found This concept is extremely important as it is also used in the design and operation of all shift valves and limiting valves in the valve body as well as the pistons of the transmission which activate the dutches and bands It is nothing more than using a difference of area to create a difference in pressure to move an object 80bfe274 Fig 19 Force Multiplication 45RFE AUTOMATIC TRANSMISSION 21 193 PISTON TRAVEL The relationship between hydraulic lever and a mechanical lever is the same With a mechanical lever it s a weight to distance output rather than a pressure to area output Using the same forces and areas as in the previous example the smaller piston Fig 20 has to move ten times the distance required to move the larger piston one inch Therefore for every inch the larger piston moves the smaller pis ton moves ten inches This principle is true in other instances also A common garage floor jack is a good example To raise car weighing 2000 Ibs an effort of only 100 165 may be required For every inch the car moves upward the input piston at the jack han dle
75. OVERDRIVE CLUTCH PACK RETAINING RING WJ 42RE AUTOMATIC TRANSMISSION 21 139 DISASSEMBLY AND ASSEMBLY Continued J9321 355 Fig 258 Overdrive Clutch Pack Removal Fig 260 Overdrive Clutch Wave Spring Removal Installation 1 OVERDRIVE CLUTCH PACK 1 WAVE SPRING J9321 356 Fig 261 Overdrive Clutch Reaction Snap Ring Removal Installation 1 REACTION RING 2 CLUTCH HUB 3 Remove Torx head screws that attach access cover and gasket to overdrive case Fig 262 J9321 354 4 Remove access cover and gasket Fig 263 Fig 259 42RE Overdrive Clutch Component Position 1 PRESSURE PLATE TO FRONT 2 OVERDRIVE CLUTCH PACK 3 CLUTCH DISC 3 4 CLUTCH PLATE 2 5 REACTION PLATE TO REAR OVERDRIVE GEARTRAIN DISASSEMBLY 1 Remove overdrive dutch wave spring Fig 19321 357 260 2 Remove overdrive clutch reaction snap ring Fig 262 Access Cover Screw Removal Installation Fig 261 Note that snap ring is located in same 1 TORX SCREWDRIVER T25 groove as wave spring 2 ACCESS COVER SCREWS 21 140 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued J9321 358 Fig 263 Access Cover And Gasket Removal Installation 1 ACCESS COVER AND GASKET 5 Expand output shaft bearing snap ring with expanding type snap ring pliers Then push output shaft forward to release shaft bearing from locating ring Fig 264 PUSH OU
76. Shift 42RE AUTOMATIC TRANSMISSION ACCUMULATOR OVERDRIVE CLUTCH m e 3 4 ACCUMULATOR 1 LOGK UP VALVE Fig 39 3 4 Quick Fill Valve After Shift 21 33 80c07154 21 34 42RE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued ie prey Jes S SE GOVERNOR PLUG a T 11 n L DORA TTT E INE INE Ex 80 07149 Fig 40 Throttle Valve THROTTLE VALVE In all gear positions the throttle valve Fig 40 is being supplied with line pressure The throttle valve meters and reduces the line pressure that now becomes throttle pressure The throttle valve is moved by a spring and the kickdown valve which is mechanically connected to the throttle The larger the throttle opening the higher the throttle pressure to maximum of line pressure The smaller the throttle opening the lower the throttle pressure to a minimum of zero at idle As engine speed increases the increase in pump speed increases pump output The increase in pressure and volume must be regu lated to maintain the balance within the transmis sion To do this throttle pressure is routed to th
77. The 2C dutch is hydraulically applied in second gear by pressurized fluid against the 2C piston When the 2C dutch is applied the reverse sun gear assembly is held or grounded to the transmission case by holding the reaction planetary carrier WJ DESCRIPTION AND OPERATION Continued REACTION PLATE SNAP RING SELECT 45RFE AUTOMATIC TRANSMISSION 21 197 M 22022 PLATE L R CLUTCH RETAINER PISTON 80c07033 Fig 24 Low Heverse Clutch SNAP OVERRUNNING RING CLUTCH GN 7 BELLEVILLE SNAP RETAINER SPRING RING 4C CLUTCH The 4C dutch is hydraulically applied in fourth gear by pressurized fluid against the 4C dutch pis ton When the 4C dutch is applied the reaction annulus gear is held or grounded to the transmission case LOW REVERSE CLUTCH The Low Reverse clutch is hydraulically applied in park reverse neutral and first gears by pressurized fluid against the Low Reverse clutch piston When the Low Reverse clutch is applied the input annulus assembly is held or grounded to the transmission case 21 198 45RFE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued BEARING NUMBER 8 REACTION ANNULUS BEARING NUMBER 6 BEARING NUMBER 7 THRUST PLATE REACTION SUN GEAR S LEX s Z 9a BEARING NUMBER 9 REACTION PLANETARY CARRIER 80c07031 Fig 25 Reaction Planetary Geartrain PLANETARY GEARTRAIN DESCRIPTION The planetar
78. and planetary gears Fig 234 6 Remove front planetary gear front thrust washer from annulus gear hub 7 Separate and remove driving shell rear plane tary and rear annulus from output shaft Fig 235 8 Remove front planetary rear thrust washer from driving shell 9 Remove tabbed thrust washers from rear plan etary gear 10 Remove lock ring that retains sun gear in driving shell Then remove sun gear spacer and thrust plates ASSEMBLY 1 Lubricate output shaft and planetary compo nents with transmission fluid Use petroleum jelly to lubricate and hold thrust washers and plates in posi tion J9421 175 Fig 232 Front Annulus And Planetary Assembly Removal 1 DRIVING SHELL 2 FRONT ANNULUS AND PLANETARY ASSEMBLY 3 PLANETARY SNAP RING J9421 176 Fig 233 Front Planetary Snap Ring Removal 1 FRONT ANNULUS GEAR 2 PLANETARY SNAP RING 2 Assemble rear annulus gear and support if dis assembled Be sure support snap ring is seated and that shoulder side of support faces rearward Fig 236 3 Install rear thrust washer on rear planetary gear Use enough petroleum jelly to hold washer in place Also be sure all four washer tabs are properly engaged in gear slots 4 Install rear annulus over and onto rear plane tary gear Fig 236 5 Install assembled rear planetary and annulus gear on output shaft Fig 237 Verify that assembly is fully seated on shaft WJ DISASS
79. annular groove the fluid is routed to the spring end of the 2 3 shift valve Fluid pressure reacting on the area of land 1 overcomes governor pressure downshifting the 2 3 shift valve into the kickdown or second gear stage of operation The valve is held in the kickdown position by throttle pressure routed from a seated check ball 2 Again if vehide speed is low enough throttle pressure will also push the 1 2 shift valve left to seat its governor plug and downshift to drive breakaway 21 26 42RE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued KICKDOWN LIMIT VALVE The purpose of the limit valve is to prevent a 3 2 downshift at higher speeds when a part throttle downshift is not desirable At these higher speeds only a full throttle 3 2 downshift will occur At low road speeds Fig 27 the limit valve does not come into play and does not affect the downshifts As the vehide s speed increases Fig 28 the governor pres sure also increases The increased governor pressure acts on the reaction area of the bottom land of the limit valve overcoming the spring force trying to push the valve toward the bottom of its bore This pushes the valve upward against the spring and bot toms the valve against the top of the housing With the valve bottomed against the housing the throttle pressure supplied to the valve will be dosed off by the bottom land of the limit valve When the supply of throttle pressure has been shut off
80. at center and working outward J9521 107 Fig 150 Boost Valve Tube And Brace 1 BOOST VALVE TUBE 2 TUBE BRACE J9321 147 Fig 149 Boost Valve Tube 1 BOOST VALVE TUBE 2 LOWER HOUSING 3 DISENGAGE THIS END OF TUBE FIRST 4 UPPER HOUSING J9521 108 Fig 151 Securing Boost Valve Tube With Brace Tabs 1 BEND TABS UP AGAINST TUBE AS SHOWN 3 4 ACCUMULATOR 1 Position converter clutch valve and 3 4 shift valve springs in housing Fig 152 2 Loosely attach accumulator housing with right side screw Fig 152 Install only one screw at this time as accumulator must be free to pivot upward for ease of installation 3 Install 3 4 shift valve and spring 4 Install converter clutch timing valve and spring 5 Position plug on end of converter clutch valve spring Then compress and hold springs and plug in place with fingers of one hand 6 Swing accumulator housing upward over valve springs and plug 7 Hold accumulator housing firmly in place and install remaining two attaching screws Be sure springs and clutch valve plug are properly seated Fig 153 Tighten screws to 4 N m 35 Ibs VALVE BODY FINAL 1 Install boost valve valve spring retainer and cover plate Tighten cover plate screws to 4 35 165 torque 2 Insert manual lever detent spring in upper housing 3 Position detent ball on end of spring Then hold detent ball and spring in dete
81. body lever from the idle position Proper adjustment will allow simultaneous movement without causing the transmission throttle lever to either move ahead of or lag behind the lever on the throttle body Checking Throttle Valve Cable Adjustment 1 Turn ignition key to OFF position 2 Remove air cleaner 3 Verify that lever on throttle body is at curb idle position Then verify that transmission throttle lever Fig 317 is also at idle fully forward position 4 Slide cable off attachment stud on throttle body lever 5 Compare position of cable end to attachment stud on throttle body lever THROTTLE VALVE CABLE THROTTLE BODY THROTTL VALVE LEVER 80ba79c5 Fig 317 Throttle Valve Cable e Cable end and attachment stud should be aligned or centered on one another to within 1mm 0 039 in in either direction f cable end and attachment stud are misaligned off center cable will have to be adjusted as described in Throttle Valve Cable Adjustment proce dure WJ ADJ USTMENTS Continued 6 Reconnect cable end to attachment stud Then with aid of a helper observe movement of transmis sion throttle lever and lever on throttle body e f both levers move simultaneously from idle to half throttle and back to idle position adjustment is correct e f transmission throttle lever moves ahead of or lags behind throttle body lever cable adjustment will be necessary Or if throttle body lever pr
82. case bearing Replace any bearing exhibiting signs of roughness wear or damage SPECIFICATIONS TORQUE DESCRIPTION Bolt crossmember Plug Detent Plugs drainffill 41 54 N m 30 40 ft Ibs Bolts front brg retainer 16 24 12 18 ft Ibs 27 34 N m 20 25 ft Ibs 122 176 N m 90 130 ft Ibs 27 34 N m 20 25 ft Ibs TORQUE 41 47 N m 30 35 ft Ibs 16 24 12 18 ft Ibs Bolts case half Nut companion flange Bolts rear extension Lock nut shift 27 34 N m 20 25 ft 1 Nuts T case mount stud 33 41 N m 24 30 ft Ibs 21 330 NV247 TRANSFER CASE SPECIAL TOOLS NV247 TRANSFER CASE Installer C 3995 A Installer 5066 Installer 6952 A Handle C 4171 SO G Installer 6953 Installer 8145 6957 Remover C 4210 WJ 247 TRANSFER CASE 21 331 SPECIAL TOOLS Continued 2 Installer 8128 Remover L 4454 Installer 7884 Cup 8148
83. cavity add ing to the spring load on the valve The result of this increased modulated throttle pressure is a firmer WOT upshift WJ 42RE AUTOMATIC TRANSMISSION 21 29 DESCRIPTION AND OPERATION Continued GOVERNOR PLUG EZ 80 07147 Fig 32 2 3 Shift Valve Before Shift 2 3 SHIFT VALVE The 2 3 shift valve mechanism Fig 32 consists of the 2 3 shift valve governor plug and spring and a throttle plug After the 1 2 shift valve has completed its operation and applied the front band line pres sure is directed to the 2 3 shift valve through the connecting passages from the 1 2 shift valve The line pressure will then dead end at land 2 until the 2 3 valve is ready to make its shift Now that the vehide is in motion and under acceleration there is throttle pressure being applied to the spring side of the valve and between lands 38 and 74 As vehide speed increases governor pressure increases proportionately until it becomes great enough to overcome the combined throttle and spring pressure on the right side of the valve When this happens the governor plug is forced against the shift valve moving it to the right The shift valve causes land 4 to dose the passage supplying throttle pres sure to
84. checking fluid level Dirt grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand Take the time to wipe the cap and tube clean before withdraw ing the dipstick Engine coolant in the transmission fluid is gener ally caused by a cooler malfunction The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part If coolant has circulated WJ DIAGNOSIS AND TESTING Continued through the transmission for some time an overhaul may also be necessary especially if shift problems had developed The transmission cooler and lines should be reverse flushed whenever a malfunction generates sludge and or debris The torque converter should also be replaced at the same time Failure to flush the cooler and lines will result in recontamination Flushing applies to auxiliary cool ers as well The torque converter should also be replaced whenever a failure generates sludge and debris This is necessary because normal converter flushing procedures will not remove all contami nants PRELIMINARY DIAGNOSIS Two basic procedures are required One procedure for vehicles that are drivable and an alternate proce dure for disabled vehicles will not back up or move forward VEHICLE IS DRIVEABLE 1 Check for transmission fault codes using DRB scan tool 2 Check fluid level and condition 3 Adjust throttle and gearshift linkage if com plaint was based on
85. delayed erratic or harsh shifts 4 Road test and note how transmission upshifts downshifts and engages 5b Perform stall test if complaint is based on slug gish acceleration Or if abnormal throttle opening is needed to maintain normal speeds with a properly tuned engine 6 Perform hydraulic pressure test if shift prob lems were noted during road test 7 Perform air pressure test to check dutch band operation VEHICLE IS DISABLED 1 Check fluid level and condition 2 Check for broken or disconnected gearshift or throttle linkage 3 Check for cracked leaking cooler lines or loose or missing pressure port plugs 4 Raise and support vehicle on safety stands start engine shift transmission into gear and note following a propeller shaft turns but wheels do not problem is with differential or axle shafts b If propeller shaft does not turn and transmis sion is noisy stop engine Remove oil pan and check for debris If pan is dear remove transmis sion and check for damaged drive plate converter oil pump or input shaft 42RE AUTOMATIC TRANSMISSION 21 53 c If propeller shaft does not turn and transmis sion is not noisy perform hydraulicpressure test to determine if problem is hydraulic or mechanical PARK NEUTRAL POSITION SWITCH The center terminal of the park neutral position switch is the starter circuit terminal It provides the ground for the starter solenoid circuit through the
86. dutch retainer This prevents front rear dutches from coming out when oil pump is removed 3 Remove oil pump and remove pump seal Inspect pump housing drainback and vent holes for obstructions Clear holes with solvent and wire 4 Inspect pump bushing and converter hub If bushing is scored replace it If converter hub is scored either polish it with crocus doth or replace converter WJ DIAGNOSIS AND TESTING Continued RH254 Fig 70 Converter Leak Points Typical 1 OUTSIDE DIAMETER WELD 2 TORQUE CONVERTER HUB WELD 3 STARTER RING GEAR 4 LUG 5 Install new pump seal O ring and gasket Replace oil pump if cracked porous or damaged in any way Be sure to loosen the front band before installing the oil pump damage to the oil pump seal may occur if the band is still tightened to the front dutch retainer 42RE AUTOMATIC TRANSMISSION 21 59 6 Loosen kickdown lever pin access plug three turns Apply Loctite 592 or Permatex No 2 to plug threads and tighten plug to 17 N m 150 in Ibs torque 7 Adjust front band 8 Lubricate pump seal and converter hub with transmission fluid or petroleum jelly and install con verter 9 Install dust shield 10 Lower vehicle DIAGNOSIS TABLES AND CHARTS RE TRANSMISSION The diagnosis charts provide additional reference when diagnosing a transmission fault The charts provide general information on a variety of transmis sion overdrive unit an
87. e Manual lever detent ball e Throttle lever e Fluid filter e Pressure adjusting screw bracket e Governor pressure solenoid e Governor pressure sensor includes transmission temperature thermistor e Converter clutch overdrive solenoid assembly and harness e Governor housing gasket e Solenoid case connector O rings The remaining valve body components are serviced only as part of a complete valve body assembly WJ 72 AUTOMATIC TRANSMISSION 21 85 REMOVAL AND INSTALLATION Continued 10 Work manual lever shaft and electrical con nector out of transmission case 11 Lower valve body rotate valve body away from case pull park rod out of sprag and remove valve body Fig 98 A 80315867 Fig 95 Pressure Solenoid and O ring 1 PRESSURE SOLENOID 2 O RING 3 GOVERNOR 80c072b1 Fig 96 Governor Body and Gasket 1 GOVERNOR BODY 2 GASKET J9321 387 Fig 97 Transmission Case Connector 1 SOLENOID CASE CONNECTOR 2 PARK NEUTRAL POSITION SWITCH CONNECTOR TERMINAL REMOVAL 1 Shift transmission into NEUTRAL 2 Raise vehide 3 Remove gearshift and throttle levers from shaft of valve body manual lever 4 Disconnect wires at solenoid case connector Fig 97 5 Position drain pan under transmission oil pan 6 Remove transmission oil pan and gasket 7 Remove fluid filter from valve 8 Remove bolts attaching va
88. e front bearing retainer rear retainer oil pump case halves NV242 TRANSFER CASE 21 289 J8921 214 Fig 51 Low Range Gear Disassembly 1 THRUST WASHERS 2 LOW RANGE GEAR 3 GEAR 4 RETAINER J8921 270 Fig 52 Inspecting Low Range Annulus Gear 1 LOW RANGE ANNULUS GEAR DIFFERENTIAL 1 Mark differential case halves for reference 2 Remove differential case bolts 3 Invert differential on workbench 4 Separate top case from bottom case Use slots in case halves to pry them apart Fig 53 5 Remove thrust washers and planet gears from case pins Fig 54 21 290 NV242 TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 6 Remove mainshaft and sprocket gears from bottom case Fig 55 Note gear position for reference before separating them J8921 272 Fig 54 Planet Gears And Thrust Washer Removal 1 BOTTOM CASE 2 THRUST WASHERS 12 J8921 271 3 PLANET GEARS 6 Fig 53 Separating Differential Case Halves 1 TOP CASE 2 CASE BOLTS 3 CASE BOLTS 4 CASE SLOTS 5 CASE BOLTS ASSEMBLY Lubricate transfer case components with automatic transmission fluid or petroleum jelly where indi cated during assembly CAUTION The bearing bores in various transfer case components contain oil feed holes Make sure replacement bearings do not block the holes BEARING AND SEAL 1 Remove snap ring that re
89. end and con verts fluid pressure into mechanical movement The fluid pressure exerted on the piston is contained within the system through the use of piston rings or seals OPERATION The principal which makes this operation possible is known as Pascal s Law Pascal s Law can be stated as Pressure on a confined fluid is transmitted equally in all directions and acts with equal force on equal areas PRESSURE Pressure Fig 17 is nothing more than force Ibs divided by area in or ft or force per unit area Given a 100 Ib block and an area of 100 sq in on the floor the pressure exerted by the block is 100 lbs 100 in or 1 pound per squareinch or PSI asit is commonly referred to PRESSURE ON A CONFINED FLUID Pressure is exerted on a confined fluid Fig 18 by applying a force to some given area in contact with the fluid A good example of this is a cylinder filled WJ FORCE ON EACH SQUARE INCH 100 POUNDS PRESSURE 1 POUND PER SQUARE INCH 100 1000 POUNDS POUNDS OUTPUT INPUT AREA 100 SQ IN F P A AREA 54 FORCE LBS 10 SQ IN PRESSURE AREA 50 FORCE ON LARGE PISTON 1000 LBS 80bfe272 Fig 17 Force and Pressure Relationship with fluid and equipped with a piston that is closely fitted to the cylinder wall If a force is applied to the piston pressure will be developed in the fluid Of course no pressure will be created if the fluid is not confined It will simply leak
90. fluid is a result of overheating which has two primary causes 1 A result of restricted fluid flow through the main and or auxiliary cooler This condition is usu ally the result of a faulty or improperly installed drainback valve a damaged main cooler or severe restrictions in the coolers and lines caused by debris or kinked lines 2 Heavy duty operation with a vehicle not prop erly equipped for this type of operation Trailer tow ing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped Such vehicles should have an auxiliary transmission fluid cooler a heavy duty cooling sys tem and the engine axle ratio combination needed to handle heavy loads FLUID CONTAMINATION Transmission fluid contamination is generally a result of e adding incorrect fluid failure to clean dipstick and fill tube when checking level e engine coolant entering the fluid internal failure that generates debris overheat that generates sludge fluid break down e failure to reverse flush cooler and lines after repair e failure to replace contaminated converter after repair The use of non recommended fluids can result in transmission failure The usual results are erratic shifts slippage abnormal wear and eventual failure due to fluid breakdown and sludge formation Avoid this condition by using recommended fluids only The dipstick cap and fill tube should be wiped dean before
91. four detents rearward from full forward position This is Reverse range 5 Move transmission throttle lever fully forward then fully rearward and note reading at Gauge C 3293 SP 6 Pressure should be 145 175 psi 1000 1207 kPa with throttle lever forward and increase to 230 280 psi 1586 1931 kPa as lever is gradually moved rearward Test Five Governor Pressure NOTE This test checks governor operation by measuring governor pressure response to changes in vehicle speed It is usually not necessary to check governor operation unless shift speeds are incorrect or if the transmission will not downshift The test should be performed on the road or on a hoist that will allow the rear wheels to rotate freely 1 Move 100 psi Test Gauge C 3292 to governor pressure port 2 Move transmission shift lever two detents rear ward from full forward position This is D range 3 Have helper start and run engine at curb idle speed Then firmly apply service brakes so wheels will not rotate 4 Note governor pressure WJ DIAGNOSIS AND TESTING Continued Governor pressure should be no more than 20 6 kPa 3 psi at curb idle speed and wheels not rotat ing f pressure exceeds 20 6 kPa 3 psi a fault exists in governor pressure control system 5 Release brakes slowly increase engine speed and observe speedometer and pressure test gauge do not exceed 30 mph on speedometer Governor pres sure should increase in
92. from rear retainer 4 Remove rear bearing snap ring Fig 20 5 Remove bolts holding rear retainer to rear case half 6 Remove speedometer adapter WJ DISASSEMBLY AND ASSEMBLY Continued A 80c070b7 Fig 16 Rear Seal Removal 1 REAR RETAINER 2 OUTPUT SHAFT SEAL 80207008 Fig 17 Rear Bearing 1 0 Retaining Ring Removal 1 SNAP RING PLIERS 2 REAR BEARING RETAINING RING NV242 TRANSFER CASE 21 281 80010965 Fig 18 Rear Retainer Removal 1 MAINSHAFT 2 REAR RETAINER 7 Loosen rear retainer with pry tool to break sealer bead Pry only against retainer boss as shown Fig 21 8 Slide retainer off case and output shaft Fig 22 Fig 19 Remove Extension Housing 1 EXTENSION HOUSING 2 PLASTIC HAMMER 3 REAR RETAINER 21 282 NV242 TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued RR21F22 Fig 20 Remove Rear Bearing Snap ring 1 REAR RETAINER 2 SNAP RING 3 REAR BEARING RR21F23 Fig 21 Loosening Rear Retainer 1 REAR RETAINER 2 TAB 2 3 SCREWDRIVER 4 TAB OIL PUMP AND REAR CASE HALF 1 Remove rear bearing O D retaining ring with snap ring pliers Then tilt pump and slide it off out put shaft Fig 23 2 Remove pickup tube O ring from pump Fig 24 but do not disassemble pump it is not a repair able part 3 Remove seal from oil pump with pry tool 4 Remove bolts attachin
93. gasket 1 Place gasket in position on back of governor body Fig 96 2 Place governor body in position on valve body 3 Install bolts to hold governor body to valve body 4 Lubricate O ring on pressure sensor with transmission fluid 5 Align pressure sensor to bore in governor body 6 Push pressure sensor into governor body 7 Lubricate O ring on pressure solenoid with transmission fluid 8 Align pressure solenoid to bore in governor body Fig 95 9 Push solenoid into governor body 10 Place solenoid retainer in position on governor Fig 94 11 Install screws to hold pressure solenoid retainer to governor body 12 Engage wire connectors into pressure sensor and solenoid Fig 93 13 Install transmission fluid pan and new filter 14 Lower vehide and road test to verify repair VALVE BODY The valve body can be removed for service without having to remove the transmission assembly The valve body can be disassembled for cleaning and inspection of the individual components Refer to Disassembly and Assembly section for proper proce dures The only replaceable valve body components are e Manual lever 80c072b0 Fig 93 Governor Solenoid And Pressure Sensor 1 PRESSURE SENSOR 2 PRESSURE SOLENOID 3 GOVERNOR 80915866 Fig 94 Pressure Solenoid Retainer 1 PRESSURE SOLENOID RETAINER 2 GOVERNOR e Manual lever washer seal E clip and shaft seal
94. 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 308 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 308 d Select proper thickness end play spacer from spacer chart based on distance measured Fig 309 e Remove Gauge Alignment Tool 6312 OD THRUST PLATE SELECTION 1 Place overdrive unit in vertical position Mount it on blocks or in workbench with appropriate size 42RE AUTOMATIC TRANSMISSION 21 153 J9221 47 Fig 308 Shaft End Play Measurement 1 SPECIAL TOOL 6312 2 SPECIAL TOOL 6311 3 SPECIAL TOOL C 4962 End Play Measure Spacer Thickness ment Inches Inches 7336 7505 158 159 7506 7675 175 176 7676 7855 193 194 7856 8011 211 212 19121 341 Fig 309 Intermediate Shaft End Play Spacer Selection mounting hole cut into it Be sure unit is facing upward for access to direct dutch 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 o
95. hammer until tool is securely engaged into the lock pin c Install a t handle such as from a tap and die set onto the easy out tool d Securely tighten the t handle onto the tool e In one motion pull upward and turn the t handle counter clockwise to remove the lock pin J8921 251 Fig 31 Drive Sprocket Snap Ring Removal 1 DRIVE SPROCKET 2 DRIVE SPROCKET SNAP RING J8921 252 Fig 32 Drive Sprocket And Chain Removal 1 DRIVE SPROCKET 2 DRIVE CHAIN 4 Remove shift rail by pulling it straight up and out of fork Fig 35 5 Remove mode fork and mainshaft as assembly Fig 36 WJ DISASSEMBLY AND ASSEMBLY Continued UB i 18921 253 Fig 33 Removing Front Output Shaft 1 FRONT OUTPUT SHAFT J9121 426 Fig 34 Detent Component Removal 1 PLUNGER 2 O RING 3 PLUG 4 SPRING 6 Remove mode shift sleeve and mode fork assembly from mainshaft Fig 37 Note position of mode sleeve in fork and remove sleeve 7 Remove intermediate clutch shaft snap ring Fig 38 8 Remove dutch shaft thrust ring Fig 39 9 Remove intermediate clutch shaft Fig 40 NV242 TRANSFER CASE 21 285 J8921 255 Fig 35 Shift Rail Removal 1 SHIFT RAIL 2 MODE FORK 52 U ES SS E gt a Fig 36 Mode Fork And Mainshaft Removal 1 MAINSHAFT ASSEMBLY 2 MODE FORK 21 2
96. if necessary WJ REMOVAL AND INSTALLATION TRANSFER CASE REMOVAL 1 Shift transfer case into Neutral 2 Raise vehicle 3 Remove transfer case drain plug and drain transfer case lubricant 4 Mark front and rear propeller shaft yokes for alignment reference 5 Support transmission with jack stand 6 Remove rear crossmember and skid plate if equipped Fig 4 CROSSMEMBER MOUNT Fig 4 Crossmember Removal installation 80ba79c7 7 Disconnect front propeller shaft from transfer case at companion flange Remove rear propeller shaft from vehide Refer to Group 3 Differential and Driveline for the correct procedures CAUTION Do not allow propshafts to hang at attached end Damage to joint can result 8 Disconnect transfer case cable from range lever 9 Disconnect transfer case vent hose Fig 5 10 Support transfer case with transmission jack 11 Secure transfer case to jack with chains 12 Remove nuts attaching transfer case to trans mission 13 Pull transfer case and jack rearward to disen gage transfer case Fig 5 14 Remove transfer case from under vehicle NV247 TRANSFER CASE 21 311 TRANSFER CASE 42RE 80ba79c9 Fig 5 Transfer Case Mounting INSTALLATION 1 Mount transfer case on a transmission jack 2 Secure transfer case to jack with chains 3 Position transfer case under vehicle 4 Align transfer case and transmissio
97. is needed to keep the clutches applied The 45RFE pump pressure control system monitors input torque and adjusts the pump pressure accordingly The primary stage of the pump works continuously the second stage is bypassed when demand is low The control system also moni tors input and output speed and if incipient clutch slip is observed the pressure control solenoid duty is varied increasing pressure in proportion to demand WJ DESCRIPTION AND OPERATION Continued A high travel torque converter damper assembly allow earlier torque converter clutch engagement to reduce slippage Needle type thrust bearings reduce internal friction The 45RFE is packaged in a one piece die cast aluminum case To reduce NVH the case has high lateral vertical and torsional stiffness It is also designed to maximize the benefit of the structural dust cover that connects the bottom of the bell housing to the engine bedplate enhancing over all power train stiffness Dual filters protect the pump and other components A pump return filter is added to the customary main sump filter Indepen dent lubrication and cooler circuits assure ample pressure for normal transmission operation even if the cooler is obstructed or the fluid cannot flow due to extremely low temperatures The hydraulic control system design without elec tronic assist provides the transmission with PARK REVERSE NEUTRAL SECOND and THIRD gears based solely on driver
98. must move 20 inches downward 80bfe275 Fig 20 Piston Travel 21 194 45RFE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued SNAP SEAL INPUT CLUTCH HUB BELLEVILLE SNAP SPRING RING OD REV PISTON SNAP RING RING UD BALANCE PISTON CLUTCH RETAI PLATE 80c07013 Fig 21 Input Clutch Assembly Part 1 INPUT CLUTCHES DESCRIPTION Three hydraulically applied input clutches are used to drive planetary components The underdrive over drive and reverse clutches are considered input clutches and are contained within the input clutch assembly Fig 21 and Fig 22 The input clutch assembly also contains Input shaft e Input hub e Clutch retainer Underdrive piston Overdrive reverse piston Overdrive hub Underdrive hub OPERATION The three input clutches are responsible for driving different components of the planetary geartrain UNDERDRIVE CLUTCH The underdrive clutch is hydraulically applied in first second and third direct gears by pressurized fluid against the underdrive piston When the under drive clutch is applied the underdrive hub drives the input sun gear 5 AUTOMATIC TRANSMISSION 21 195 DESCRIPTION AND OPERATION Continued REV REACTION SNAP RING PLATE SELECT REV HUB SHAFT SNAP RING REACTION PLATE BEARING NUMBER 4 SNAP RING
99. n IE m gi FU ts FRONT CLUTCH LUBRICATION TO LUBRICATION 80c07152 Fig 45 Boost Valve After Lock up ACCUMULATOR DESCRIPTION The accumulator Fig 46 is a hydraulic device that has the sole purpose of cushioning the applica tion of a band or clutch The accumulator consists of a dual land piston and a spring located in a bore in the transmission case The 3 4 accumulator is located in a housing attached to the side of the valve body Fig 47 J9121 118 Fig 46 Accumulator 1 ACCUMULATOR PISTON 2 PISTON SPRING 804d8eb9 Fig 47 3 4 Accumulator and Housing 1 ACCUMULATOR PISTON 2 3 4 ACCUMULATOR HOUSING 3 TEFLON SEALS 4 PISTON SPRING 5 COVER PLATE AND SCREWS WJ DESCRIPTION AND OPERATION Continued OPERATION Both the accumulator and the 3 4 accumulator function the same Line pressure is directed between the lands of the piston Fig 48 bottoming it against the accumulator plate The accumulator stays in this position after the transmission is placed into a Drive position When the 1 2 upshift occurs Fig 49 line pressure is directed to the large end of the piston and then to the kickdown servo As the line pressure reaches the accumulator the combination of spring pressure and line pressure forces the piston away from the accumulator plate This causes a balanced pressure situation which r
100. of the system TURBINE The turbine Fig 4 is the output or driven mem ber of the converter The turbine is mounted within the housing opposite the impeller but is not attached to the housing The input shaft is inserted through the center of the impeller and splined into the tur bine The design of the turbine is similar to the 2 W TURBINE STATOR ASSEMBLY CONVERTER TURBINE HUB HUB CONVERTER CLUTCH PISTON O RING IMPELLER ASSEMBLY 80660650 Fig 2 Torque Converter Assembly impeller except the blades of the turbine are curved in the opposite direction IMPELLER VANE CONSTRUCTION AND CURVATURE 80bfe26a Fig 3 Impeller 1 ENGINE FLEXPLATE 2 OIL FLOW FROM IMPELLER SECTION INTO TURBINE SECTION 3 IMPELLER VANES AND COVER ARE INTEGRAL 4 ENGINE ROTATION 5 ENGINE ROTATION 5 AUTOMATIC TRANSMISSION 21 185 DESCRIPTION AND OPERATION Continued 9 BLADE CONSTRUCTION 80bfe26b Fig 4 Turbine 1 TURBINE VANE 4 PORTION OF TORQUE CONVERTER COVER 2 ENGINE ROTATION 5 ENGINE ROTATION 3 INPUT SHAFT 6 OIL FLOW WITHIN TURBINE SECTION 21 186 45RFE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued STATOR The stator assembly Fig 5 is mounted on a sta tionary shaft which is an integral part of the oil pump The stator is located between the impeller and tu
101. off any further flow of line pressure oil After the switch valve is shuttled right allowing line pressure to engage the TCC torque converter pressure is directed past the switch valve into the transmission cooler and lubrication circuits WJ DESCRIPTION AND OPERATION Continued 42RE AUTOMATIC TRANSMISSION 21 37 mc PLUG Cp ae H L3 inim en ME E Ji REM 80c0714c Fig 43 Manual Valve MANUAL VALVE The manual valve Fig 43 is a relay valve The purpose of the manual valve is to direct fluid to the correct circuit needed for a specific gear or driving range The manual valve as the name implies is manually operated by the driver with a lever located on the side of the valve body The valve is connected mechanically by either a cable or linkage to the gear shift mechanism The valve is held in each of its positions by a spring loaded roller or ball that engages the roostercomb of the manual valve CONVERTER CLUTCH LOCK UP VALVE The torque converter dutch TCC lock up valve controls the back ON side of the torque converter dutch When the PCM energizes the TCC solenoid to engage the converter clutch piston pressure is applied to the TCC lock up valve which moves to the right and applies pressure to the torque converter dutch CONVERTER CLUTCH LOCK UP TIMING V
102. on the rear dutch pack in comparison to the front clutch pack is needed to hold against the greater torque load imposed onto the rear pack The rear clutch is directly behind the front dutch and is considered a driving component NOTE The number of discs and plates may vary with each engine and vehicle combination OPERATION To apply the dutch pressure is applied between the dutch retainer and piston The fluid pressure is provided by the oil pump transferred through the control valves and passageways and enters the dutch through the hub of the reaction shaft support With pressure applied between the dutch retainer and piston the piston moves away from the clutch retainer and compresses the dutch pack This action applies the dutch pack allowing torque to flow through the input shaft into the driving discs and into the dutch plates and pressure plate that are lugged to the dutch retainer The waved snap ring is used to cushion the application of the clutch pack In some transmissions the snap ring is selective and used to adjust dutch pack clearance 21 44 42 AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued OVERDRIVE CLUTCH DISCS 3 CLUTCH PLATES 2 J9321 369 Fig 56 Overdrive Clutch 1 REACTION PLATE 2 PRESSURE PLATE When pressure is released from the piston the spring returns the piston to its fully released position and disengages the dutch The release spring also helps
103. pawl and has not displaced into this cavity 8 Install accumulator springs and piston into case Then swing valve body over piston and outer spring to hold it in place 9 Align accumulator piston and outer spring manual lever shaft and electrical connector in case 10 Then seat valve body in case and install one or two bolts to hold valve body in place 11 Tighten valve body bolts alternately and evenly to 11 N m 100 in Ibs torque 12 Install new fluid filter on valve body Tighten filter screws to 4 N m 35 in Ibs torque 13 Install throttle and gearshift levers on valve body manual lever shaft 14 Check and adjust front and rear bands if nec essary 15 Connect solenoid case connector wires 16 Install oil pan and new gasket Tighten pan bolts to 17 N m 13 ft Ibs torque 17 Lower vehide and fill transmission with Mopar ATF Plus 3 type 7176 fluid 18 Check and adjust gearshift and throttle valve cables if necessary OVERDRIVE UNIT REM OVAL 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 J9321 389 Fig 99 Valve Body Harness Connector O Ring Seal 1 CONNECTOR O RINGS 2 VALVE BODY HARNESS CONNECTOR 3 HARNESS Fig 100 Manual Lever Shaft Seal 1 15 16 SOCKET 2 SEAL 4 J9121 230 Fig 101 Accumulato
104. proportion to speed Or approximately 6 89 kPa 1 psi for every 1 mph 6 Governor pressure rise should be smooth and drop back to no more than 20 6 kPa 3 psi after engine returns to curb idle and brakes are applied to prevent wheels from rotating 7 Compare results of pressure test with analysis chart Test Six Transmission In Overdrive Fourth Gear NOTE This test checks line pressure at the over drive clutch in fourth gear range Use 300 psi Test Gauge C 3293 SP for this test The test should be performed on the road or on a chassis dyno 1 Remove tachometer it is not needed for this test 2 Move 300 psi Gauge to overdrive clutch pres sure test port Then remove other gauge and reinstall test port plug 3 Lower vehicle 4 Turn OD switch on 5 Secure test gauge so it can be viewed from drivers seat 6 Start engine and shift into D range 7 Increase vehicle speed gradually until 3 4 shift occurs and note gauge pressure 8 Pressure should be 469 496 kPa 68 72 psi with dosed throttle and increase to 620 827 kPa 90 120 psi at 1 2 to 3 4 throttle Note that pressure can increase to around 896 kPa 130 psi at full throttle 9 Return to shop or move vehicle off chassis dyno AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION Air pressure testing can be used to check transmis sion front rear clutch and band operation The test can be conducted with the transmission either in
105. put into motion by the impel ler blades strikes the blades of the turbine some of 80bfe26f Fig 7 Torque Converter Clutch TCC 1 IMPELLER FRONT COVER 2 THRUST WASHER ASSEMBLY 3 IMPELLER 4 STATOR 5 TURBINE 6 FRICTION DISC WJ DESCRIPTION AND OPERATION Continued TORQUE CONVERTER CLUTCH RELEASED 45RFE AUTOMATIC TRANSMISSION 21 187 VENTED 2 TORQUE CONVERTER CLUTCH APPLIED 300 276 Fig 8 Torque Converter Fluid Operation 1 APPLY PRESSURE 2 THE PISTON MOVES SLIGHTLY FORWARD 3 RELEASE PRESSURE 4 THE PISTON MOVES SLIGHTLY REARWARD the energy and rotational force is transferred into the turbine and the input shaft This causes both of them turbine and input shaft to rotate in a dockwise direction following the impeller As the fluid is leav ing the trailing edges of the turbine s blades it con tinues in a hindering direction back toward the impeller If the fluid is not redirected before it strikes the impeller it will strike the impeller in such a direction that it would tend to slow it down STATOR Torque multiplication is achieved by l
106. remove rod from grom met and cut away old grommet Use pliers to snap new grommet into cable and to snap grommet onto lever 22 Connect gearshift and throttle valve cable to transmission 23 Connect wires to park neutral position switch and transmission solenoid connector Be sure trans mission harnesses are properly routed CAUTION It is essential that correct length bolts be used to attach the converter to the driveplate Bolts that are too long will damage the clutch sur face inside the converter 24 Install torque converter to driveplate bolts Tighten bolts to 31 N m 270 in 165 25 Install converter housing access cover Tighten bolt to 23 N m 200 in Ibs 26 Install the bell housing brace to the torque converter cover and the engine to transmission bend ing brace Tighten the bolts and nut to 41 N m 30 ft Ibs 27 Install starter motor and cooler line bracket 28 Connect cooler lines to transmission 29 Install transmission fill tube Install new seal on tube before installation 30 Install exhaust components 31 Install transfer case Tighten transfer case nuts to 35 26 ft Ibs WJ REMOVAL AND INSTALLATION Continued 32 Install the transfer case shift cable to the cable support bracket and the transfer case shift lever 33 Align and connect propeller shaft s 34 Adjust gearshift linkage and throttle valve cable if necessary 35 Lower vehicle 36 Fill tra
107. ring is fully seated in groove and is not twisted 3 Lubricate splined end of input shaft and dutch retainer with transmission fluid Then press input shaft into retainer Use a suitably sized press tool to support retainer as close to input shaft as possible 4 Install input shaft snap ring Fig 225 5 Invert retainer and press input shaft in oppo site direction until snap ring is seated 6 Install new seals on clutch piston Be sure lip of each seal faces interior of dutch retainer 7 Lubricate lip of piston seals with generous quantity of Mopar Door Ease Then lubricate retainer hub and bore with light coat of transmission fluid 8 Install dutch piston in retainer Use twisting motion to seat piston in bottom of retainer A thin strip of plastic about 0 020 thick can be used to guide seals into place if necessary CAUTION Never push the clutch piston straight in This will fold the seals over causing leakage and clutch slip In addition never use any type of metal tool to help ease the piston seals into place Metal tools will cut shave or score the seals 9 Install piston spring in retainer and on top of piston Fig 229 Concave side of spring faces down ward toward piston WJ 10 Install wave spring in retainer Fig 229 Be sure spring is completely seated in retainer groove J9121 538 Fig 226 Rear Clutch Retainer And Input Shaft Seal Ring Installation 1 REAR CLUTCH RETAINER HU
108. same speed and the stator is freewheeling providing no torque multipli cation By applying the turbine s piston to the front cover s friction material total converter engage ment can be obtained The result of this engagement is a direct 1 1 mechanical link between the engine and the transmission Converter clutch engagement in third or fourth gear range is controlled by sensor inputs to the pow ertrain control module Inputs that determine clutch engagement are coolant temperature engine rpm vehicle speed throttle position and manifold vac uum The torque converter clutch is engaged by the clutch solenoid on the valve body The clutch can be engaged in third and fourth gear ranges depending on overdrive control switch position If the overdrive control switch is in the normal ON position the clutch will engage after the shift to fourth gear and above approximately 72 km h 45 mph If the control switch is in the OFF position the clutch will engage after the shift to third gear at approximately 56 km h 35 mph at light throttle ELECTRONICALLY MODULATED CONVERTER CLUTCH ENGAGEMENT DESCRIPTION In order to reduce heat build up in the transmis sion and buffer the powertrain against torsional vibrations the TCM can duty cycle the L R CC Sole noid to achieve a smooth application of the torque converter clutch This function referred to as Elec tronically Modulated Converter Clutch EMCC can occur at various times depe
109. sense Battery temperature Battery voltage Brake switch J 1850 bus circuits Camshaft position sensor signal Crankshaft position sensor Data link connections for DRB scan tool Engine coolant temperature sensor Five volts primary Five volts secondary Fuel level WJ e Generator battery voltage output Ignition circuit sense ignition switch in on off crank run position e Intake manifold air temperature sensor Leak detection pump switch sense if equipped Manifold absolute pressure MAP sensor Oil pressure Overdrive override switch Oxygen sensors Park neutral switch auto trans only Power ground Sensor return Signal ground Speed control multiplexed single wire input Throttle position sensor Transmission governor pressure sensor Transmission temperature sensor Vehide speed from ABS module NOTE PCM Outputs A C clutch relay e Auto shutdown ASD relay 1850 circuits for speedometer voltmeter fuel gauge oil pressure gauge lamp engine temp gauge and speed control warn lamp e Data link connection for DRB scan tool EGR valve control solenoid if equipped EVAP canister purge solenoid Fuel injectors Fuel pump relay Generator field driver Generator field driver Generator lamp if equipped Idle air control I AC motor Ignition coil e Leak detection pump e Malfunction indicator lamp Check engine lamp Driven through J 1850 circuits e Overdrive indicator lamp if equipp
110. servo Fig 61 consists of a two land piston with an inner piston a piston rod and guide and a return spring The dual land piston uses seal rings on its outer diameters and an O ring for the inner piston 80be45fa Fig 61 Front Servo 1 VENT 2 INNER PISTON 3 PISTON 4 SPRING 5 RELEASE PRESSURE 6 APPLY PRESSURE 7 PISTON ROD LOW REVERSE REAR SERVO The rear low reverse servo consists of a single stage or diameter piston and a spring loaded plug The spring is used to cushion the application of the rear low reverse band WJ DESCRIPTION AND OPERATION Continued OPERATION KICKDOWN FRONT SERVO The application of the piston is accomplished by applying pressure between the two lands of the pis ton The pressure acts against the larger lower land to push the piston downward allowing the piston rod to extend though its guide against the apply lever Release of the servo at the 2 3 upshift is accom plished by a combination of spring and line pressure acting on the bottom of the larger land of the piston The small piston is used to cushion the application of the band by bleeding oil through a small orifice in the larger piston The release timing of the kickdown servo is very important to obtain a smooth but firm shift The release has to be very quick just as the front clutch application is taking place Otherwise engine runaway or a shift hesitation will occur To a
111. side housing attaching screws Fig 123 J9321 426 Fig 119 Detent Ball And Spring 1 DETENT HOUSING 2 DETENT SPRING 3 DETENT BALL 4 PENCIL MAGNET J9321 430 Fig 120 Adjusting Screw Bracket Fastener 1 T25 TORX BIT 2 REMOVE THESE SCREWS FIRST 3 BRACKET 4 BRACKET 5 REMOVE THIS SCREW LAST 23 Carefully rotate 3 4 accumulator housing upward and remove 3 4 shift valve spring and con verter dutch valve plug and spring Fig 124 24 Remove left side screw and remove 3 4 accu mulator housing from valve body Fig 125 25 Bend back tabs on boost valve tube brace Fig 126 WJ 2 AUTOMATIC TRANSMISSION 21 93 DISASSEMBLY AND ASSEMBLY Continued 2 IN uen Z GN 5 CE 0 E c7 J9321 432 J9321 431 a Fig 123 Accumulator Housing Screw Locations Fig 121 Adjusting Screw Bracket And Spring 1 LOOSEN THIS SCREW 1 SWITCH VALVE SPRING 2 REMOVE THESE SCREWS SE D SS SCREW 8 3 4 ACCUMULATOR HOUSING 3 THROTTLE PRESSURE ADJUSTING SCREW 4 ADJUSTING SCREW BRACKET 5 PRESSURE REGULATOR VALVE SPRING J9321 155 Fig 122 Upper Housing Control Valve Locations 1 UPPER HOUSING 8 MANUAL VALVE 2 REGULATOR VALVE 9 1 2 GOVERNOR PLUG 3 SWITCH VALVE 10 GOVERNOR PLUG COVER 4 REGULATOR VALVE SPRING 11 THROTTLE PLUG 5 KICKDOWN VALVE 12 2 3 GOVERNOR PL
112. size charts and selection procedures in Intermiediate shaft spacer Overdrive Unit D amp A procedures PRESSURE TEST Overdrive clutch Fourth gear only Pressure should be 469 496 kPa 68 72 psi with closed throttle and increase to 620 896 kPa 90 130 psi at 1 2 to 3 4 throttle Line pressure at Closed throttle 372 414 kPa 54 60 psi accumulator Third gear only No more than 21 kPa 3 psi lower than line pressure 3 psi Rear servo 1 range No more than 21 kPa 3 psi lower than line pressure R range 1103 kPa 160 psi at idle builds to 1862 kPa 270 psi at 1600 rpm Governor D range closed throttle Pressure should respond smoothly to changes in mph and return to 0 7 kPa 0 1 5 psi when stopped with transmission in D 1 2 Pressure above 7 kPa 1 5 psi at stand still will prevent transmission from downshifting SPECIAL TOOLS RE TRANSMISSIONS EN Gauge Bar 6311 Spring Compressor and Alignment Shaft 6227 21 178 42 AUTOMATIC TRANSMISSION SPECIAL TOOLS Continued Extension Housing Pilot C 3288 B 90114420 Dial Indicator C 3339 Spring Compressor C 3422 B Puller Slide Hammer C 3752 Gauge Throttle Setting C 3763 g Seal Installer C 3860 A Y Seal Remover C 3985 B 2 AUTOMATIC TRANSMISSION 21 179 SPECIAL TOOLS Continued 0 Installer C 3995 A c Nut Bushing Remover SP 1191 From kit C 3887 J Univ
113. solvent Dry them with compressed air after clean ing Inspect condition of each dutch part after cleaning Replace the overrunning dutch roller and spring assembly if any rollers or springs are worn or dam aged or if the roller cage is distorted or damaged Replace the cam if worn cracked or damaged Replace the low reverse drum if the clutch race roller surface or inside diameter is scored worn or damaged Do not remove the clutch race from the low reverse drum under any circumstances Replace the drum and race as an assembly if either component is damaged Examine the overdrive piston retainer carefully for wear cracks scoring or other damage Be sure the retainer hub is a snug fit in the case and drum Replace the retainer if worn or damaged ACCUMULATOR Inspect the accumulator piston and seal rings Fig 312 Replace the seal rings if worn or cut Replace the piston if chipped or cracked Check condition of the accumulator inner and outer springs Fig 312 Replace the springs if the coils are cracked distorted or collapsed FRONT SERVO Clean the servo piston components with solvent and dry them with compressed air Wipe the band clean with lint free shop towels 4 19121 230 Fig 312 Accumulator Components 1 INNER SPRING 2 ACCUMULATOR PISTON 3 OUTER SPRING 4 SEAL RINGS Replace the front band if distorted lining is burned flaking off or worn to the point where the grooves in the linin
114. that correct length bolts be used to attach the converter to the driveplate Bolts that are too long will damage the clutch sur face inside the converter 23 Install torque converter to driveplate bolts Tighten bolts to 31 N m 270 in 165 24 Install starter motor and cooler line bracket 25 Connect cooler lines to transmission 26 Install transmission fill tube 27 Install exhaust components 28 Install transfer case Tighten transfer case nuts to 35 26 ft Ibs 29 Install the transfer case shift cable to the cable support bracket and the transfer case shift lever 30 Install the transmission collar onto the trans mission and the engine Tighten the bolts to 54 N m 40 ft Ibs 31 Align and connect propeller shaft s 32 Adjust gearshift cable if necessary 33 Lower vehicle 34 Fill transmission with Mopar ATF Plus 3 Type 7176 fluid TORQUE CONVERTER REMOVAL 1 Remove transmission and torque converter from vehicle 2 Place a suitable drain pan under the converter housing end of the transmission CAUTION Verify that transmission is secure on the lifting device or work surface the center of gravity of the transmission will shift when the torque con verter is removed creating an unstable condition The torque converter is a heavy unit Use caution when separating the torque converter from the transmission 3 Pull the torque converter forward until the cen ter hub cle
115. that will not move Refer to procedure in diagnosis section 4 Filter Plugged 4 Remove and disassemble transmission Repair or replace failed components as needed Replace filter If filter and fluid contained clutch material or metal particles an overhaul may be necessary Perform lube flow test Flush oil Replace cooler as necessary 5 Oil Pump Damaged 5 Perform pressure test to confirm low pressure Replace pump body assembly if necessary 6 Valve Body Malfunctioned 6 Check and inspect valve body Replace valve body as assembly if any valve or bore is damaged Clean and reassemble correctly if all parts are in good condition 7 Transmission Internal Component 7 Remove and disassemble transmission Damaged Repair or replace failed components as needed 8 Park Sprag not Releasing Check 8 Remove disassemble repair Stall Speed Worn Damaged Stuck 9 Torque Converter Damage 9 Inspect and replace as required 2 AUTOMATIC TRANSMISSION 21 63 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION SHIFTS DELAYED OR 1 Fluid Level Low High 1 Correct fluid level and check for leaks if ERRATIC SHIFTS ALSO low HARSH AT TIMES 2 Fluid Filter Clogged 2 Replace filter If filter and fluid contained clutch material or metal particles an overhaul may be necessary Perform lube flow test 3 Throttle Linkage Misadjusted 3 Adjust linkage as descri
116. the bullet is worn or the rod itself is bent or distorted Do not attempt to straighten the rod 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 WJ CLEANING AND INSPECTION Continued 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
117. the 2 3 shift valve Without throttle pressure present in the circuit now the governor plug will push the valve over far enough to bottom the valve in its bore This allows land 2 to direct line pressure to the front clutch 21 30 42RE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued ur THROTTLE GOVERNOR PLUG PLUG 2 3 SHIFT VALVE GOVERNOR PLUG 5 1 2 SHIFT VALVE Fig 33 2 3 Shift Valve After Shift After the shift Fig 33 line pressure is directed to the land between the shift valve and the governor plug and to the release side of the kickdown servo This releases the front band and applies the front dutch shifting into third gear or direct drive The rear dutch remains applied as it has been in the other gears During a manual 1 or manual 2 gear selection line pressure is sent between the two lands of the 2 3 governor plug This line pressure at the governor plug locks the shift valve into the second gear position preventing an upshift into direct drive The theory for the blocking of the valve is the same as that of the 1 2 shift valve THROTTLE PLUG SHUTTLE VALVE 1 2 SHIFT CONTROL VALVE 80c07148 WJ DESCRIPTION AND OPERATION Continued 3 4 SHIFT VALVE The PCM energizes the overdrive solenoid during the 3 4 upshift Fig 34 This causes the solenoid check ball to close the vent port allowing line pres sure from the 2 3 shift valve to act directl
118. the 3 2 part throttle downshift plug becomes inoperative because no pressure is acting on its reaction area GOVERNOR LIMIT VALVE MIC E 1 2 SHIFT VALVE The 1 2 shift valve assembly Fig 29 or mecha nism consists of the 1 2 shift valve governor plug and a spring on the end of the valve After the man ual valve has been placed into a forward gear range line pressure is directed to the 1 2 shift valve As the throttle is depressed throttle pressure is applied to the right side of the 1 2 shift valve assembly With throttle pressure applied to the right side of the valve there is now both spring pressure and throttle pressure acting on the valve holding it against the governor plug As the vehicle begins to move and build speed governor pressure is created and is applied to the left of the valve at the governor plug THROTTLE PL ME PLUG DUC 1 2 SHIFT CONTROL VALVE ur rL Z 80c07142 Fig 27 Kickdown Limit Valve Low Speeds LIMIT VALVE 2 3 SHIFT VALVE GOVERNOR PLUG 1 2 SHIFT VALVE Fig THROTTLE PLUG SHUTTLE VALVE 1 2 SHIFT CONTROL VALVE 80c07143 28 Kickdown Limit Valve High Speeds WJ 42RE AUTOMATI DESCRIPTION AND OPERATION Continued LIMIT VALVE THROTTLE PLUG
119. the ECE check ball from the transfer plate Fig 129 The ECE check ball is approximately 4 8 mm 3 16 in in diameter 31 Remove transfer plate from upper housing Fig 130 WJ DISASSEMBLY AND ASSEMBLY Continued 32 Turn transfer plate over so upper housing sep arator plate is facing upward 33 Remove upper housing separator plate from transfer plate Fig 131 Note position of filter in separator plate for assembly reference 34 Remove rear clutch and rear servo check balls from transfer plate Note check ball location for assembly reference Fig 132 J9321 147 Fig 127 Boost Valve Tube 1 BOOST VALVE TUBE 2 LOWER HOUSING 3 DISENGAGE THIS END OF TUBE FIRST 4 UPPER HOUSING 80b170f8 Fig 128 Lower Housing 1 LOWER HOUSING 2 OVERDRIVE SEPARATOR PLATE 3 TRANSFER PLATE AND UPPER HOUSING 42RE AUTOMATIC TRANSMISSION 21 95 Q Os J a 5 alc 80017125 Fig 129 Check Ball 1 ECE CHECK BALL 3 16 80b170f9 Fig 130 Transfer Plate 1 UPPER HOUSING 2 TRANSFER PLATE VALVE BODY UPPER HOUSING 1 Note location of check balls in valve body upper housing Fig 133 Then remove the one large diam eter and the six smaller diameter check balls 2 Remove governor plug and shuttle valve covers Fig 135 3 Remove E dip that
120. the input clutch assembly into Input Clutch Pressure Fixture 8260 Fig 113 Mount dial indicator to the assembly push down on the clutch discs and zero the indicator against the under drive clutch discs Fig 114 Apply 20 psi of air pres sure to the underdrive clutch and record the dial indicator reading Measure and record UD clutch pack measurement in four 4 places 90 apart Take average of four measurements and compare with U D clutch pack clearance specification The correct clutch clearance is 0 76 1 16 mm 0 030 0 063 Adjust as necessary Install the chosen reaction plate and re measure to verify selection INPUT CLUTCH 80c07429 Fig 113 Input Clutch Assembly Mounted on Tool 8260 17 Install the overdrive clutch pack into the input clutch retainer Fig 107 The overdrive steel separator plates can be identified by the lack of the half moon cuts in the locating tabs 18 Install the overdrive clutch wavy snap ring with the two tabbed ears into the input clutch retainer 19 Install the OD reverse reaction plate into the input clutch retainer The reaction plate is non direc tional Fig 107 20 Install the OD reverse reaction plate flat snap ring into the input clutch retainer 21 Mount a dial indicator to the assembly and zero the indicator against the OD reverse reaction plate Fig 115 Apply 20 psi of air pressure to the overdrive clutch and record the dial indicator read ing Measu
121. to the oil pump Fig 68 WJ DISASSEMBLY AND ASSEMBLY Continued VALVE BODY TO CASE BOLT 6 5 RING 7 C TRANSMISSION outer snap COVER RING 80c07355 Fig 68 Remove Transmission Front Cover 20 Reaching through a case opening in the valve body area with a long blunted tool remove the trans mission front cover from the transmission case 21 Remove the bolts holding the oil pump into the transmission case Fig 69 22 Remove the oil pump Hold inward on the input shaft to prevent pulling the input dutch assembly with the oil pump Fig 69 23 Remove the number 1 bearing from the input dutch assembly Fig 70 24 Remove the input dutch assembly from the transmission case Fig 70 25 Remove the number 5 bearing and selective thrust plate from the input clutch assembly Fig 70 or the 4C dutch retainer bulkhead 26 Remove the 4C dutch retainer bulkhead tapered snap ring from the transmission case Fig 71 45RFE AUTOMATIC TRANSMISSION 21 225 OIL PUMP TO CASE BOLT 6 gt N P M P ENI Fig 69 Remove Oil Pump 80 07356 BEARING NUMBER 5 THRUST PLATE SELECT INPUT CLUTCH ASSEMBLY BEARING NUMBER 1 a Fig 70 Remove Input Clutch Assembly 0c07357 27 Remove the 4C dutch retainer bulkhead from the transmission case Fig 71 28 Remove the front 2C dutch pack snap ring from the transmissio
122. transmis sion is not noisy perform hydraulic pressure test to determine if problem is hydraulic or mechanical BRAKE TRANSMISSION SHIFT INTERLOCK 1 Verify that the key can only be removed in the PARK position 2 When the shift lever is in PARK And the shift handle pushbutton is in the OUT position the igni tion key cylinder should rotate freely from OFF to LOCK When the shifter is in any other gear or neu tral position the ignition key cylinder should not rotate to the LOCK position 3 Shifting out of PARK should be possible when the ignition key cylinder is in the OFF position 4 Shifting out of PARK should not be possible while applying 25 Ib maximum handle pushbutton force and ignition key cylinder is in the RUN or START positions unless the foot brake pedal is depressed approximately 1 2 inch 12 mm 5 Shifting out of PARK should not be possible when the ignition key cylinder is in the ACCESSORY or LOCK positions 6 Shifting between any gears NEUTRAL or into PARK may be done without depressing foot brake pedal with ignition switch in RUN or START posi tions and vehicle stationary or in motion 45RFE AUTOMATIC TRANSMISSION 21 207 GEARSHIFT CABLE 1 The floor shifter lever and gate positions should be in alignment with all transmission PARK NEUTRAL and gear detent positions 2 Engine starts must be possible with floor shift lever in PARK or NEUTRAL gate positions only Engine starts must not be po
123. transmission compo nents DO NOT use solvents containing acids water gasoline or any other corrosive liquids 2 Reinstall filler plug on Tool 6906A 3 Verify pump power switch is turned OFF Con nect red alligator clip to positive battery post Connect black alligator clip to a good ground 4 Disconnect the cooler lines at the transmission NOTE When flushing transmission cooler and lines ALWAYS reverse flush 5 Connect the BLUE pressure line to the OUT LET From cooler line Connect the CLEAR return line to the INLET To cooler line 7 Turn pump ON for two to three minutes to flush cooler s and lines 8 Turn pump OFF 9 Disconnec CLEAR suction line from reservoir at cover plate Disconnect CLEAR return line at cover plate and place it in a drain pan 10 Turn pump ON for 30 seconds to purge flush ing solution from cooler and lines Turn pump OFF 11 Place CLEAR suction line into a one quart container of Mopar ATF Plus 3 type 7176 automatic transmission fluid 12 Turn pump ON until all transmission fluid is removed from the one quart container and lines This purges any residual cleaning solvent from the trans mission cooler and lines Turn pump OFF 13 Disconnect alligator dips from battery Recon nect flusher lines to cover plate and remove flushing adapters from cooler lines TRANSMISSION QUICK LEARN PROCEDURE The quick learn procedure requires the use of the DRB scan to
124. 00 7 Support geartrain on Tool 6227 1 Fig 301 Be sure tool is securely seated in clutch hub 8 Install overdrive gear case on geartrain Fig 301 19321 403 Fig 300 Correct Hear Bearing Locating Ring Position 1 CASE ACCESS HOLE 2 TAB ENDS OF LOCATING RING 42RE AUTOMATIC TRANSMISSION 21 151 9 Expand front bearing locating ring with snap ring pliers Fig 302 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 303 PUSH OUTPUT SHAFT FORWARD TO FREE BEARING Je 19321 359 Fig 302 Seating Locating Ring In Rear Bearing 1 EXPAND BEARING LOCATING RING WITH SNAP RING PLIER 2 ACCESS HOLE J9321 360 Fig 301 Overdrive Gear Case Installation 1 GEARTRAIN ASSEMBLY 2 GEAR CASE J9321 357 Fig 303 Locating Ring Access Cover And Gasket Installation 1 TORX SCREWDRIVER T25 2 ACCESS COVER SCREWS 21 152 42 AUTOMATIC TRANSMISSION WJ DISASSEMBLY AND ASSEMBLY Continued OVERDRIVE CLUTCH ASSEMBLY 1 Install overdrive clutch reaction ring first Reaction ring is flat with notched ends Fig 304 2 Install wave spring on top of reaction ring Fig 305 Reaction ring and wave ring both fit in same ring groove Use screwdriver to seat each ring securely in groove Also ens
125. 0091 IY Ezzzzzzzzzzzzzzzzzz z zz 3j 1N3A A 1 HOSN3S Saud HVA SdA H 1Od BS LEInIW SW 14 YALYAANOO 990 HOLN19 HOLMIO Puc Oc d Q31VA3 1d 10 HVA SJA HOLIMS S3Hd Sd dyl 905599 1 WoOJv In Wnoov ov 19 JSU8H3A3H 0H lt 5 8 daads 1 JILVIMS3HOS DITNVYGAH 3ddSr 21 253 vb67ed08 0091 IV NO 29 440 99 an sw isalsaunssaud 08 5 cor se 2222272 r males _ E 45RFE AUTOMATIC TRANSMISSION T r Es f 14 LNJASA Q31VA3T37 4 HOSN3S SdHd HVA SdA 7106 HVA SJA Ov 1O313 LEIGW SW HOLIAS S3Hd Sd 553 2 14 H31H3ANOO 29 HOLWINWNDOV 0V HOLn19 3suaAdu ou Lan 26 3SHu3A3H MOT H1 9 Ajao 8 Q33ds SCHEMATICS AND DIAGRAMS Continued WJ 45RFE AUTOMATIC TRANSMISSION SCHEMATICS AND DIAGRAMS
126. 136 9 Remove 1 2 shift control valve and spring Fig 136 2 AUTOMATIC TRANSMISSION 21 97 DISASSEMBLY AND ASSEMBLY Continued J9421 217 Fig 135 Shuttle And Boost Valve Components 1 SPRING 8 SHUTTLE VALVE COVER 2 RETAINER 9 SHUTTLE VALVE 3 BOOST VALVE 10 SHUTTLE VALVE PRIMARY SPRING 4 BOOST VALVE PLUG 11 GOVERNOR PLUG COVER 5 SPRING GUIDES 12 THROTTLE PLUG 6 E CLIP 13 UPPER HOUSING 7 SHUTTLE VALVE SECONDARY SPRING 14 BOOST VALVE COVER 21 98 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued J9321 157 Fig 136 Upper Housing Shift Valve And Pressure Plug Locations 1 UPPER HOUSING 8 RETAINER 2 1 2 SHIFT VALVE AND SPRING 9 1 2 SHIFT CONTROL VALVE AND SPRING 3 2 3 SHIFT VALVE AND SPRING 10 PRESSURE PLUG COVER 4 2 3 THROTTLE PLUG 11 LINE PRESSURE PLUG 5 LIMIT VALVE HOUSING 12 PLUG SLEEVE 6 LIMIT VALVE COVER 13 THROTTLE PRESSURE SPRING AND PLUG 7 LIMIT VALVE AND SPRING 2 AUTOMATIC TRANSMISSION 21 99 DISASSEMBLY AND ASSEMBLY Continued 80607265 Fig 137 Lower Housing Shift Valves Springs 1 3 4 ACCUMULATOR HOUSING 11 TIMING VALVE COVER 2 8 4 SHIFT VALVE AND SPRING 12 PLUG 3 PLUG 13 3 4 TIMING VALVE AND SPRING 4 SPRING RETAINER 14 LOWER HOUSING 5 C
127. 168 9 0 3unssaud TI gt zm NOILORS 134 25 6 3unssaud 38frvH3183ANOO 159 0z sz 159 6 0 aunssaud 29 0 3ufnsSsaud HONH3AOD 189 76 25 3unssatid dV39 GNODAS NI MO TJ Ol TOVHGAH FTLLOYHL dqNO23S 3AIHG NI H3A31 0194136 NOLLVOIuS HOL YIO LNOtid NOLLYOINEM OL H3lH3ANOO anouol 3ATVA SNIINLL dfl H5O1 NE 3A1VA 3ATVA HO1V 10938 WONVA 3A1VA 1OHLNOO L4IHS 2 1 L4IHS 6 1 HONH3AO t t AATWA AINO oss IMYA 3111nHS hu 1 onde 1 O IMIWA HONHJAOO HOLY INANDDY H E o H21f119 LNOtid n HOLN19 OAH3S HV3H 5 HONH3AOS 3AIHQH3AO YOLVTINAINDSY OAH3S 21 169 42RE AUTOMATIC TRANSMISSION WJ SCHEMATICS AND DIAGRAMS Continued 58 9 08 sd 5 0 3unssaud NOLLONS 19 9 3unssaud 38n T u3lH3ANOO isd 76 0 sunssatid JILLOHHL ORAA isd 09 0 55 HONH3AOD isd 96 6 3unssaud LON H LNT H31H3ANOO
128. 1d 3 TLLOHHL 3ATVA H91019 1NOHd OAH3S 1INOUJ OAH3S HV3H o N33H05 3NTVA HOlV In9o3H AATVA SATVA LAIHS 2 1 ond YONHAAOD SATWA LAIHS STLLOYHL HONH3AO9 HV3H GION310S HONH3AOD 42RE AUTOMATIC TRANSMISSION SCHEMATICS AND DIAGRAMS Continued 21 172 28 5 189 09 9 aunssaud JH31H3ANOO 001 0 aunssauq 3TLLOHHL tsd 09 0 aunssatudq HONH3AOS isd 061 6 3unssaud INIT 0311997 21112 H3183ANOO 9 3AIHG NI 933307 1 uv39 3AIHQU3AO NI H3A31 40199373S 3AT1VA ONIINLL df15201 3ATVA j QION310S dfi201 105 AdQu3A0 p 21112 LNOYA OL 110 YALYAANOD anouol FATWA 18008 3ATVA 7 6 TI AJNO 9 6 v HOLfTIO m SATIVA NIMOCDIODI zd 3ATVA TILLOYHL 3ATVA uo1vTnb3u SS 3A
129. 5 turns Be sure adjusting screw turns freely in case Apply lubricant to screw threads if necessary 3 Tighten band adjusting screw to 8 N m 72 in Ibs torque with Inch Pound Torque Wrench C 3380 A a 3 in extension and appropriate Torx socket CAUTION If Adapter C 3705 is needed to reach the adjusting screw tighten the screw to only 5 N m 47 50 in Ibs torque 4 Back off front band adjusting screw 3 turns 5 Hold adjuster screw in position and tighten locknut to 41 N m 30 ft Ibs torque 6 Lower vehicle 80c070ac Fig 320 Front Band Adjustment Screw Location 1 LOCK NUT 2 FRONT BAND ADJUSTER REAR BAND ADJUSTMENT The transmission oil pan must be removed for access to the rear band adjusting screw 1 Raise vehicle 2 Remove transmission oil pan and drain fluid 3 Loosen band adjusting screw locknut 5 6 turns Fig 321 Be sure adjusting screw turns freely in lever 4 Tighten adjusting screw to 8 N m 72 in 165 torque 5 Back off adjusting screw 4 turns 9 Q W O i uu O Oo 0 3 8007269 Fig 321 Rear Band Adjusting Screw Location 1 ADJUSTING SCREW 2 REAR BAND LEVER 3 LOCKNUT 6 Hold adjusting screw in place and tighten lock nut 34 N m 25 ft 165 torque 7 Position new gasket on oil pan and install pan on transmission Tighten pan bolts to 17 N m 13 ft Ibs torque 8
130. 5RFE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued f BALANCE PISTON 80c07426 80c07427 Fig 108 Compressing UD OD Balance Piston Using Fig 110 Install Underdrive Piston Using Tool 8504 Tool 8251 SNAP SEAL SNAP INPUT CLUTCH RING UD BALANCE RING PISTON HUB SEAL O CLUTCH RETAI NER OD REV PISTON BELLEVILLE PLATE SNAP RING SPRING 80 07013 Fig 109 Input Clutch Assembly Part WJ DISASSEMBLY AND ASSEMBLY Continued TOOL 8252 80c07428 Fig 111 Install Balance Piston Using Tool 8252 11 Using Spring Compressor 8251 compress the UD OD return spring pack and secure the piston in place with the snap ring Fig 112 BALANCE PISTON 80c07426 Fig 112 Compressing UD OD Balance Piston Using Tool 8251 12 Install the underdrive clutch pack into the input clutch retainer Fig 109 13 Install the UD OD reaction plate lower flat snap ring Fig 107 The correct snap ring can be identified by the two tabbed ears 14 Install the UD OD reaction plate into the input clutch retainer The reaction plate is to be installed with the big step down The reaction plate is also selectable and should be changed to achieve the correct clutch clearances 45RFE TRANSMISSION 21 241 15 Install the UD OD reaction plate upper tapered snap ring with tapered side up 16 Install
131. 66 Install Front Output Shaft Rear Bearing 1 HANDLE C 4171 2 OUTPUT SHAFT INNER BEARING 3 INSTALLER 5066 14 Install new seal in oil pump feed housing with Special Tool 7888 Fig 67 19521 35 Fig 67 Oil Pump Seal Installation 1 HOUSING SEAL 2 SPECIAL TOOL 7888 3 OIL PUMP FEED HOUSING 15 Install new pickup tube O ring in oil pump Fig 68 16 Remove rear retainer bearing with Installer 8128 and Handle C 4171 NV242HD only 17 Install rear bearing in retainer with Handle C 4171 and Installer 5064 Fig 69 NV242HD only 21 294 NV242 TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued J8921 286 Fig 68 Pickup Tube O Ring Installation 1 PICKUP TUBE O RING 800bdfag Fig 69 Installing Rear Bearing In Retainer 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL 5064 3 REAR RETAINER DIFFERENTIAL 1 Lubricate differential components with auto matic transmission fluid 2 Install sprocket gear in differential bottom case Fig 70 3 Install differential planet gears and new thrust washers Fig 71 Be sure thrust washers are installed at top and bottom of each planet gear 4 Install differential mainshaft gear Fig 71 J8921 279 Fig 70 Installing Differential Sprocket Gear 1 SPROCKET GEAR 2 BOTTOM CASE J8921 280 Fig 71 Installing Mainshaft And Planet Gears 1 MAINSHAFT GEAR 2 THRUST WASHERS 12 3 PLANET GEARS 6
132. 7 11 Position the 2C Belleville spring onto the 2C piston 12 Position the 2C Belleville spring snap ring onto the 2C Belleville spring Fig 117 13 Using Spring Compressor 8249 and a suitable shop press Fig 119 compress the belleville spring 21 244 45 AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued PRESS 80c07419 Fig 118 Compress 4C Piston Return Spring Using Tool 8250 until the snap ring is engaged with the snap ring groove in the retainer bulkhead 80c07418 Fig 119 Compress 2C Belleville Spring Using Tool 8249 PLANETARY GEAR SET DISASSEMBLY 1 Remove the snap ring holding the input annu lus into the input carrier Fig 120 2 Remove the input annulus from the input car rier Fig 120 3 Remove the number 9 bearing from the reverse planetary carrier Note that this planetary carrier has four pinion gears 4 Remove the reverse planetary gear carrier Fig 120 5 Remove the number 10 bearing from the input sun gear Fig 120 6 Remove the input sun gear from the input car rier Fig 120 7 Remove the number 11 bearing from the input carrier Fig 120 ASSEMBLY 1 Clean and inspect all components Replace any components which show evidence of excessive wear or scoring 2 Install the number 11 bearing into the input planetary carrier with the flat side up and facing for ward Fig 120 3
133. 7 0 031 0 042 mm in 2C Clutch Pack 0 53 1 27 0 021 0 050 Clearance mm in 4C Clutch Pack 0 81 1 35 0 032 0 053 Clearance mm in L R Clutch Pack 1 14 1 91 0 045 0 075 Clearance mm in OD Clutch Pack 1 016 1 65 0 040 0 065 Clearance mm in UD Clutch Pack 0 76 1 160 0 030 0 063 Clearance mm in Reverse Clutch Pack 0 81 1 24 0 032 0 049 Clearance mm in Recommended fluid Plus 3 type 7176 GEAR RATIOS GEAR RATIO IST s Ak dw 3 00 1 2ND bua each ba buc vdd 1 67 1 2ND PRIME gc ein eee aw 1 50 1 1 00 1 CRM MH 0 75 1 REVERSE ur 3 00 1 TORQUE DESCRIPTION TORQUE Fitting Cooler Line 17 5 N m 155 in Ibs Bolt Torque Convertor 31 23 ft 165 Bolt Driveplate 75 N m 55 ft 165 Bolt nut Crossmember 68 N m 50 ft Ibs Bolt Oil Pan 11 8 N m 105 in Ibs Screw Primary Oil Filter 4 5 N m 40 Ibs Filter Cooler Return 14 125 in Ibs Bolt Oil Pump 28 2 N m 250 in 165 Bolt Oil Pump Body to Cover 4 5 Nm 40 in 165 Screw Plate to Oil Pump Body 4 5 40 Ibs Plug Pressure Test Port 5 1 N m 45 in 165 45RFE AUTOMATIC TRANSMISSION 21 271 DESCRIPTION TORQUE Bolt Reaction Shaft Support 11 8 105 16 Bolt Va
134. 78 screw Tighten the manual selector shaft retaining 48 Remove the manual selector shaft seal screw to 28 250 in 155 49 Remove the dipstick tube seal 6 Install the park pawl spring and shaft Fig 78 21 228 45RFE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued PARK PAWL MANUAL SHAFT LEVER 80c07414 Fig 78 Manual Shaft Park Lock Components SEAL Y 5 QQ 7 S lt lt TOOL 8253 80 07415 Fig 79 Install Selector Shaft Seal Using Tool 8253 7 Install the park rod and e dip Fig 78 8 Install the park rod guide and snap ring Fig 78 9 Install a new dipstick tube seal using Seal Installer 8254 Fig 80 NOTE Before final assembly of transmission cen terline the 2C 4C clutch components should be installed into position and measured adjusted as follows I L NS _ Emm 80c07416 Fig 80 Install Dipstick Tube Seal Using Tool 8254 10 Install the 2C reaction plate into the trans mission case Fig 72 The reaction plate is selective and directional The plate must be installed with the flat side toward the front 11 Install the 2C dutch pack into the transmis sion case Fig 72 12 Install the flat 2C dutch snap ring into the transmission case Fig 72 13 Install the 4C retainer bulkhead into the transmission case Make sure that the oil feed holes are pointing toward the valve body area 14
135. 86 NV242 TRANSFER CASE D n n s lt snlnwWiJ DISASSEMBLY AND ASSEMBLY Continued J8921 259 Fig 39 Clutch Shaft Thrust Ring Removal 1 CLUTCH SHAFT THRUST RING 18921 257 Fig 37 Mode Fork And Sleeve Removal 1 MAINSHAFT 2 SLEEVE 3 MODE FORK ASSEMBLY J8921 260 Fig 40 Intermediate Clutch Shaft Removal 1 INTERMEDIATE CLUTCH SHAFT 10 Remove differential snap ring Fig 41 J8921 258 11 Remove differential Fig 42 Fig 38 Intermediate Clutch Shaft Snap Ring Removal 1 SNAP RING 2 INTERMEDIATE CLUTCH SHAFT 12 Remove differential needle bearings and both needle bearing thrust washers from mainshaft 13 Slide low range fork pin out of shift sector slot Fig 43 WJ 242 TRANSFER CASE 21 287 DISASSEMBLY AND ASSEMBLY Continued J8921 261 J8921 263 Fig 43 Disengaging Low Range Fork Fig 41 Differential Snap Ring Removal 1 SHIFT SECTOR 1 DIFFERENTIAL SNAP RING 2 LOW RANGE FORK 3 PIN 4 SLOT J8921 262 Fig 42 Differential Removal 1 DIFFERENTIAL 2 MAINSHAFT J8921 264 Fig 44 Low Range Fork And Hub Removal 14 Remove low range fork and hub Fig 44 1 LOW RANGE FORK 15 Remove shift sector Fig 45 2 FORK HUB 16 Remove shift sector bushing and O ring Fig 46 INPUT GEAR LOW RANGE ASSEMBLY 1 Remove front bearing ret
136. 9 3 Remove shift lever bezel and floor console as necessary for access to the brake transmission shift interlock cable 4 Pull cable lock button up to release cable Fig 316 5 Pull cable rearward Then release cable and press lock button down until it snaps in place BTSI FUNCTION CHECK 1 Verify removal of ignition key allowed in park position only 2 When the shift lever is in park and the shift handle push button is in the out position the igni tion key cylinder should rotate freely from off to lock When the shifter is in any other position the ignition key should not rotate from off to lock 3 Shifting out of park should be possible when the ignition key cylinder is in the off position 4 Shifting out of park should not be possible while applying 25 16 max handle push button force and ignition key cylinder is in the run or start posi tions unless the foot brake pedal is depressed approximately 1 2 inch 12 mm 5 Shifting out of park should not be possible when the ignition key cylinder is in the accessory or lock position 6 Shifting between any gears neutral or park may be done without depressing foot brake with igni tion switch in run or start positions and vehicle sta tionary or in motion 7 The floor shifter lever and gate positions should be in alignment with all transmission detent positions 8 Engine starts must be possible with shifter lever in park or neutral gate positions only
137. AGNOSIS Automatic transmission problems can be a result of poor engine performance incorrect fluid level incor rect linkage or cable adjustment band or hydraulic control pressure adjustments hydraulic system mal functions or electrical mechanical component mal functions Begin diagnosis by checking the easily accessible items such as fluid level and condition linkage adjustments and electrical connections A road test will determine if further diagnosis is neces sary EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid Air in the fluid will cause fluid pressures to be low and develop slower than normal If the transmission is overfilled the gears churn the fluid into foam This aerates the fluid and causing the same conditions occurring with a low level In either case air bubbles cause fluid overheating oxi dation and varnish buildup which interferes with valve dutch and servo operation Foaming also causes fluid expansion which can result in fluid over flow from the transmission vent or fill tube Fluid 21 52 42RE AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING Continued 80ba79c2 Fig 66 Ignition Interlock Cable 4 STEERING COLUMN ASSEMBLY 5 INTERLOCK CABLE 1 SHIFT MECHANISM 2 SHIFTER BTSI LEVER 3 ADJUSTMENT CLIP overflow can easily be mistaken for a leak if inspec tion is not careful CAUSES OF BURNT FLUID Burnt discolored
138. ALVE The torque converter clutch TCC lock up timing valve is there to block any 4 3 downshift until the TCC is completely unlocked and the clutch is disen gaged SHUTTLE VALVE The assembly is contained in a bore in the valve body above the shift valves When the manual valve is positioned in the Drive range throttle pressure acts on the throttle plug of the shuttle valve Fig 31 to move it against a spring increasing the spring force on the shuttle valve During a part or full throt tle 1 2 upshift the throttle plug is bottomed by throttle pressure holding the shuttle valve to the right against governor pressure and opening a by pass circuit The shuttle valve controls the qual ity of the kickdown shift by restricting the rate of fluid discharge from the front dutch and servo release circuits During a 3 2 kickdown fluid dis charges through the shuttle by pass circuit When the shuttle valve closes the by pass circuit fluid dis charge is restricted and controlled for the application of the front band During a 2 3 lift foot upshift the shuttle valve by passes the restriction to allow full fluid flow through the by pass groove for a faster release of the band 21 38 42RE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued BOOST VALVE The boost valve Fig 44 provides increased fluid apply pressure to the overdrive clutch during 3 4 upshifts Fig 45 and when accelerating in fourth gear
139. ANNULUS INPUT PLANETARY CARRIER GEAR 80c07034 Fig 26 Reverse Input Planetary Geartrain SNAP RING REVERSE PLANETARY CARRIER OPERATION Manual low 1 range provides first gear only Overrun braking is also provided in this range Man ual second 2 range provides first and second gear only Drive range provides first second third and over drive fourth gear ranges The shift into overdrive fourth gear range occurs only after the transmission has completed the shift into D third gear range No further movement of the shift mechanism is required to complete the 3 4 shift The fourth gear upshift occurs automatically when the overdrive selector switch is in the ON position An upshift to fourth gear may not occur or may be delayed in some of the possible shift schedules Refer to the Transmission Control Module information for further details OVERDRIVE OFF SWITCH DESCRIPTION The overdrive OFF control switch is located in the shifter handle The switch is a momentary con tact device that signals the PCM to toggle current status of the overdrive function OPERATION At key on overdrive operation is allowed Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off The overdrive OFF mode defaults to ON after the ignition switch i
140. ANSMISSION SCHEMATICS AND DIAGRAMS Continued 21 258 6 6 908 354957 622 33059 3NIT 5 08 51 tice core Ep HO1v in93dH cor mt er A gt S i 14 IN3A A GO3lvA3dd HOSN3S Sdud HVA SdA 7106 39HOH HVA SHJA LOATAS ILINW SA HOLIMS Satid Sd 3HfiSS3Hd 1d H31H3ANOO 05 HO4fTTO 10 an HOLNTO 02 MOT H1 0 4 NOUS uvao 1544 21 259 45RFE AUTOMATIC TRANSMISSION SCHEMATICS AND DIAGRAMS Continued WJ OrTVHdAH 3ddSr 0061 IV NO 29 4409292 3NIT iSsd s34nisS3Hd 08 1 811 65 5091 66 1 x Ln Y 111 HOlv1no3H Ale Pt e Jl Z Z Z an H H 4 a Sd EILIIIIIIKIIIIIIIIIIIZIIIZ Sd 4 H ezzzzzzzzzzzzzzzzzezo e 14 14 is d INSA A MOTIHH3AO q31VA313 x m HOSN3S S3Hd 7108 30HOd HVA SJA ov ov lOS 13S LEIW SIWN HOLIMS S3td Sd 2 3HnSS3Hd ld 10 29 HOlv1nWnoov ov HOLATO
141. ASSEMBLY Continued J8921 267 Fig 75 Input Gear Snap Ring Installation 1 INPUT GEAR 2 SNAP RING J8921 276 Fig 76 Installing Front Bearing Retainer 1 FRONT BEARING RETAINER Fig 77 Sector O Ring And Bushing Installation 1 SECTOR BUSHING 2 O RING SHIFT FORKS AND MAINSHAFT 1 Install new sector shaft O ring and bushing Fig 77 2 Install shift sector 3 Install new pads on low range fork if neces sary Fig 78 4 Assemble low range fork and hub Fig 78 5 Position low range fork and hub in case Be sure low range fork pin is engaged in shift sector slot Fig 79 J8921 278 Fig 78 Assembling Low Range Fork And Hub 1 LOW RANGE FORK 2 PADS 3 HUB 6 Install first mainshaft bearing spacer on main shaft Fig 80 7 Install bearing rollers on mainshaft Fig 80 Coat bearing rollers with generous quantity of petroleum jelly to hold them in place Nv242 TRANSFER CASE 21 297 DISASSEMBLY AND ASSEMBLY Continued 9 Install differential Fig 81 Do not displace mainshaft bearings when installing differential 10 Install differential snap ring Fig 82 11 Install intermediate clutch shaft Fig 83 w 4 18921 263 Fig 79 Positioning Low Range Fork 1 SHIFT SECTOR 2 LOW RANGE FORK 3 PIN 4 SLOT J8921 283 Fig 81 Differential Installation 1
142. Adjustment Procedure 1 Shift transmission into Park 2 Remove shift lever bezel and floor console as necessary for access to the shift cable adjustment 3 Loosen the shift cable adjustment screw Fig 318 4 Raise vehicle 42RE AUTOMATIC TRANSMISSION 21 161 80ba79cb Fig 318 Shift Cable at the Shifter 1 SHIFT LEVER PIN 2 ADJUSTMENT SCREW 3 SHIFT CABLE 4 SHIFTER ASSEMBLY BRACKET 5 Unsnap cable eyelet from transmission shift lever Fig 319 6 Verify transmission shift lever is in Park detent by moving lever fully rearward Last rearward detent is Park position 7 Verify positive engagement of transmission park lock by attempting to rotate propeller shaft Shaft will not rotate when park lock is engaged 8 Snap cable eyelet onto transmission shift lever 9 Lower vehicle 10 Tighten the shift cable adjustment screw to 7 N m 65 in Ibs 11 Verify correct operation 12 Install the shifter bezel and any floor console components removed for access MANUAL LEVER 80ba79c4 Fig 319 Shift Cable Attachment At Transmission 21 162 42 AUTOMATIC TRANSMISSION ADJ USTMENTS Continued BAND ADJUSTMENTS FRONT BAND ADJUSTMENT The front kickdown band adjusting screw is located on the left side of the transmission case above the manual valve and throttle valve levers 1 Raise vehide 2 Loosen band adjusting screw locknut Fig 320 Then back locknut off 3
143. B SEAL RING 2 INPUT SHAFT SEAL RINGS 80 070 5 Fig 227 Input Shaft Seal Ring Identification 1 PLASTIC REAR SEAL RING 2 TEFLON FRONT SEAL RING SQUEEZE RING TOGETHER SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT WJ DISASSEMBLY AND ASSEMBLY Continued 2 J9121 152 Fig 228 Pressing Input Shaft Into Rear Clutch Retainer 1 INPUT SHAFT 2 REAR CLUTCH RETAINER 3 PRESS RAM J9121 153 Fig 229 Piston Spring Wave Spring Position 1 REAR CLUTCH RETAINER 2 PISTON SPRING 3 WAVE SPRING 4 CLUTCH PISTON 11 Install bottom pressure plate Fig 224 Ridged side of plate faces downward toward piston and flat side toward dutch pack 12 Install first dutch disc in retainer on top of bottom pressure plate Then install a dutch plate fol lowed by a dutch disc until entire clutch pack is 42RE AUTOMATIC TRANSMISSION 21 131 installed 4 discs and 3 plates are required Fig 224 13 Install top pressure plate 14 Install selective snap ring Be sure snap ring is fully seated in retainer groove 15 Using a suitable gauge bar and dial indicator measure clutch pack clearance Fig 230 a Position gauge bar across the clutch drum with the dial indicator pointer on the pressure plate Fig 230 b Using two small screw drivers lift the pres sure plate and release it c Zero the dial indicator d Lift the pressure plate until it contacts the snap ring
144. BINE VANE 4 PORTION OF TORQUE CONVERTER COVER 2 ENGINE ROTATION 5 ENGINE ROTATION 3 INPUT SHAFT 6 OIL FLOW WITHIN TURBINE SECTION TURBINE The turbine Fig 11 is the output or driven mem ber of the converter The turbine is mounted within the housing opposite the impeller but is not attached to the housing The input shaft is inserted through the center of the impeller and splined into the tur bine The design of the turbine is similar to the impeller except the blades of the turbine are curved in the opposite direction 21 14 42RE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued STATOR The stator assembly Fig 12 is mounted on a sta tionary shaft which is an integral part of the oil pump The stator is located between the impeller and turbine within the torque converter case Fig 13 The stator contains an over running dutch which allows the stator to rotate only in a dockwise direc tion When the stator is locked against the over run ning dutch the torque multiplication feature of the torque converter is operational SIDE OF STATOR SHOWING VANE CURVATURE 80bfe26c VIEW FROM ENGINE SIDE Fig 12 Stator Components 1 CAM OUTER RACE 2 ROLLER 3 SPRING 4 INNER RACE 80bfe26d Fig 13 Stator Location 1 STATOR 2 IMPELLER 3 FLUID FLOW 4 TURBINE TORQUE CONVERTER CLUTCH TCC The TCC Fig 14 was installed to improve the
145. Belleville spring and install the split retaining ring to hold the Belleville spring into the low reverse dutch retainer 7 Install the lower overrunning clutch snap ring Fig 122 8 Assemble the inner and outer races of the over running clutch Fig 122 9 Position the overrunning dutch spacer on the overrunning dutch WJ DISASSEMBLY AND ASSEMBLY Continued OUTER RACE SNAP RING OVERRUNNING SPACER CLUTCH 80b9a598 Fig 122 Overrunning Clutch BELLEVILLE SPRING 80c07420 Fig 123 Compress Low Reverse Belleville Spring Using Tool 8285 10 Install the upper overrunning clutch snap ring Fig 122 11 Assemble and install the low reverse clutch pack into the low reverse clutch retainer Fig 121 12 Install the low reverse reaction plate into the low reverse clutch retainer Fig 121 The reaction plate is directional and must be installed with the flat side down 13 Install the low reverse clutch pack snap ring Fig 121 The snap ring is selectable and should be chosen to give the correct dutch pack dearance 14 Measure the low reverse clutch pack clearance and adjust as necessary The correct dutch clearance is 1 14 1 91 mm 0 045 0 05 in 45RFE AUTOMATIC TRANSMISSION 21 247 15 Install the overrunning dutch into the low re verse dutch retainer making sure that the index splines are aligned with the retainer 16 Install the overrunning dutch inner snap ri
146. CH ASSEMBLY BEARING NUMBER 1 80c07357 Fig 90 Install Input Clutch Assembly 43 Install the oil pump into the transmission case Fig 91 44 Install the bolts to hold the oil pump into the transmission case Tighten the oil pump bolts to 28 N m 250 in Ibs 45 Using Adapter 8266 1 from End Play Tool Set 8266 and Dial Indicator C 3339 measure and record the input shaft end play Fig 92 The correct end play is 0 79 1 07 mm 0 031 0 042 in Adjust as necessary Install the chosen spacer on the number 5 bearing and re measure end play to verify selection 21 232 45 AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued OIL PUMP TO CASE BOLT 6 S lt 80 07356 80 07352 Fig 92 Measure Input Shaft End Play NOTE When measuring the input shaft end play two stops will be felt When the input shaft is pushed inward and the dial indicator zeroed the first stop felt when the input shaft is pulled out ward is the movement of the input shaft in the input clutch housing hub This value should not be included in the end play measured value and there fore must be recorded and subtracted from the dial indicator reading 46 Install the transmission front cover into the transmission case Fig 93 47 Install the outer snap ring to hold the trans mission front cover into the transmission case Fig 93 WJ 48 Partially install the inner transmission front cove
147. CH HUB WARNING THE NEXT STEP JGEARTRAIN 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 HYDRAULIC TYPE SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 6 INCHES THE PRESS MUST ALSO HAVE A BED J9321 397 THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED RELEASE CLUTCH SPRING TENSION Fig 295 Direct Clutch Pack And Clutch Hub SLOWLY AND COMPLETELY TO AVOID PERSONAL installation 1 CLUTCH HUB 2 DIRECT CLUTCH PACK 3 CLUTCH DRUM 21 150 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued 20 Position Compressor Tool 6227 1 on dutch hub 21 Compress dutch 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 dutch pack snap ring and dutch hub retaining ring 23 Realign clutch pack on hub and seat dutch discs and plates in clutch drum 24 Install direct dutch pack snap ring Fig 296 Be very sure snap ring is fully seated in clutch drum ring groove 25 Install dutch hub retaining ring Fig 297 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 Fig 296 Direct
148. Cable From Transmission 7 Disconnect cable at shift lever and shifter assembly bracket Fig 55 8 Remove the nuts holding the shift cable seal plate to the floor pan Fig 56 9 Pull cable through floor panel opening 10 Remove shift cable from vehicle INSTALLATION 1 Route cable through hole in floor pan 2 Install seal plate to studs in floor pan 3 Install nuts to hold seal plate to floor pan Tighten nuts to 7 N m 65 in Ibs 4 Install the shift cable to the shifter assembly bracket Push cable into the bracket until secure 5 Place the floor shifter lever in park position 6 Loosen the adjustment screw on the shift cable 7 Snap the shift cable onto the shift lever pin 8 Raise the vehicle 80ba79cb Fig 55 Transmission Shift Cable at Shifter 1 SHIFT LEVER PIN 2 ADJUSTMENT SCREW 3 SHIFT CABLE 4 SHIFTER ASSEMBLY BRACKET 80 79 Fig 56 Shift Cables at Floor 1 SEAL PLATES 2 TRANSMISSION SHIFT CABLE 3 TRANSFER CASE SHIFT CABLE 9 Install the shift cable to the shift cable support bracket 10 Shift the transmission into PARK PARK is the rearmost detent position on the transmission manual shift lever 11 Snap the shift cable onto the transmission manual shift lever 12 Lower vehicle 13 Verify that the shift lever is in the PARK posi tion 14 Tighten the adjustment screw to 7 N m 65 in Ibs 15 Verify correct sh
149. Check for shift variations and engine flare which indicates slippage Note if shifts are harsh spongy delayed early or if part throttle downshifts are sensitive Slippage indicated by engine flare usually means dutch band or overrunning dutch problems If the condition is advanced an overhaul will be necessary to restore normal operation A slipping dutch or band can often be determined by comparing which internal units are applied in the various gear ranges The Clutch and Band Applica tion chart provides a basis for analyzing road test results WJ DIAGNOSIS AND TESTING Continued ANALYZING ROAD TEST Refer to the Clutch and Band Application chart and note which elements are in use in the various gear ranges Note that the rear clutch is applied in all forward ranges D 2 1 The transmission overrunning clutch is applied in first gear D 2 and 1 ranges only The rear band is applied in 1 and R range only Note that the overdrive clutch is applied only in fourth gear and the overdrive direct clutch and over running clutch are applied in all ranges except fourth gear For example If slippage occurs in first gear in D and 2 range but not in 1 range the transmission overrunning dutch is faulty Similarly if slippage occurs any two forward gears the rear clutch is slipping Applying the same method of analysis note that the front and rear clutches are applied simulta neously only in D range third and fourth gea
150. Checking Converter Seating 1 SCALE 2 STRAIGHTEDGE 12 Move transmission forward Then raise lower or tilt transmission to align converter housing with engine block dowels 13 Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft 14 Install two bolts to attach converter housing to engine 15 Install remaining torque converter housing to engine bolts Tighten to 68 N m 50 ft Ibs 16 Install rear transmission crossmember Tighten crossmember to frame bolts to 68 N m 50 ft Ibs 17 Install rear support to transmission Tighten bolts to 47 N m 35 ft Ibs 18 Lower transmission onto crossmember and install bolts attaching transmission mount to cross member Tighten clevis bracket to crossmember bolts to 47 N m 35 ft Ibs Tighten the devis bracket to rear support bolt to 68 50 ft Ibs 19 Remove engine support fixture 20 Install new plastic retainer grommet on any shift cable that was disconnected Grommets should not be reused Use pry tool to remove rod from grom met and cut away old grommet Use pliers to snap new grommet into cable and to snap grommet onto lever 21 Connect gearshift cable to transmission 22 Connect wires to solenoid and pressure switch assembly connector input and output speed sensors and line pressure sensor Be sure transmission har nesses are properly routed WJ CAUTION It is essential
151. Continued 3 Disconnect wires at the solenoid and pressure switch assembly connector 4 Position drain pan under transmission oil pan 5 Remove transmission oil pan 6 Remove the primary oil filter from valve body 7 Remove bolts attaching valve body to transmis sion case Fig 41 8 Lower the valve body and work the electrical connector out of transmission case 9 Separate the valve body from the transmission g VALVE BODY TO CASE BOLT 6 0 80 07354 Fig 41 Valve Body Bolts INSTALLATION 1 Check condition of seals on valve body and the solenoid and pressure switch assembly Replace seals if cut or worn 2 Place TRS selector plate in the PARK position 3 Place the transmission in the PARK position 4 Lubricate seal on the solenoid and pressure switch assembly connector with petroleum jelly 5 Position valve body in transmission and align the manual lever on the valve body to the pin on the transmission manual shift lever 6 Seat valve body in case and install one or two bolts to hold valve body in place 7 Tighten valve body bolts alternately and evenly to 12 N m 105 165 torque 8 Install new fluid filter on valve body Tighten filter screws to 4 5 N m 40 in Ibs torque 9 Connect the solenoid and pressure switch assembly connector 10 Install oil pan Tighten pan bolts to 12 N m 105 in 165 torque 11 Lower vehicle and fill transmission with
152. Continued 16 Install mode fork and mainshaft assembly in case Fig 88 Rotate mainshaft slightly to engage shaft with low range gears J8921 257 Fig 87 Installing Mode Fork And Sleeve 1 MAINSHAFT 2 SLEEVE 3 MODE FORK ASSEMBLY 17 Rotate mode fork pin into shift sector slot 18 Install shift rail Fig 89 Be sure rail is seated in both shift forks 19 Rotate shift sector to align lockpin hole in low range fork with access hole in case 20 Insert an easy out in range fork lockpin to hold it securely for installation Fig 90 Lockpin is slightly tapered on one end Insert tapered end into fork and rail 21 Insert lockpin through access hole and into shift fork Fig 90 Then remove easy out and seat the pin with pin punch 22 Install plug in lockpin access hole 23 Install detent plunger detent spring detent plug in case Fig 91 NV242 TRANSFER CASE 21 299 Ed ES SS e gt f 5 xA N Bf fu 28921 256 Fig 88 Assembled Mainshaft And Mode Fork Installation 1 MAINSHAFT ASSEMBLY 2 MODE FORK J8921 255 Fig 89 Shift Rail Installation 1 SHIFT RAIL 2 MODE FORK 21 300 NV242 TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued J8921 254 Fig 90 Installing Low Range Fork Lockpin 1 LOW RANGE FORK LOCK PIN 2 ACCESS H
153. DIAGNOSIS AND TESTING Continued CLUTCH APPLICATION CHART SLP UD OD R 2C 4C L R OVERRUNNING P PARK ON R REVERSE ON ON N NEUTRAL ON D OVERDRIVE FIRST ON ON ON SECOND ON ON SECOND PRIME ON ON THIRD ON ON FOURTH ON ON LIMP IN ON ON 2 FIRST ON ON ON SECOND ON ON LIMP IN ON ON 1 LOW ON ON ON L R clutch is on only with the output shaft speed below 150 rpm HYDRAULIC PRESSURE TEST An accurate tachometer and pressure test gauges are required Test Gauge C 3293 SP has a 300 psi range and is used at all locations where pressures exceed 100 psi Pressure Test Port Locations Only two pressure ports are supplied on the trans mission case The torque converter ON and torque converter OFF ports are located on the right side of the transmission case Fig 31 FROM T C L U ON SX ae li Hs FROM COOLER LINE PRESSURE TRANSDUCER 80ba79d0 Fig 31 Torque Converter Pressure Locations To determine the line pressure there are two avail able methods The DRB scan tool can be used to read line pressure from the line pressure sensor The sec ond method is to install Line Pressure Adapter 8259 Fig 33 into the transmission case and then install the pressure gauge and the original sensor into the adapter This will allow a comparison of the
154. EMBLY AND ASSEMBLY Continued J9421 177 Fig 234 Front Planetary And Annulus Gear Disassembly 1 FRONT ANNULUS 2 THRUST WASHER 3 THRUST PLATE 4 FRONT THRUST WASHER 5 FRONT PLANETARY N Q LL P J9421 178 Fig 235 Removing Driving Shell Rear Planetary And Rear Annulus 1 REAR ANNULUS 2 REAR PLANETARY 3 DRIVING SHELL 4 OUTPUT SHAFT 42RE TRANSMISSION 21 133 7 Install spacer on sun gear Fig 239 8 Install thrust plate on sun gear Fig 240 Note that driving shell thrust plates are interchangeable Use either plate on sun gear and at front rear of shell J9121 156 Fig 236 Assembling Rear Annulus And Planetary Gear 1 REAR ANNULUS GEAR 2 TABBED THRUST WASHER 3 REAR PLANETARY 6 Install front thrust washer on rear planetary gear Fig 238 Use enough petroleum jelly to hold washer on gear Be sure all four washer tabs are seated in slots J9121 157 Fig 237 Installing Rear Annulus And Planetary On Output Shaft 1 REAR ANNULUS AND PLANETARY GEAR ASSEMBLY 2 OUTPUT SHAFT 21 134 42 AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued J9121 158 Fig 238 Installing Rear Planetary Front Thrust Washer 1 FRONT TABBED THRUST WASHER 2 REAR PLANETARY GEAR J9121 159 Fig 239 Installing Spacer On Sun Gear 1 SUN GEAR 2 SUN GEAR SPACER J9121 161
155. ETER CHECK BALLS 6 2 LARGE DIAMETER CHECK BALL 1 J9321 439 Fig 143 Installing Transfer Plate On Upper Housing 1 FILTER SCREEN 2 TRANSFER PLATE SEPARATOR PLATE ASSEMBLY 3 UPPER HOUSING 21 102 42 AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued J9321 441 Fig 144 Lower Housing Plate 1 BE SURE TO ALIGN BORES 2 TRANSFER PLATE 3 LOWER HOUSING OVERDRIVE SEPARATOR PLATE 4 J9321 442 Fig 145 Installing Lower Housing On Transfer Plate And Upper Housing 1 VALVE BODY SCREWS 13 2 LOWER HOUSING 3 UPPER HOUSING 4 TRANSFER PLATE UPPER HOUSING VALVE AND PLUG Refer to Fig 146 Fig 147 and Fig 148 to per form the following steps 1 Lubricate valves plugs springs with dean transmission fluid 2 Assemble regulator valve line pressure plug sleeve throttle plug and spring Insert assembly in upper housing and install cover plate Tighten cover plate screws to 4 N m 35 in Ibs torque 3 Install 1 2 and 2 3 shift valves and springs 4 Install 1 2 shift control valve and spring 5 Install retainer spring limit valve and 2 3 throttle plug from limit valve housing 6 Install limit valve housing and cover plate Tighten screws to 4 N m 35 in Ibs 7 Install shuttle valve as follows a Insert plastic guides in shuttle valve second ary spring and install spring on end of valve b Install
156. FT INTERLOCK 53 VALVE BODY occa Rye 89 GEARSHIFT 54 5 109 THROTTLE VALVE 54 OVERRUNNING CLUTCH CAM OVERDRIVE ROAD 54 PISTON 120 21 2 42RE AUTOMATIC TRANSMISSION FRONT SERVO PISTON 122 REAR SERVO 5 122 OIL PUMP AND REACTION SHAFT SUPPORT 123 FRONT CLUTCH 127 REAR CLUTCH wisi eR es 129 PLANETARY GEARTRAIN OUTPUT SHAFT 132 OVERDRIVE 0 137 CLEANING AND INSPECTION VALVE BODY 55 t en 154 155 OVERRUNNING CLUTCH LOW REVERSE DRUM OVERDRIVE PISTON RETAINER 156 156 FRONT SERVO ois ini ga 156 REAR SERVO 156 OIL PUMP AND REACTION SHAFT SUPPORT 156 FRONT CLUTCH 157 DESCRIPTION AND OPERATION 42RE AUTOMATIC TRANSMISSION DESCRIPTION The 42RE is a four speed fully automatic transmis sion Fig 1 with an electronic governor The 42RE is equipped with a lock up clutch in the torque con verter First through third gear ranges are provided by the clutches bands overrunning clutch and plan etary gear sets in the transmission Fourth gear ran
157. Fig 98 Do not remove the screws on the top of the solenoid and pressure switch assembly 2 Separate the solenoid and pressure switch assembly from the valve body 3 Remove the screw holding the detent spring Fig 99 onto the valve body 4 Remove the detent spring from the valve body 45RFE AUTOMATIC TRANSMISSION 21 233 OUTPUT SPEED SENSOR LINE PRESSURE INPUT SPEED SENSOR SENSOR 80c07350 Fig 97 Install Input Output and Line Pressure Sensors SOLENOID PACK BOLTS 15 80c07445 Fig 98 Solenoid and Pressure Switch Assembly Screws 5 Remove the TRS selector plate from the valve body and the manual valve 6 Remove the dutch passage seals from the valve body if necessary 7 Remove the screws holding the accumulator cover onto the valve body Fig 100 8 Remove the accumulator springs and pistons from the valve body Note which accumulator piston and spring belong in each location 9 Place the valve body on the bench with the transfer plate upward 21 234 45RFE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued TRS SELECTOR CLUTCH PASSAGE s 1 lt gt 80c072f3 Fig 99 Valve Body External Components NOTE The valve body contains seven check balls The transfer plate must be placed upward to pre vent losing the check balls when the transfer plate is removed from the
158. HAFT SEAL 312 REAR RETAINER BUSHING AND SEAL 313 DISASSEMBLY AND ASSEMBLY NV247 TRANSFER 314 CLEANING AND INSPECTION NV247 328 SPECIFICATIONS jolie rq 329 SPECIAL TOOLS NV247 TRANSFER 330 The transfer case serial number also represents the date of build FILL PLUG 80ba7a32 Fig 2 Transfer Case I D Tag OPERATION Under normal driving conditions the system oper ates conventionally and the majority of available torque is applied to the rear wheels However when front to rear wheel speed variations exist the pro gressive differential transfers torque to the axle with the better traction thus minimizing wheel spin and maximizing control The key to this design is a progressive coupling Fig 3 which is supplied with pressurized oil by a gerotor style pump The pump rotor and case are driven by the front and rear driveshafts respectively and deliver pressurized oil flow to the coupling in proportion to their speed difference The progressive coupling contains a multi disc clutch pack that is alternately splined to the front and rear driveshafts and controls torque variation between the front and rear driveshafts as dictated by the pump WJ DESCRIPTION AND OPERATION Continued A set of orifices and valves control the speed differ ential starting point and rate of torque transfer rise in the cl
159. INE TO TRANSMISSION COLLAR 80ba79d2 Fig 44 Transmission Collar 45RFE MANUAL LEVER 80ba79c4 Fig 45 Transmission Shift Cable 17 Support rear of engine with safety stand or jack 18 Raise transmission slightly with service jack to relieve load on crossmember and supports 19 Remove bolts securing rear support and cush ion to transmission and crossmember Fig 47 20 Remove bolts attaching crossmember to frame and remove crossmember 21 Remove transfer case Fig 48 and Fig 49 22 Remove all remaining converter housing bolts 23 Carefully work transmission and torque con verter assembly rearward off engine block dowels 24 Hold torque converter in place during trans mission removal 25 Lower transmission and remove assembly from under the vehicle WJ REMOVAL AND INSTALLATION Continued A WS TRANSFER CASE Sex SHIFT LEVER Y oe V 2 Me LESS ca TRANSFER CASE SHIFT CABLE 80ba79c6 Fig 46 Transfer Case Shift Cable CROSSMEMBER TRANSMISSION MOUNT 80ba79c7 Fig 47 Rear Transmission Crossmember 26 To remove torque converter carefully slide torque converter out of the transmission INSTALLATION 1 Check torque converter hub and hub drive notches for sharp edges burrs scratches or nicks Polish the hub and notches with 320 400 grit paper and crocus doth if necessary The hub must be smooth to avoid damaging pum
160. ITCH 3 Remove the shift cable eyelet from the trans mission manual shift lever Fig 85 4 Remove shift cable from the cable support bracket 45RFE MANUAL LEVER 80ba79c4 Fig 85 Remove Shift Cable From Transmission 5 Lower vehicle 6 Remove shift lever bezel and necessary console parts for access to shift lever assembly and shift cable 7 Disconnect cable at shift lever and shifter assembly bracket Fig 86 8 Remove the nuts holding the shift cable seal plate to the floor pan Fig 87 9 Pull cable through floor panel opening 10 Remove shift cable from vehicle 80ba79cb Fig 86 Transmission Shift Cable at Shifter 1 SHIFT LEVER PIN 2 ADJUSTMENT SCREW 3 SHIFT CABLE 4 SHIFTER ASSEMBLY BRACKET 80 79 Fig 87 Shift Cables at Floor Pan 1 SEAL PLATES 2 TRANSMISSION SHIFT CABLE 3 TRANSFER CASE SHIFT CABLE INSTALLATION 1 Route cable through hole in floor pan 2 Install seal plate to studs in floor pan 3 Install nuts to hold seal plate to floor pan Tighten nuts to 7 65 in Ibs 4 Install the shift cable to the shifter assembly bracket Push cable into the bracket until secure 5 Place the floor shifter lever in park position 6 Loosen the adjustment screw on the shift cable 7 Snap the shift cable onto the shift lever pin 8 Raise the vehide 9 Install the shift cable to the shift cable support bracket WJ REMO
161. Install the input sun gear into the input carrier Fig 120 4 Install the number 10 bearing onto the rear of the reverse planetary carrier with the flat side toward the carrier Fig 120 5 Install the number 9 bearing onto the front of the reverse planetary carrier with the rounded side toward the carrier and the flat side facing upward Fig 120 6 Install the reverse planetary gear carrier into the input carrier Fig 120 7 Install the input annulus gear into the input carrier Fig 120 8 Install the snap ring to hold the input annulus gear into the input carrier Fig 120 WJ BEARING BEARING NUMBER 10 AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued NUMBER 11 INPUT SUN 21 245 ANNULUS INPUT PLANETARY CARRIER GEAR 80c07034 Fig 120 Reverse Input Planetary Carrier Assembly SNAP RING REVERSE PLANETARY CARRIER LOW REVERSE CLUTCH DISASSEMBLY 1 Remove the inner overrunning clutch snap ring from the low reverse clutch retainer Fig 121 2 Remove the outer low reverse reaction plate flat snap ring Fig 121 3 Remove the low reverse clutch and the over running clutch from the low reverse clutch retainer as an assembly Fig 121 4 Separate the low reverse clutch from the over running clutch 5 Remove the overrunning clutch snap ring Fig 122 6 Remove the spacer from the overrunning clutch Fig 122 7 Sepa
162. L TOOL 6583 POSITIONED ON DETENT HOUSING 13 Secure detent ball and spring with Retainer Tool 6583 Fig 115 14 Remove park rod E dip and separate rod from manual lever Fig 116 15 Remove E dip and washer that retains throt tle lever shaft in manual lever Fig 117 16 Remove manual lever and throttle lever Fig 118 Rotate and lift manual lever off valve body and throttle lever shaft Then slide throttle lever out of valve body 3 9121 81 Fig 116 Park Rod 1 MANUAL LEVER 2 E CLIP 3 PARK ROD 21 92 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued J9321 424 Fig 117 Throttle Lever E Clip And Washer 1 THROTTLE LEVER SHAFT 2 E CLIP AND WASHER 3 MANUAL SHAFT J9321 425 Fig 118 Manual And Throttle Lever 1 PARK ROD 2 MANUAL LEVER ASSEMBLY 3 THROTTLE LEVER 19 Remove adjusting screw bracket line pressure adjusting screw pressure regulator valve spring and switch valve spring Fig 121 Do not remove throttle pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during removal 20 Turn upper housing over and remove switch valve regulator valve and spring and manual valve Fig 122 21 Remove kickdown detent kickdown valve and throttle valve and spring Fig 122 22 Loosen left side 3 4 accumulator housing attaching screw about 2 3 threads Then remove cen ter and right
163. Lower vehicle and refill transmission with Mopar ATF Plus 3 Type 7176 fluid VALVE BODY CONTROL PRESSURE ADJUSTMENTS There are two control pressure adjustments on the valve body e Line Pressure e Throttle Pressure Line and throttle pressures are interdependent because each affects shift quality and timing As a result both adjustments must be performed properly and in the correct sequence Adjust line pressure first and throttle pressure last LINE PRESSURE ADJUSTMENT Measure distance from the valve body to the inner edge of the adjusting screw with an accurate steel scale Fig 322 Distance should be 33 4 mm 1 5 16 in If adjustment is required turn the adjusting screw in or out to obtain required distance setting NOTE The 33 4 mm 1 5 16 in setting is an approximate setting Manufacturing tolerances may make it necessary to vary from this dimension to obtain desired pressure One complete turn of the adjusting screw changes line pressure approximately 1 2 3 psi 9 kPa 2 AUTOMATIC TRANSMISSION 21 163 USTMENTS Continued Turning the adjusting screw counterclockwise Maintain pressure against kickdown valve spring increases pressure while turning the screw clockwise Turn throttle lever stop screw until the screw head decreases pressure touches throttle lever tang and the throttle lever cam touches gauge tool NOTE The kickdown valve spring must be fully
164. Lubrication and Maintenance for proper service intervals The fluid capacity of the 45RFE is approx imately 13 25 liters 14 0 quarts REMOVAL 1 Hoist and support vehicle on safety stands 2 Place a large diameter shallow drain pan beneath the transmission pan 3 Remove bolts holding front and sides of pan to transmission 4 Loosen bolts holding rear of pan to transmis sion 5 Slowly separate front of pan away from trans mission allowing the fluid to drain into drain pan 6 Hold up pan and remove remaining bolt hold ing pan to transmission 7 While holding pan level lower pan away from transmission 8 Pour remaining fluid in pan into drain pan 9 Remove screws holding filter to valve body Fig 37 10 Separate filter from valve body and oil pump and pour fluid in filter into drain pan 11 Remove and discard the oil filter seal from the bottom of the oil pump 12 Using Oil Filter Wrench 8321 remove the cooler return filter from the transmission 13 Dispose of used trans fluid and filter properly COOLER FILTER FILTER BYPASS VALVE PRIMARY OIL FILTER 80b9a595 Fig 37 Transmission Filters 21 212 45 AUTOMATIC TRANSMISSION SERVICE PROCEDURES Continued INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal A light coating of dutch material on the bottom of the pan does not indicate a problem unless accompanied by a slipping condit
165. M Malfunction 3 Test with DRB scan tool Replace POM if faulty 4 Valve Body Stuck Valves 4 Repair stuck 3 4 lockup or lockup timing valve CLUNK NOISE FROM 1 Transmission Fluid Low 1 Add Fluid DRIVELINE ON CLOSED THROTTLE 4 3 DOWNSHIFT 2 Throttle Cable Misadjusted 2 Adjust cable 3 Overdrive Clutch Select Spacer 3 Replace overdrive piston thrust plate Wrong Spacer spacer 21 68 42RE AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION 3 4 UPSHIFT OCCURS 1 Overdrive Solenoid Connector or 1 Test connector and wiring for loose IMMEDIATELY AFTER 2 3 Wiring Shorted connections shorts or ground and repair as SHIFT needed 2 TPS Malfunction 2 Test TPS and replace as necessary Check with DRB scan tool 3 PCM Malfunction 3 Test PCM with DRB scan tool and replace controller if faulty 4 Overdrive Solenoid Malfunction 4 Replace solenoid 5 Valve Body Malfunction 5 Remove disassemble clean and inspect valve body components Make sure all valves and plugs slide freely in bores Polish valves with crocus cloth if needed WHINE NOISE RELATED 1 Fluid Level Low 1 Add fluid and check for leaks TO ENGINE SPEED 2 Shift Cable Incorrect Routing 2 Check shift cable for correct routing Should not touch engine or bell housing 2 AUTOMATIC TRANSMISSION 21 69 DIAGNOSIS AND TESTING Continued
166. MANUAL VALVE 9 1 2 GOVERNOR PLUG 10 GOVERNOR PLUG COVER 11 THROTTLE PLUG 12 2 3 GOVERNOR PLUG 13 SHUTTLE VALVE PRIMARY SPRING 1 UPPER HOUSING 2 REGULATOR VALVE 3 SWITCH VALVE 4 REGULATOR VALVE SPRING 5 KICKDOWN VALVE 6 KICKDOWN DETENT 7 THROTTLE VALVE AND SPRING VALVE BODY DESCRIPTION The valve body consists of a cast aluminum valve body a separator plate and transfer plate The valve body contains valves and check balls that control fluid delivery to the torque converter clutch bands and frictional clutches The valve body contains the following components Fig 18 Fig 19 Fig 20 and Fig 21 e Regulator valve Regulator valve throttle pressure plug Line pressure plug and sleeve Kickdown valve Kickdown limit valve 1 2 shift valve 1 2 control valve 2 3 shift valve 2 3 governor plug 3 4 shift valve 3 4 timing valve 3 4 quick fill valve 3 4 accumulator Throttle valve Throttle pressure plug Switch valve Manual valve Converter clutch lock up valve Converter clutch lock up timing Valve Shuttle valve Shuttle valve throttle plug Boost Valve e 10 check balls By adjusting the spring pressure acting on the reg ulator valve transmission line pressure can be adjusted 21 18 2 AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued J9421 217 Fig 19 Shuttle and Boost Valve Locations 1 SPRING 8
167. MPERATURE SENSOR DESCRIPTION The transmission temperature sensor is a ther mistor that is integral to the Transmission Range Sensor TRS OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump Since fluid temperature can affect transmis sion shift quality and convertor lock up the TCM requires this information to determine which shift schedule to operate in Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature Calculated temperature is a pre dicted fluid temperature which is calculated from a combination of inputs Battery ambient temperature e Engine coolant temperature run time since start up SOLENOIDS DESCRIPTION Solenoids are used to control the L R 2C 4C OD and UD friction elements The reverse clutch is con trolled by line pressure and the position of the man ual valve in the valve body All the solenoids are contained within the Solenoid and Pressure Switch Assembly The solenoid and pressure switch assembly contains one additional solenoid Multi Select MS which serves primarily to provide 2nd and 3rd gear limp in operation 45RFE AUTOMATIC TRANSMISSION 21 205 OPERATION The solenoids receive electrical power from the Transmission Control Relay through a single wire The TCM energizes or operates the solenoids individ ua
168. Make sure all passages are clean and free from obstructions Do not use rags or shop towels to dry or wipe off valve body components Lint from these materials can stick to valve body parts interfere with valve operation and clog filters and fluid passages Wipe the governor pressure sensor solenoid valve with dry lint free shop towels only The O rings on the sensor and solenoid valve are the only service able components Be sure the vent ports in the sole noid valve are open and not blocked by dirt or debris Replace the valve and or sensor only when DRB scan tool diagnosis indicates this is necessary Or if either part has sustained physical damage dented deformed broken etc CAUTION Do not turn the small screw at the end of the solenoid valve for any reason Turning the screw in either direction will ruin solenoid calibra tion and result in solenoid failure In addition the filter on the solenoid valve is serviceable Do not try to remove the filter as this will damage the valve housing Inspect the throttle and manual valve levers and shafts Do not attempt to straighten a bent shaft or correct a loose lever Replace these components if worn bent loose or damaged in any way Inspect all of the valve body mating surfaces for scratches nicks burrs or distortion Use a straight edge to check surface flatness Minor scratches may be removed with crocus doth using only very light pressure WJ CLEANING
169. N SHIFT INTERLOCK REMOVAL 1 Lower the steering column 2 Remove the transmission shift interlock cable from steering column Fig 61 3 Remove the center console and related trim Refer to Group 23 Body for proper procedures 4 Disconnect the BTSI cable from the shift BTSI lever and remove the cable from the shifter assembly bracket 5 Disengage the wire connector at the solenoid on the cable 6 Release the BTSI cable from any remaining dips 7 Remove BTSI cable from the vehicle INSTALLATION NOTE The gearshift cable must be secured into position and properly adjusted before the installa tion of the Brake Transmission Interlock Cable BTSI 1 Snap the BTSI cable assembly into the steering column 2 Snap BTSI cable solenoid tie strap into hole in steering column tube 3 Engage the wiring connector from brake light switch into BTSI cable solenoid housing 4 Route BTSI cable to the shifter mechanism 5 Install the BTSI cable end fitting into shifter BTSI lever 6 Pull rearward on the BTSI cable housing and install the cable housing into the shifter assembly bracket 7 Place the ignition key cylinder in the LOCK position 8 Snap BTSI cable adjuster ears into floor shifter bracket and 9 Push the cable adjuster lock clamp downward to lock it WJ REMOVAL AND INSTALLATION Continued 45RFE TRANSMISSION 21 223 Yee xr AN ES
170. N m 30 ft Ibs torque 9 Remove transmission jack and support stand 10 Connect shift rod to transfer case range lever 11 Adjust transfer case shift cable 21 278 NV242 TRANSFER CASE REMOVAL AND INSTALLATION Continued 12 Lower vehide and verify transfer case shift operation FRONT OUTPUT SHAFT SEAL REMOVAL 1 Raise vehicle 2 Remove front propeller shaft Refer to Group 3 Differential and Driveline for proper procedure 3 Remove front output shaft companion flange 4 Remove seal from front case with pry tool Fig 6 lt A e 2 2 ff CA E aie e 80a1108b Fig 6 Remove Front Output Shaft Seal 1 OUTPUT SHAFT SEAL 2 PRYBAR INSTALLATION 1 Install new front output seal in front case with Installer Tool 6952 A as follows a Place new seal on tool Garter spring on seal goes toward interior of case b Start seal in bore with light taps from ham mer Fig 7 Once seal is started continue tapping seal into bore until installer tool seats against case 2 Install companion flange and tighten nut to 122 176 90 130 ft Ibs torque 3 Install front propeller shaft Refer to Group 3 Differential and Driveline for the correct procedure and torque specification NV242HD REAR RETAINER BUSHING AND SEAL REM OVAL 1 Raise vehide 2 Remove rear propeller shaft Refer to Group 3 Differential and Driveline for proper proced
171. NISM 2 SHIFTER BTSI LEVER 3 ADJUSTMENT CLIP 21 222 45 AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION Continued 80ba79cd Fig 59 Transfer Case Shift Cable 1 CLIP 2 SHIFTER 3 TRANSFER CASE SHIFT LEVER PIN 4 TRANSFER CASE SHIFT CABLE Fig 60 Shifter Assembly 1 FLOOR PLAN 2 SHIFTER ASSEMBLY 2 Install the nuts to hold the shifter assembly onto the floor pan Tighten nuts to 28 N m 250 in Ibs 3 Install wiring harness to the shifter assembly bracket Engage any wire connectors removed from the shifter assembly 4 Install the transfer case shift cable to the shifter assembly bracket Install dip to hold cable to the bracket 5 Snap the transfer case shift cable onto the transfer case shift lever pin 6 Install the brake transmission interlock cable into the shifter assembly bracket and into the shifter BTSI lever WJ 7 Install the shift cable to the shifter assembly bracket Push cable into the bracket until secure 8 Place the floor shifter lever in park position 9 Loosen the adjustment screw on the shift cable 10 Snap the shift cable onto the shift lever pin 11 Verify that the shift lever is in the PARK posi tion 12 Tighten the adjustment screw to 7 N m 65 in Ibs 13 Verify correct shifter operation 14 Install shift lever bezel and any console parts removed for access to shift lever assembly and shift cables BRAKE TRANSMISSIO
172. NSMISSION DESCRIPTION AND OPERATION Continued 1 80c07146 Fig 31 1 2 Shift Control Valve The physical blocking of the upshift while in the manual 1 position is accomplished by the directing of line pressure between both lands of the governor plug The line pressure reacts against the larger land of the plug pushing the plug back against the end plate overcoming governor pressure With the combi nation of the line pressure and spring pressure the valve cannot move preventing any upshift 1 2 SHIFT CONTROL VALVE It contains a valve with four lands and a spring It is used as both a relay and balanced valve The valve has two specific operations Fig 31 Aid in quality of the 1 2 upshift Aid in the quality and timing of the 3 2 kick down ranges When the manual valve is set to the Drive position and the transmission is in the first or second gear range 1 2 shift control or modulated throttle pres sure is supplied to the middle of the accumulator piston by the 1 2 shift control valve During the 1 2 upshift this pressure is used to control the kickdown servo apply pressure that is needed to apply the kick down and accumulator pistons Thus the 1 2 shift point is cushioned and the quality is improved During WOT kickdown kickdown pressure is applied between the kickdown valve and the 1 2 shift control valve This additional pressure is directed to the 1 2 shift control s spring
173. OID 19 SOLENOID GASKET 1 0 OVERDRIVE SOLENOID 20 HARNESS WJ DESCRIPTION AND OPERATION Continued 42RE AUTOMATIC TRANSMISSION 21 21 TE TORQUE CONVERTER OIL FILTER BCR Ra TO LUBRICATION 80c0713c Fig 22 Regulator Valve in Park Position OPERATION NOTE Refer to the Hydraulic Schematics for a visual aid in determining valve location operation and design REGULATOR VALVE The pressure regulator valve is needed to control the hydraulic pressure within the system and reduce the amount of heat produced in the fluid The pres sure regulator valve is located in the valve body near the manual valve The pressure regulator valve train controls the maximum pressure in the lines by metering the dumping of fluid back into the sump Regulated pressure is referred to as line pressure The regulator valve Fig 22 has a spring on one end that pushes the valve to the left This closes dump vent that is used to lower pressure The dos ing of the dump will cause the oil pressure to increase Oil pressure on the opposite end of the valve pushes the valve to the right opening the dump and lowering oil pressure The result is spring pressure working against oil pressure to maintain the oil at specific pressures With the engine run ning fluid flows from the pump to the pressure reg ulator valve manual valve and the i
174. OLE 3 EASY OUT FRONT OUTPUT SHAFT AND DRIVE CHAIN 1 Install front output shaft Fig 92 2 Install drive chain Fig 92 Engage chain with front output shaft sprocket teeth 3 Install drive sprocket Fig 92 Engage drive sprocket teeth with chain Then engage sprocket splines with mainshaft splines J9121 426 Fig 91 Detent Pin Spring And Plug Installation 1 PLUNGER 2 O RING 3 PLUG 4 SPRING J8921 285 Fig 92 Drive Chain And Sprocket Installation 1 FRONT OUTPUT SHAFT 2 DRIVE CHAIN 3 DRIVE SPROCKET 4 Install drive sprocket snap ring Fig 93 J8921 251 Fig 93 Drive Sprocket Snap Ring Installation 1 DRIVE SPROCKET 2 DRIVE SPROCKET SNAP RING WJ DISASSEMBLY AND ASSEMBLY Continued OIL PUMP AND REAR CASE 1 Insert oil pickup tube in oil pump and attach oil screen and connector hose to pickup tube Then install assembled pump tube and screen in rear case Fig 94 Be sure screen is seated in case slot as shown 2 Install magnet in front case pocket Fig 95 J8921 287 Fig 94 Oil Screen And Pickup Tube Installation 1 OIL PUMP 2 OIL SCREEN 3 CONNECTOR 4 PICKUP TUBE J8921 288 Fig 95 Installing Case Magnet 1 MAGNET NV242 TRANSFER CASE 21 301 3 Apply 3 mm 1 8 in wide bead of Mopar gas ket maker or silicone adhesive sealer to seal surface of front case 4 Align and install rear cas
175. ONVERTER CLUTCH VALVE AND SPRING 15 ACCUMULATOR END PLATE 6 CONVERTER CLUTCH TIMING VALVE AND SPRING 16 3 4 ACCUMULATOR PISTON AND SPRING 7 OVERDRIVE SEPARATOR PLATE 17 E CLIP 8 CASE CONNECTOR 18 3 4 QUICK FILL SPRING AND VALVE 9 CONVERTER CLUTCH SOLENOID 19 SOLENOID GASKET 10 OVERDRIVE SOLENOID 20 HARNESS VALVE BODY LOWER HOUSING 1 Remove timing valve cover 2 Remove 3 4 timing valve and spring 3 Remove 3 4 quick fill valve spring and plug 4 Remove 3 4 shift valve and spring 5 Remove converter dutch valve spring and plug Fig 137 6 Remove converter dutch timing valve retainer and valve spring 21 100 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued 3 4 ACCUMULATOR HOUSING 1 Remove end plate from housing 2 Remove piston spring 3 Remove piston Remove and discard piston seals Fig 138 D 804d8eb9 Fig 138 Accumulator Housing Components 1 ACCUMULATOR PISTON 2 3 4 ACCUMULATOR HOUSING 3 TEFLON SEALS 4 PISTON SPRING 5 COVER PLATE AND SCREWS ASSEMBLY CAUTION Do not force valves or plugs into place during reassembly If the valve body bores valves and plugs are free of distortion or burrs the valve body components should all slide into place easily In addition do not overtighten the transfer plate and valve body screws during reassembly Over tightening can distort the housings resulting in valve st
176. OUSING 3 WOOD BLOCKS 21 126 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued 19321 465 Fig 215 Pump Inner Gear Installation 1 OUTER GEAR 2 INNER GEAR 6 Install new thrust washer on hub of reaction shaft support Lubricate washer with transmission fluid or petroleum jelly 7 If reaction shaft seal rings are being replaced install new seal rings on support hub Fig 216 Lubricate seal rings with transmission fluid or petro leum jelly after installation Squeeze each ring until ring ends are securely hooked together CAUTION The reaction shaft support seal rings will break if overspread or twisted If new rings are being installed spread them only enough for instal lation Also be very sure the ring ends are securely hooked together after installation Otherwise the rings will either prevent pump installation or break during installation 9 2 19321 218 Fig 216 Hub Seal Ring Position 1 SEAL RINGS 2 SUPPORT HUB Fig 217 Assembling Reaction Shaft Support And Pump Housing 1 PUMP HOUSING 2 REACTION SHAFT SUPPORT 8 Install reaction shaft support on pump housing Fig 217 9 Align reaction support on pump housing Use alignment marks made at disassembly Or rotate support until bolt holes in support and pump housing are all aligned holes are offset for one way fit 10 Install all bolts that attach support to pump h
177. Position tachom eter so it can be observed from driver seat if helper will be operating engine Raise vehicle on hoist that will allow rear wheels to rotate freely 2 Connec 100 psi Gauge C 3292 to accumulator port Then connect 300 psi Gauge C 3293 SP to rear servo port 3 Disconnect throttle and gearshift cables from levers on transmission valve body manual shaft 4 Have helper start and run engine at 1000 rpm 5 Move transmission shift lever fully forward into 1 range 6 Gradually move transmission throttle lever from full forward to full rearward position and note pressures on both gauges Line pressure at accumulator port should be 54 60 psi 372 414 kPa with throttle lever forward and gradually increase to 90 96 psi 621 662 kPa as throttle lever is moved rearward e Rear servo pressure should be same as line pres sure within 3 psi 20 68 kPa Test Two Transmission In 2 Range NOTE This test checks pump output line pressure and pressure regulation Use 100 psi Test Gauge C 3292 for this test 1 Leave vehide in place on hoist and leave Test Gauge C 3292 connected to accumulator port 2 Have helper start and run engine at 1000 rpm 3 Move transmission shift lever one detent rear ward from full forward position This is 2 range 4 Move transmission throttle lever from full for ward to full rearward position and read pressure on gauge 5 Line pressure should be 54 60 psi 372 414 kPa with
178. R CASE DISASSEMBLY AND ASSEMBLY Continued 19321 13 Fig 22 Rear Case Alignment Bolt Locations 1 ALIGNMENT BOLT AND WASHER AT EACH END OF CASE 2 c mmm Fig 23 Loosening Rear Case 1 REAR CASE 2 PRY TOOL IN CASE SLOT 3 FRONT CASE 5 Remove oil pickup tube from rear case Fig 25 6 Remove drive gear snap ring Fig 26 7 Disengage drive gear Fig 26 gear upward and off mainshaft as shown 8 Remove front output shaft drive chain and drive gear as assembly Fig 26 9 Remove output shaft drive gear snap ring 10 Remove output shaft drive gear from output shaft SHIFT FORKS AND MAINSHAFT REMOVAL 1 Remove detent plug O ring detent spring and detent plunger Fig 27 2 Remove shift rail from shift fork and transfer case housing 3 Rotate range shift fork until it disengages from shift sector 4 Remove mainshaft and shift fork from input gear pilot bearing Ed REAR HOUSING MAINSHAFT E U gt TRANSFER CASE 80ba7a51 Fig 24 Rear Case Removal 19321 16 Fig 25 Oil Pickup Tube Removal NOTE Loose needle bearings are used to support the drive sprocket hub on the mainshaft Do not lift mainshaft by drive sprocket hub or needle bearings will become dislodged 5 Wrap rag around mainshaft underneath drive sprocket hub and remove
179. R CLUTCH APPLIED 8 KICKDOWN BAND APPLIED 9 INPUT SHAFT SECOND GEAR POWERFLOW In drive second Fig 7 the same elements are applied as in manual second Therefore the power flow will be the same and both gears will be dis cussed as one in the same In drive second the trans mission has proceeded from first gear to its shift point and is shifting from first gear to second The second gear shift is obtained by keeping the rear dutch applied and applying the front kickdown band The front band holds the front dutch retainer that is locked to the sun gear driving shell With the rear clutch still applied the input is still on the front annulus gear turning it clockwise at engine speed Now that the front band is holding the sun gear sta tionary the annulus rotation causes the front planets to rotate in clockwise direction The front carrier is then also made to rotate in a clockwise direction but at a reduced speed This will transmit the torque to the output shaft which is directly connected to the front planet carrier The rear planetary annulus gear will also be turning because it is directly splined to the output shaft All power flow has occurred in the front planetary gear set during the drive second stage of operation and now the over running dutch in the rear of the transmission is disengaged and freewheeling on its hub WJ DESCRIPTION AND OPERATION Continued Vu N
180. RING COLUMN ASSEMBLY 5 INTERLOCK CABLE 1 SHIFT MECHANISM 2 SHIFTER BTSI LEVER 3 ADJUSTMENT CLIP 5 Shifting out of park should not be possible when the ignition key cylinder is in the accessory or lock position 6 Shifting between any gears neutral or park may be done without depressing foot brake with igni tion switch in run or start positions and vehide sta tionary or in motion 7 The floor shifter lever and gate positions should be in alignment with all transmission detent positions 8 Engine starts must be possible with shifter lever in park or neutral gate positions only Engine starts must not be possible in any other gate posi tions other than park or neutral 9 With shifter lever handle push button not depressed and lever detent in PARK POSITION apply forward force on center of handle and remove pressure Engine start must be possible e PARK POSITION apply rearward force on cen ter of handle and remove pressure Engine start must be possible e NEUTRAL POSITION engine start must be possible e NEUTRAL POSITION ENGINE RUNNING AND BRAKES APPLIED Apply forward force on center of shift handle Transmission should not be able to shift into reverse detent GEARSHIFT CABLE Check adjustment by starting the engine in Park and Neutral Adjustment is OK if the engine starts only in these positions Adjustment is incorrect if the engine starts in one but not both positions If the engi
181. Replace the carrier if worn or dam aged Inspect the overrunning dutch 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 Inspect the output shaft and governor components 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 USTMENTS BRAKE TRANSMISSION SHIFT INTERLOCK The park interlock cable is part of the brake shift lever interlock system Correct cable adjustment is important to proper interlock operation The gear shift and park lock cables must both be correctly adjusted in order to shift out of Park Park Interlock Cable Adjustment Procedure 1 Shift the transmission into the PARK position 2 Turn ignition switch to LOCK position Be sure ignition key cylinder is in the LOCK posi tion Cable will not adjust correctly in any other position 42RE AUTOMATIC TRANSMISSION 21 15
182. S DITNVYGAH 354957 0081 Iv NO 99 440 55 ANI SW 99 41 iSsd s34nssaud 08 61 91 66 Q3ZIDH3N3 SCIONS 10 ALITWNO LAIHS HOS LO310Hd OL 7105 20 91 9 ASS VIA H1 27 ME HOSN3S SdHd HVA SdA 193 13S LEIDIW SMW HALYAANOD 99 9 Or HOLNTD Puc Oc 1 4 IN3A A AO 1d3AO 31VA3T37 dins HOJv 1n93H eor FEST TOS 3OuOd HVA SJA HOLIMS Sd3Hd Sd 3dfisS3Hd 1d IO 3 43434 984 39943434 M0141 99 HO N uv39 1Sul4 mn H E 21 257 45RFE AUTOMATIC TRANSMISSION WJ SCHEMATICS AND DIAGRAMS Continued 3ddSr 0061 19 NO 99 440209 INIT SOPH isasqunssaud 08 91 9ri se 991 56 np I A N fiL3d IN3A A MO IHH3AO O3JVA3 T37 14 HOSN3S SdHd HVA SdA 7105 30HOd HVA SJA I1O3 HOLIMS 539 5 d COOLER 5 4 14 H31H3ANO2 00 HO LNTO HO1 119 2 02 3SH3A3u AAO1 H1 s LS3H HONNV 4941 9 ne uv3o 1sul4 45RFE AUTOMATIC TR
183. SSEMBLY AND ASSEMBLY Continued E 5 INPUT REVERSE LASS QU PLANETARY ASSEMBLY Fig 74 Remove Park Sprag Snap Ring BEARING gt 4 12 BEARING 80207412 NUMBER 9 80 07410 Fig 76 Remove Input Reverse Planetary Assembly LOW REVERSE OVERRUNNING CLUTCH ASSEMBLY PARK SPRAG GEAR SNAP RING 80c07411 50607413 Fig 77 Remove Low Heverse Retainer Fig 75 Remove Park Sprag Gear ASSEMBLY 40 Remove the number 12 bearing from the 1 Clean and inspect all components Replace any input reverse planetary assembly Fig 76 components which show evidence of excessive wear 41 Remove the snap ring holding the low reverse 9 scoring dutch retainer into the transmission case Fig 77 2 Install the cooler filter bypass valve 42 Remove the low reverse clutch retainer from 3 Torque the bypass valve to specification The the transmission case Fig 77 valve uses a tapered pipe thread and excessive 43 Remove the park pawl rod and e dip Fig 78 torque can damage the transmission case Tighten 44 Remove the park pawl rod guide snap ring m em filter bypass valve to 11 3 N m 100 in Fig 78 p 45 Remove the park pawl rod guide Fig 78 4 Install a new selector shaft seal using Seal 46 Remove the park pawl pivot shaft park Installer 8253 Fig 79 m and spring Fig 78 5 Install the manual selector shaft and retaining 47 Remove the manual selector shaft Fig
184. Screen Installation 1 UPPER HOUSING SEPARATOR PLATE 2 FILTER SCREEN J9321 150 Fig 141 Brace Plate 1 BRACE 2 TRANSFER PLATE 3 SEPARATOR PLATE UPPER AND LOWER HOUSING 1 Position upper housing so internal passages and check ball seats are facing upward Then install check balls in housing Fig 142 Eight check balls are used The single large check ball is approxi mately 8 7 mm 11 32 in diameter The single small check ball is approximately 4 8 3 16 diameter The remaining 6 check balls are approxi mately 6 3 mm 1 4 in in diameter 2 Position assembled transfer plate and upper housing separator plate on upper housing Fig 143 Be sure filter screen is seated in proper housing recess 3 Install the ECE check ball into the transfer plate Fig 129 The ECE check ball is approximately 4 8 mm 3 16 in in diameter 4 Position lower housing separator transfer plate Fig 144 plate on 42RE AUTOMATIC TRANSMISSION 21 101 5 Install lower housing on assembled transfer plate and upper housing Fig 145 6 Install and start all valve body screws by hand except for the screws to hold the boost valve tube brace Save those screws for later installation Then tighten screws evenly to 4 N m 35 in Ibs torque Start at center and work out to sides when tighten ing screws Fig 145 J9321 154 Fig 142 Check Ball Locations In Upper Housing 1 SMALL DIAM
185. Sd S3unsSsSatud oe cr 811 66 cL n 27272279771 UM H Li IN3A A AO Tddd3AO Q3l1VA3 37x HOSN3S S3Hd HVA SdA 7105 39H04 HVA SJA LOJIS ANWES HOLIMS Sdud Sd 3dnsSsdHd ld 79 HALYSAANOD 99 Uv r TO 3SuaAdud od o H LNTO 3SuadA3u AO T d1 20 SOI 45RFE AUTOMATIC TRANSMISSION SCHEMATICS AND DIAGRAMS Continued 21 268 JILVISHOS OrT VHGAH 3ddSr 95 99 dns oog iy 059 Aan 0821 811 6 6691 06 e EL A 2 XA Nu Aa 2 i i tnm 00 1 A A UP LIIIIA I I A IN3A A d31VA313 HOSN3S SHHd HVA SdA 7105 dOHOdH HVA SHA LOATAS ILINNESA HOLIMS SdHd Sd 3ufisS3dd 1ld 19 H31H8JANOO OOD YOLVINANDOV OV Uv Or 12 3SuaAau od HOLN19 puc 2c 5 u 8 2 2 1 151 MOILSOLNV HO 21 269 45RFE AUTOMATIC TRANSMISSION WJ SCHEMATICS AND DIAGRAMS Continued 8110509 JILVASHOS DITINVYGAH 3ddSr 9055 34655 aans Isd saunssaud 08 91 811 96 691 95 B L
186. THROTTLE VALVE AND SPRING 2 AUTOMATIC TRANSMISSION 21 105 DISASSEMBLY AND ASSEMBLY Continued J9321 157 Fig 148 Upper Housing Shift Valve And Pressure Plug Locations 1 UPPER HOUSING 8 RETAINER 2 1 2 SHIFT VALVE AND SPRING 9 1 2 SHIFT CONTROL VALVE AND SPRING 3 2 3 SHIFT VALVE AND SPRING 10 PRESSURE PLUG COVER 4 2 3 THROTTLE PLUG 11 LINE PRESSURE PLUG 5 LIMIT VALVE HOUSING 12 PLUG SLEEVE 6 LIMIT VALVE COVER 13 THROTTLE PRESSURE SPRING AND PLUG 7 LIMIT VALVE AND SPRING 21 106 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued BOOST VALVE TUBE AND BRACE 1 Position valve body assembly so lower housing is facing upward Fig 149 2 Lubricate tube ends and housing ports with transmission fluid or petroleum jelly 3 Start tube in lower housing port first Then swing tube downward and work opposite end of tube into upper housing port Fig 149 4 Insert and seat each end of tube in housings 5 Slide tube brace under tube and into alignment with valve body screw holes Fig 150 6 Install and finger tighten three screws that secure tube brace to valve body housings Fig 150 7 Bend tube brace tabs up and against tube to hold it in position Fig 151 8 Tighten all valve body housing screws to 4 35 in Ibs torque after tube and brace are installed Tighten screws in diagonal pattern starting
187. TOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued PRESSURE Pressure Fig 50 is nothing more than force Ibs divided by area in or ft or force per unit area Given a 100 Ib block and an area of 100 sq in on the floor the pressure exerted by the block is 100 Ibs 100 in or 1 pound per square inch or PSI as it is commonly referred to FORCE ON EACH SQUARE INCH 100 POUNDS PRESSURE 1 POUND PER SQUARE INCH 100 1000 POUNDS POUNDS OUTPUT INPUT AREA 100 SQ IN F P A AREA P S FORCE LBS 10 SQ IN PRESSURE AREA 50 FORCE ON LARGE PISTON 1000 LBS 80bfe272 Fig 50 Force and Pressure Relationship PRESSURE ON A CONFINED FLUID Pressure is exerted on a confined fluid Fig 51 by applying a force to some given area in contact with the fluid A good example of this is a cylinder filled with fluid and equipped with a piston that is dosely fitted to the cylinder wall If a force is applied to the piston pressure will be developed in the fluid Of WJ course no pressure will be created if the fluid is not confined It will simply leak past the piston There must be a resistance to flow in order to create pres sure Piston sealing is extremely important in hydraulic operation Several kinds of seals are used to accomplish this within a transmission These indude but are not limited to O rings D rings lip seals sealing rings or extremely dose tolerances between the piston a
188. TOR PISTON 5 GOVERNOR PRESSURE SOLENOID 15 Thread bolts of Slide Hammer Tools C 3752 into threaded holes in pump body flange Fig 162 21 110 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued 7 2 3 19121 208 Fig 161 Accumulator Piston And Springs 1 ACCUMULATOR PISTON 2 OUTER SPRING 3 INNER SPRING 16 Bump slide hammer weights outward to remove pump and shaft support assembly from case Fig 162 9121 120 Fig 162 Removing Oil Pump And Reaction Shaft Support Assembly 1 OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY 2 SLIDE HAMMER TOOLS C 3752 2 lt lt 5 WJ 19 Remove front band lever Fig 164 20 Remove front band lever shaft plug if neces sary from converter housing 21 Remove front band lever shaft t e gt lo 3 19121 121 Fig 163 Removing Installing Front Band Strut 1 BAND LEVER 2 BAND STRUT 3 FRONT BAND 17 Loosen front band adjusting screw until band is completely loose 18 Squeeze front band together and remove band strut Fig 163 Fig 164 Removing Installing Front Band Lever 1 FRONT BAND LEVER WJ DISASSEMBLY AND ASSEMBLY Continued 22 Remove front and rear clutch units as assem bly Grasp input shaft hold clutch units together and remove them from case Fig 165 23 Lift front clutch off rear clutch Fig 166 Set clutch
189. TPUT SHAFT FORWARD 19321 359 FROM RING pem Fig 264 Releasing Bearing From Locating Ring 1 EXPAND BEARING LOCATING RING WITH SNAP RING PLIERS 2 ACCESS HOLE 6 Lift gear case up and off geartrain assembly Fig 265 7 Remove snap ring that retains rear bearing on output shaft 8 Remove rear bearing from output shaft Fig 266 DIRECT CLUTCH HUB AND SPRING DISASSEMBLY 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 J9321 360 Fig 265 Removing Gear Case From Geartrain Assembly 1 GEARTRAIN ASSEMBLY 2 GEAR CASE J9321 362 Fig 266 Rear Bearing Removal 1 OUTPUT SHAFT 2 REAR BEARING 3 SNAP RING 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 267 2 Position Compressor Tool 6227 1 on dutch hub Fig 267 Support output shaft flange with steel press plates as shown and center assembly under press ram a2RE AUTOMATIC TRANSMISSION 21 141 DISASSEMBLY AND ASSEMBLY Continued 3 Apply
190. TVA TVDNVIN JAVA 104409 IHS 2 1 rj 3ATVA 3 ILLOHS SESE HONH3AOD r IAAI JILLOHHL 1 L 10119 LNOY T OAu3S LNOHJ 3NT1VA 1 6 6 6 IMYA TTTITITITITTTITTITTIITITIITTILLTIITITITILITILIEI J ma ailioBHL HONH3AOD US Lr oll YO o OAH3S HOLfTIO HV3H GION3108 HONH3AOS 21 173 42RE AUTOMATIC TRANSMISSION WJ SCHEMATICS AND DIAGRAMS Continued 3823908 isd 5 0 TI 3AIHQH3AO NOLLONS isd 9 8 dunssdud 189 0 0 dunssaud HONH3AOD isd 95 95 71044409 IHS 2 isd 29 55 lt INN L MOT NI J3I1LLOHHL Q3S012 HV3O 1544 L NI H3A31 01241468 3ATVA d 1201 NOILVO2IHS TI H21f 19 LNOYS i a anm HOLIMS f 3ATVA dfi5201 n Hos _ l GION310S II 105 AYQHIAO fo NOILVDIHS TI OL 1500
191. UG 6 KICKDOWN DETENT 13 SHUTTLE VALVE PRIMARY SPRING 7 THROTTLE VALVE AND SPRING 21 94 42 AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued J9321 433 Fig 124 3 4 Shift And Converter Clutch Valve Springs And Plug 1 ACCUMULATOR HOUSING 2 CONVERTER CLUTCH VALVE SPRING 3 CLUTCH VALVE PLUG 4 3 4 SHIFT VALVE SPRING 9321 434 Fig 125 Accumulator Housing Valve Springs And Plug 1 3 4 SHIFT VALVE SPRING 2 CONVERTER CLUTCH VALVE SPRING AND PLUG 3 3 4 ACCUMULATOR HOUSING J9521 101 Fig 126 Boost Valve Tube Brace 1 BOOST VALVE TUBE 2 TUBE BRACE DOUBLE TAB 26 Remove boost valve connecting tube Fig 127 Disengage tube from upper housing port first Then rock opposite end of tube back and forth to work it out of lower housing CAUTION Do not use tools to loosen or pry the connecting tube out of the valve body housings Loosen and remove the tube by hand only 27 Turn valve body over so lower housing is fac ing upward Fig 128 In this position the two check balls in upper housing will remain in place and not fall out when lower housing and separator plate are removed 28 Remove screws attaching valve body lower housing to upper housing and transfer plate Fig 128 Note position of boost valve tube brace for assembly reference 29 Remove lower housing and overdrive separa tor plate from transfer plate Fig 128 30 Remove
192. V247 TRANSFER CASE 21 319 J9321 35 Fig 38 Input Gear Removal 1 INPUT GEAR 2 LOW RANGE GEAR J9321 36 Fig 39 Rear Tabbed Thrust Washer Removal 1 LOW RANGE GEAR 2 REAR TABBED THRUST WASHER ASSEMBLY Lubricate transfer case components with Dexron automatic transmission fluid or petroleum jelly where indicated during assembly CAUTION The bearing bores in various transfer case components contain oil feed holes Make sure replacement bearings do not block the holes BEARING AND SEAL INSTALLATION 1 Remove front output shaft seal from front case with pry tool Fig 40 2 Remove snap ring that retains front output shaft bearing in front case Fig 41 3 Using tool 6953 remove bearing from front case Fig 42 21 320 NV247 TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued QU x P yr e e 80a1108b Fig 40 Remove Front Output Shaft Seal 1 OUTPUT SHAFT SEAL 2 PRYBAR FRONT CASE OUTPUT SHAFT FRONT BEARING BEARING SNAP RING Fig 41 Output Shaft Front Bearing Snap Ring Removal 4 Using tool 6953 install new bearing 5 Install snap ring to hold bearing into case 6 Install new front output seal in front case with Installer Tool 6952 A as follows a Place new seal on tool Garter spring on seal goes toward interior of case b Start seal in bore with light taps
193. VAL AND INSTALLATION Continued 10 Shift the transmission into PARK PARK is the rearmost detent position on the transmission manual shift lever 11 Snap the shift cable onto the transmission manual shift lever 12 Lower vehicle 13 Verify that the shift lever is in the PARK tion 14 Tighten the adjustment screw to 7 N m 65 in Ibs 15 Verify correct shifter operation 16 Install shift lever bezel and any console parts removed for access to shift lever assembly and shift cable SHIFTER REMOVAL 1 Shift transmission into Park 2 Remove shift lever bezel and any necessary console parts for access to shift lever assembly and shifter cables 3 Disconnect the transmission shift cable at shift lever and shifter assembly bracket Fig 88 4 Disconnect the brake transmission interlock cable from the shifter BTSI lever and the shifter assembly bracket 5 Disconnect the transfer case shift cable from the transfer case shift lever pin Fig 90 Remove the clip holding the transfer case shift cable to the shifter assembly bracket 7 Remove the transfer case shift cable from the shifter assembly bracket 8 Disengage all wiring connectors from the shifter assembly 9 Remove all nuts holding the shifter assembly to the floor pan Fig 91 10 Remove the shifter assembly from the vehicle INSTALLATION 1 Install shifter assembly onto the shifter assem bly studs on the floor p
194. Verify that front rear clutches are still seated before continuing 23 Check seal rings on reaction shaft support hub Verify that seal rings are hooked together and that front dutch thrust washer is properly positioned 21 118 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued 2 9121 192 Fig 188 Aligning Rear Clutch Disc Lugs 1 REAR CLUTCH DISCS 2 USE SMALL SCREWDRIVER TO ALIGN CLUTCH DISC TEETH D J9121 124 Fig 189 Installing Front Rear Clutch Assemblies 1 SHAFT 2 FRONT CLUTCH 3 REAR CLUTCH Fig 190 Front Band Linkage Installation 1 BAND LEVER 2 BAND STRUT 3 FRONT BAND J9121 194 Fig 191 Reaction Shaft Support Seal Rings And Front Clutch Thrust Washer 1 REACTION SHAFT SUPPORT HUB 2 FRONT CLUTCH THRUST WASHER 3 SEAL RINGS Fig 191 Use petroleum jelly to hold thrust washer in place if necessary 24 Lubricate oil pump body seal with petroleum jelly Lubricate pump shaft seal lip with petroleum jelly 25 Thread two Pilot Stud Tools C 3288 B into bolt holes in oil pump bore flange Fig 192 26 Align and install oil pump gasket Fig 192 27 Install oil pump Fig 193 Align and position pump on pilot studs Slide pump down studs and work it into front clutch hub and case by hand Then install 2 or 3 pump bolts to hold pump in place 28 Remove pilot stud tools and install remaining oil pump
195. Y AND ASSEMBLY Continued 800bdfae Fig 97 Rear Bearing Retaining Ring Installation 1 REAR BEARING O D RETAINING RING 2 SNAP RING PLIERS Drive seal into rear bearing retainer with Installer C 4076 B and Handle M D 998323 Fig 99 80a50355 Fig 98 Output Shaft Seal and Protector 1 OUTPUT SHAFT SEAL 2 SPECIAL TOOL 6992 3 TRANSFER CASE 10 Install rear slinger with Installer 8408 11 Install boot on output shaft slinger and crimp retaining clamp with tool C 4975 A Fig 100 NV242HD REAR RETAINER 1 Install rear bearing O D retaining ring with snap ring pliers Fig 101 Be sure retaining ring is fully seated in retainer groove 2 Apply bead of Sealer P N 82300234 or Loctite Ultra Gray to mating surface of rear retainer Sealer bead should be a maximum of 3 16 in 80298368 Fig 99 Rear Seal Installation 1 SPECIAL TOOL C 4076 B 2 SPECIAL TOOL MD998323 3 TRANSFER CASE 80a50357 Fig 100 Slinger Boot Installation 1 SPECIAL TOOL C 4975 A 2 SLINGER 3 BOOT 4 CLAMP 3 Install rear retainer on rear case Tighten retainer bolts to 20 27 N m 15 20 ft 165 torque 4 Install new output shaft bearing snap ring Fig 102 Lift mainshaft slightly to seat snap ring in shaft groove if necessary 5 Apply 3 mm 1 8 in wide bead of Mopar gas ket maker or silicone adhesive sealer to mounting surface of extension housing Allow s
196. Y FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTI BLE LIQUIDS AND GASES KEEP A CLASS B FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE USED KEEP THE AREA WELL VENTILATED DO NOT LET FLUSHING SOLVENT COME IN CON TACT WITH YOUR EYES OR SKIN IF EYE CONTAM INATION OCCURS FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER SEEK MEDICAL ATTENTION COOLER FLUSH USING TOOL 6906A 1 Remove cover plate filler plug on Tool 6906A Fill reservoir 1 2 to 3 4 full of fresh flushing solution Flushing solvents are petroleum based solutions gen erally used to clean automatic transmission compo nents DO NOT use solvents containing acids water gasoline or any other corrosive liquids 2 Reinstall filler plug on Tool 6906A 3 Verify pump power switch is turned OFF Con nec red alligator clip to positive battery post Connect black alligator dip to a good ground 4 Disconnec the cooler lines at the transmission NOTE When flushing transmission cooler and lines ALWAYS reverse flush WJ SERVICE PROCEDURES Continued NOTE The converter drainback valve must be removed and an appropriate replacement hose installed to bridge the space between the transmis sion cooler line and the cooler fitting Failure to remove the drainback valve will prevent reverse flushing the system A suitable replacement hose can be found in the adapter kit supplied with
197. a clockwise direction With the front annulus gear turning in a dockwise direction it causes the front planets to turn in a dockwise direction The rotation of the front planets cause the sun to revolve in a counterdockwise direction The sun gear now transfers its counterclockwise rotation to the rear planets which rotate back in a dockwise direction With the rear annulus gear stationary the rear planet rotation on the annulus gear causes the rear planet carrier to revolve in a counterclockwise direc tion The rear planet carrier is splined into the low reverse drum and the low reverse drum is splined to the inner race of the over running clutch With the over running clutch locked the planet carrier is held and the resulting torque provided by the planet pin ions is transferred to the rear annulus gear The rear annulus gear is splined to the output shaft and rotated along with it clockwise in an underdrive gear reduction mode 21 8 42RE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued 7 Cc M p INS 7774 SSS iN MAU A Z 2 AIBA SIPS NI eck D STATIONARY MEMBER ROTATING MEMBER FRONT PLANETARY 80 070 Fig 7 Second Gear Powerflow 1 KICKDOWN BAND APPLIED 2 OUTPUT SHAFT 3 REAR CLUTCH ENGAGED 4 OUTPUT SHAFT 5 OVER RUNNING CLUTCH FREE WHEELING 6 INPUT SHAFT 7 REA
198. ade only in slots provided in retainer Fig 32 b Then remove retainer from case and gear M 19321 28 amp 1 Fig 33 Input Gear Snap Ring Removal 1 INPUT GEAR 2 SNAP RING 19321 26 Fig 31 Front Bearing Retainer Bolt Removal 1 FRONT BEARING RETAINER FRONT 1 BEARING RETAINER RETAINER 19321 29 Fig 34 Input Low Range Gear Assembly Removal 1 INPUT AND LOW RANGE GEAR ASSEMBLY INPUT AND LOW RANGE GEAR DISASSEMBLY 1 Remove snap ring that retains input gear in p low range gear Fig 35 J9321 27 2 Remove retainer Fig 36 3 Remove front tabbed thrust washer Fig 37 4 Remove input gear Fig 38 FW Bre FLAT BLADE SCREWDRIVER Fig 32 Front Bearing Retainer Removal 4 Remove snap ring that retains input gear shaft 5 Remove rear tabbed thrust washer from low in front bearing Fig 33 range gear Fig 39 5 Remove input and low range gear assembly Fig 34 6 Remove oil seals from following components e front bearing retainer e rear retainer e case halves WJ DISASSEMBLY AND ASSEMBLY Continued J9321 32 Fig 35 Input Gear Snap Ring Removal 1 INPUT GEAR SNAP RING J9321 33 Fig 36 Input Gear Retainer Removal 1 INPUT GEAR 2 LOW RANGE GEAR 3 RETAINER J9321 34 Fig 37 Front Tabbed Thrust Washer Removal 1 FRONT TABBED THRUST WASHER N
199. ainer bolts 21 288 NV242 TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued w lt j J8921 263 Fig 45 Shift Sector Position 1 SHIFT SECTOR 2 LOW RANGE FORK 3 PIN 4 SLOT 3 Remove input gear snap ring Fig 48 J8921 266 Fig 47 Front Bearing Retainer Removal 1 FRONT BEARING RETAINER 2 RETAINER SLOT 18921 207 Fig 46 Sector Bushing And Removal 1 SHIFT SECTOR BUSHING 2 O RING J8921 267 Fig 48 Input Gear Snap Ring Removal 1 INPUT GEAR 2 SNAP RING 2 Remove front bearing retainer Carefully pry retainer loose with screwdriver Fig 47 Position screwdriver in slots cast into retainer 4 Remove input low range gear assembly from bearing with Tool Handle C 4171 and Tool 7829A Fig 49 5 Remove low range gear snap ring Fig 50 6 Remove input gear retainer thrust washers and input gear from low range gear Fig 51 WJ DISASSEMBLY AND ASSEMBLY Continued Fig 49 Input And Low Range Gear Assembly Removal 1 INPUT LOW RANGE GEARS 2 SPECIAL TOOL 7829A 3 SPECIAL TOOL C 4171 J8921 269 Fig 50 Low Range Gear Snap Ring Removal Installation 1 LOW RANGE GEAR SNAP RING 7 Inspect low range annulus gear Fig 52 Gear is not a serviceable component If damaged replace gear and front case as assembly 8 Remove oil seals from following components
200. al pattern to 34 N m 25 ft Ibs 13 Install speed sensor 14 Connect speed sensor and overdrive wires 15 Install the transfer case if equipped 16 Align and install rear propeller shaft if essar y OVERDRIVE HOUSING BUSHING REM OVAL 1 Remove overdrive housing yoke seal 2 Insert Remover 6957 into overdrive housing Tighten tool to bushing and remove bushing Fig 105 INSTALLATION 1 Align bushing oil hole with oil slot in overdrive housing 80211095 Fig 105 Bushing Removal Typical 1 REMOVER 6957 2 EXTENSION HOUSING BUSHING 2 Tap bushing into place with Installer 6951 and Handle C 4171 3 Install new oil seal in housing using Seal Installer C 3995 A Fig 106 D Fig 106 Overdrive Housing Seal Installation 1 SPECIAL TOOL 3995 OR 3972 2 SPECIAL TOOL C 4471 J9521 58 OUTPUT SHAFT REAR BEARING REM OVAL 1 Remove overdrive unit from the vehicle 2 Remove overdrive geartrain from housing 3 Remove snap ring holding output shaft rear bearing into overdrive housing Fig 107 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 107 WJ REMOVAL AND INSTALLATION
201. als as rotation occurs They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module TCM OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating As the teeth of the input clutch hub pass by the sensor coil AC voltage is generated and sent to the TCM The TCM interprets this information as input shaft rpm The Output Speed Sensor generates an AC signal in a similar fashion though its coil is excited by rota tion of the rear planetary carrier lugs The TCM interprets this information as output shaft rpm The TCM compares the input and output speed signals to determine the following e Transmission gear ratio e Speed ratio error detection CVI calculation The TCM also compares the input speed signal and the engine speed signal to determine the following e Torque converter dutch slippage Torque converter element speed ratio LINE PRESSURE CONTROL DESCRIPTION The TCM utilizes a closed loop system to control transmission line pressure The system contains a variable force style solenoid the Pressure Control Solenoid mounted on the side of the solenoid and pressure switch assembly The solenoid is duty cycle controlled by the TCM to vent the unnecessary line pressure supplied by the oil pump back to the sump The system also contains a variable pressure style sensor the Line Pressure Sensor which is a direct
202. amage of any kind Inspect the upper housing lower housing 3 4 accumulator housing and transfer plate carefully Be sure all fluid passages are clean and clear Check condition of the upper housing and transfer plate check balls as well The check balls and ball seats must not be worn or damaged Trial fit each valve and plug in its bore to check freedom of operation When clean and dry the valves and plugs should drop freely into the bores Valve body bores do not change dimensionally with use If the valve body functioned correctly when new it will continue to operate properly after cleaning and inspection It should not be necessary to replace a valve body assembly unless it is damaged in han dling The only serviceable valve body components are listed below The remaining valve body components are serviced only as part of a complete valve body assembly Serviceable parts are e dual solenoid and harness assembly e solenoid gasket e solenoid case connector O rings and shoulder bolt e switch valve and spring 42RE AUTOMATIC TRANSMISSION 21 155 pressure adjusting screw and bracket assembly throttle lever manual lever and shaft seal throttle lever shaft seal washer and E clip fluid filter and screws detent ball and spring valve body screws governor pressure solenoid governor pressure sensor and retaining dip park lock rod and E dip TRANSMISSION GENERAL INFORMATION Inspect the transmission bushings during overha
203. an 2 Install the nuts to hold the shifter assembly onto the floor pan Tighten nuts to 28 N m 250 Ibs 42RE AUTOMATIC TRANSMISSION 21 81 80ba79cb Fig 88 Transmission Shift Cable at Shifter 1 SHIFT LEVER PIN 2 ADJUSTMENT SCREW 3 SHIFT CABLE 4 SHIFTER ASSEMBLY BRACKET 3 Install wiring harness to the shifter assembly bracket Engage any wire connectors removed from the shifter assembly 4 Install the transfer case shift cable to the shifter assembly bracket Install clip to hold cable to the bracket 5 Snap the transfer case shift cable onto the transfer case shift lever pin 6 Install the brake transmission interlock cable into the shifter assembly bracket and into the shifter BTSI lever 7 Install the shift cable to the shifter assembly bracket Push cable into the bracket until secure 8 Place the floor shifter lever in park position 9 Loosen the adjustment screw on the shift cable 10 Snap the shift cable onto the shift lever pin 11 Verify that the shift lever is in the PARK posi tion 12 Tighten the adjustment screw to 7 N m 65 in Ibs 13 Verify correct shifter operation 14 Install shift lever bezel and any console parts removed for access to shift lever assembly and shift cables 21 82 2 AUTOMATIC TRANSMISSION 1 REMOVAL AND INSTALLATION Continued 80ba79c2 Fig 89 Brake Transmission Interlock Ca
204. and record the dial indicator reading Clearance should be 0 559 0 914 mm 0 022 0 036 in If dlearance is incorrect steel plates discs selective snap ring and pressure plates may have to be changed The selective snap ring thicknesses are 107 109 in 098 100 in 095 097 in 083 085 in 076 078 in 071 073 in 060 062 in 16 Coat rear dutch thrust washer with petro leum jelly and install washer over input shaft and into dutch retainer Fig 231 Use enough petroleum jelly to hold washer in place 17 Set rear dutch aside for installation during final assembly 80 483 Fig 230 Checking Rear Clutch Pack Clearance 1 DIAL INDICATOR 2 PRESSURE PLATE 3 SNAP RING 4 STAND 5 REAR CLUTCH 6 GAUGE BAR 21 132 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued 1 Z e A NS S n 514 Fig 231 Installing Rear Clutch Thrust Washer 1 REAR CLUTCH RETAINER 2 REAR CLUTCH THRUST WASHER PLANETARY GEARTRAIN OUTPUT SHAFT DISASSEMBLY 1 Remove planetary snap ring Fig 232 2 Remove front annulus and planetary assembly from driving shell Fig 232 3 Remove snap ring that retains front planetary gear in annulus gear Fig 233 4 Remove tabbed thrust washer and tabbed thrust plate from hub of front annulus Fig 234 5 Separate front annulus
205. and repair as ONLY NO 1 2 OR 2 3 required UPSHIFT 2 Valve Body Malfunction 2 Repair stuck 1 2 shift valve or governor plug 3 Front Servo Kickdown Band 3 Repair replace Damaged Burned 21 64 42 AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION MOVES IN 2ND OR 3RD 1 Valve Body Malfunction 1 Remove clean and inspect Look for GEAR ABRUPTLY stuck 1 2 valve or governor plug DOWNSHIFTS TO LOW 2 Governor Valve Sticking 2 Remove clean and inspect Replace faulty parts NO LOW GEAR MOVES 1 Governor Valve Sticking 1 Remove governor clean inspect and IN 2ND OR 3RD GEAR repair as required ONLY 2 Governor Circuit Electrical Fault 2 Test with DRB scan tool and repair as required 3 Valve Body Malfunction 3 Remove clean and inspect Look for sticking 1 2 shift valve 2 3 shift valve governor plug or broken springs 4 Front Servo Piston Cocked in 4 Inspect servo and repair as required Bore 5 Front Band Linkage Malfunction 5 Inspect linkage and look for bind in linkage NO KICKDOWN OR 1 Throttle Linkage Misadjusted 1 Adjust linkage NORMAL DOWNSHIFT 2 Accelerator Pedal Travel 2 Verify floor mat is not under pedal repair Restricted worn accelerator cable or bent brackets 3 Valve Body Hydraulic Pressures 3 Perform hydraulic pressure tests to Too High or Too Low Due to Valve determine cause and repair as requ
206. ansmission from the vehicle 2 Remove the torque converter from the trans mission 3 Using a screw mounted in a slide hammer remove the oil pump front seal 45RFE AUTOMATIC TRANSMISSION 21 219 INSTALLATION 1 Clean seal bore of the oil pump of any residue or particles from the original seal 2 Install new oil seal in the oil pump housing using Seal Installer C 3860 A Fig 52 TOOL 7 7 PN ae lt N A Fig 52 Install Oil Pump Front Seal ADAPTER HOUSING SEAL REM OVAL 1 Remove the transfer case from the transmis sion 2 Using a screw mounted on a slide hammer remove the adapter housing seal INSTALLATION 1 Clean the adapter seal bore in the adapter housing of any residue or partides remaining from the original seal 2 Install new oil seal in the adapter housing using Seal Installer C 3860 A Fig 53 3 Install the transfer case onto the transmission GEARSHIFT CABLE REMOVAL 1 Shift transmission into Park 2 Raise vehicle 3 Remove the shift cable eyelet from the trans mission manual shift lever Fig 54 4 Remove shift cable from the cable support bracket 5 Lower vehide 6 Remove shift lever bezel and necessary console parts for access to shift lever assembly and shift cable 80c07423 21 220 45RFE AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION Continued 45RFE MANUAL LEVER 80ba79c4 Fig 54 Remove Shift
207. aring Removal Installation OVERDRIVE UNIT 1 THRUST BEARING 2 OVERDRIVE PISTON DISASSEM BLY 3 THRUST PLATE 1 Remove transmission speed sensor and O ring seal from overdrive case Fig 252 2 Remove overdrive piston thrust bearing Fig 253 21 138 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued OVERDRIVE PISTON DISASSEM BLY 1 Remove overdrive piston thrust plate Fig 254 Retain thrust plate It is a select fit part and may possibly be reused Fig 254 Overdrive Piston Thrust Plate Removal Installation 1 OVERDRIVE PISTON 2 OVERDRIVE PISTON SPACER SELECT FIT J9121 299 Fig 256 Overdrive Piston Removal 1 PISTON RETAINER 2 OVERDRIVE PISTON 2 Remove intermediate shaft spacer Fig 255 Retain spacer It is a select fit part and may possibly be reused 2m J9121 298 SSA LAN Fig 255 Intermediate Shaft Spacer Location 1 INTERMEDIATE SHAFT 2 INTERMEDIATE SHAFT SPACER SELECT FIT 3 Remove overdrive piston from retainer Fig 256 OVERDRIVE CLUTCH PACK DISASSEMBLY 1 Remove overdrive dutch pack wire retaining ring Fig 257 2 Remove overdrive clutch pack Fig 258 NOTE The 42RE transmission has three clutch discs and two clutch plates 3 Note position of dutch pack components for assembly reference Fig 259 9321352 Fig 257 Removing Overdrive Clutch Pack Retaining Ring 1
208. ars the oil pump seal 4 Separate the torque converter from the trans mission INSTALLATION Check converter hub and drive notches for sharp edges burrs scratches or nicks Polish the hub and notches with 320 400 grit paper or crocus cloth if nec essary The hub must be smooth to avoid damaging the pump seal at installation Check that the torque converter hub o ring on the 45RFE torque converter hub is not damaged Replace if necessary 1 Lubricate oil pump seal lip with transmission fluid WJ REMOVAL AND INSTALLATION Continued 2 Place torque converter in position on transmis sion CAUTION Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission 3 Align torque converter to oil pump seal open ing 4 Insert torque converter hub into oil pump 5 While pushing torque converter inward rotate converter until converter is fully seated in the oil pump gears 6 Check converter seating with a scale and straightedge Fig 51 Surface of converter lugs should be 1 2 in to rear of straightedge when verter is fully seated 7 If necessary temporarily secure converter with C clamp attached to the converter housing 8 Install the transmission in the vehicle 9 Fill the transmission with the recommended fluid Fig 51 Checking Torque Converter Seating Typical 1 SCALE 2 STRAIGHTEDGE OIL PUMP FRONT SEAL REMOVAL 1 Remove tr
209. arter Relay in Park and Neutral only Supply ground to the TCM for backup lamp con trol in Reverse only The TRS also has an integrated temperature sen sor thermistor that communicates transmission temperature to the TCM and PCM OPERATION The Transmission Range Sensor TRS communi cates shift lever position to the TCM as a combina tion of open and closed switches Each shift lever position has an assigned combination of switch states open closed that the TCM receives from four sense circuits The TCM interprets this information and determines the appropriate transmission gear posi tion and shift schedule There are many possible combinations of open and closed switches codes Seven of these possible codes are related to gear position and five are recognized as between gear codes This results in many codes which should never occur These are called invalid codes An invalid code will result in a DTC and the TCM will then determine the shift lever position based on pressure switch data This allows reasonably normal transmission operation with a TRS failure WJ DESCRIPTION AND OPERATION Continued GEAR C5 C4 C3 C2 C1 Park CL OP OP CL CL Temp 1 CL OP OP CL OP Reverse OP OP OP CL OP Temp 2 OP OP CL CL OP Neutral 1 OP OP CL CL CL Neutral 2 OP CL CL CL CL Temp 3 OP CL CL CL OP Drive OP CL CL OP OP Temp 4 OP CL OP OP OP Manual 2 CL CL OP OP OP Temp 5 CL OP OP OP OP Manual 1 CL OP CL OP OP TRANSMISSION TE
210. ation The gear shift and park lock cables must both be correctly adjusted in order to shift out of Park Park Interlock Cable Adjustment Procedure 1 Shift the transmission into the PARK position 2 Turn ignition switch to LOCK position Be sure ignition key cylinder is in the LOCK posi tion Cable will not adjust correctly in any other position 3 Remove shift lever bezel and floor console as necessary for access to the brake transmission shift interlock cable 4 Pull cable lock button up to release cable Fig 126 5 Pull cable rearward Then release cable and press lock button down until it snaps in place BTSI FUNCTION CHECK 1 Verify removal of ignition key allowed in park position only 2 When the shift lever is in park and the shift handle push button is in the out position the igni tion key cylinder should rotate freely from off to lock When the shifter is in any other position the ignition key should not rotate from off to lock 3 Shifting out of park should be possible when the ignition key cylinder is in the off position 4 Shifting out of park should not be possible while applying 25 16 max handle push button force and ignition key cylinder is in the run or start posi tions unless the foot brake pedal is depressed approximately 1 2 inch 12 mm 21 250 45RFE AUTOMATIC TRANSMISSION ADJ USTMENTS Continued 80ba79c2 Fig 126 Brake Transmission Shift Interlock Cable 4 STEE
211. b Remove nut with socket and impact wrench Fig 28 2 Remove yoke If yoke is difficult to remove by hand remove it with bearing splitter or with stan dard two jaw puller Fig 29 Be sure puller tool is positioned on yoke and not on slinger as slinger will be damaged 3 Remove seal washer from front output shaft Discard washer as it should not be reused 4 Remove nut and washer that attach range lever to sector shaft Then move sector to neutral position and remove range lever from shaft Fig 30 21 284 NV242 TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued y Fig 29 Yoke Removal 80010977 1 PULLER TOOL 2 YOKE RSN lt N S Qus Qe N 2 NP gt QUT lA Fig 30 Range Lever Removal 1 RANGE LEVER 2 SECTOR SHAFT 80010943 FRONT OUTPUT SHAFT AND DRIVE CHAIN 1 Remove drive sprocket snap ring Fig 31 2 Remove drive sprocket and chain Fig 32 3 Remove front output shaft Fig 33 SHIFT FORKS AND MAINSHAFT 1 Remove shift detent plug spring and pin Fig 34 2 Remove seal plug from low range fork lockpin access hole Then move shift sector to align low range fork lockpin with access hole 3 Remove range fork lockpin with size number one easy out tool as follows a Insert easy out tool through access hole in side of transfer case and into lock pin b Tap easy out tool into lock pin with
212. be 3 Engage the wiring connector from brake light switch into BTSI cable solenoid housing 4 Route BTSI cable to the shifter mechanism 5 Install the BTSI cable end fitting into shifter BTSI lever 6 Pull rearward on the BTSI cable housing and install the cable housing into the shifter assembly bracket 7 Place the ignition key cylinder in the LOCK position 8 Snap BTSI cable adjuster ears into floor shifter bracket and 9 Push the cable adjuster lock clamp downward to lock it 10 Install the center console and related trim Refer to Group 23 Body for proper procedures 11 Test the BTSI cable operation 21 84 42 AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION Continued GOVERNOR SOLENOID AND PRESSURE SENSOR REM OVAL 1 Hoist and support vehicle on safety stands 2 Remove transmission fluid pan and filter 3 Disengage wire connecors from pressure sen sor and solenoid Fig 93 4 Remove screws holding pressure solenoid retainer to governor body 5b Separate solenoid retainer from governor Fig 94 6 Pull solenoid from governor body Fig 95 7 Pull pressure sensor from governor body 8 Remove bolts holding governor body to valve body 9 Separate governor body from valve body Fig 96 10 Remove governor body gasket INSTALLATION Before installing the pressure sensor and solenoid in the governor body replace O ring seals clean the gasket surfaces and replace
213. bed in service section 4 Throttle Linkage Binding 4 Check cable for binding Check for return to closed throttle at transmission 5 Gearshift Linkage Cable 5 Adjust linkage cable as described in Misadjusted service section 6 Clutch or Servo Failure 6 Remove valve body and air test clutch and band servo operation Disassemble and repair transmission as needed 7 Governor Circuit Electrical Fault 7 Test using DRB scan tool and repair as required 8 Front Band Misadjusted 8 Adjust band 9 Pump Suction Passage Leak 9 Check for excessive foam on dipstick after normal driving Check for loose pump bolts defective gasket Replace pump assembly if needed NO REVERSE D RANGES 1 Gearshift Linkage Cable 1 Repair or replace linkage parts as OK Misadjusted Damaged needed 2 Park Sprag Sticking 2 Replace overdrive annulus gear 3 Rear Band Misadjusted Worn 3 Adjust band replace 4 Valve Body Malfunction 4 Remove and service valve body Replace valve bogy if any valves or valve bores are worn or damaged 5 Rear Servo Malfunction 5 Remove and disassemble transmission Replace worn damaged servo parts as necessary 6 Direct Clutch in Overdrive Worn 6 Disassemble overdrive Replace worn or damaged parts 7 Front Clutch Burnt 7 Remove and disassemble transmission Replace worn damaged clutch parts as required HAS FIRST REVERSE 1 Governor Circuit Electrical Fault 1 Test using DRB scan tool
214. ble 1 SHIFT MECHANISM 4 STEERING COLUMN ASSEMBLY 2 SHIFTER BTSI LEVER 5 INTERLOCK CABLE 3 ADJUSTMENT CLIP 80be44bc Fig 91 Shifler Assembly 1 FLOOR PAN 2 SHIFTER ASSEMBLY Fig 90 Transfer Case Shift Cable 1 CLIP 2 SHIFTER 3 TRANSFER CASE SHIFT LEVER PIN 4 TRANSFER CASE SHIFT CABLE WJ REMOVAL AND INSTALLATION Continued 42RE AUTOMATIC TRANSMISSION 21 83 80ba79c2 Fig 92 Brake Transmission Shift Interlock 4 STEERING COLUMN ASSEMBLY 5 INTERLOCK CABLE 1 SHIFT MECHANISM 2 SHIFTER BTSI LEVER 3 ADJUSTMENT CLIP BRAKE TRANSMISSION SHIFT INTERLOCK REMOVAL 1 Lower the steering column 2 Remove the transmission shift interlock cable from steering column Fig 92 3 Remove the center console and related trim Refer to Group 23 Body for proper procedures 4 Disconnect the 5 cable from the shift BTSI lever and remove the cable from the shifter assembly bracket 5 Disengage the wire connector at the solenoid on the cable 6 Release the 5 cable from any remaining clips 7 Remove BTSI cable from the vehicle INSTALLATION NOTE The gearshift cable must be secured into position and properly adjusted before the installa tion of the Brake Transmission Interlock Cable BTSI 1 Snap the BTSI cable assembly into the steering column 2 Snap BTSI cable solenoid tie strap into hole in steering column tu
215. bolts Tighten bolts alternately in diagonal pattern to 20 15 ft 165 29 Measure input shaft end play Fig 194 NOTE If end play is incorrect transmission is incorrectly assembled or the intermediate shaft thrust washer is incorrect The intermediate shaft thrust washer is selective WJ DISASSEMBLY AND ASSEMBLY Continued J9121 195 Fig 192 Installing Pilot Studs And Oil Pump Gasket 1 OIL PUMP GASKET 2 PILOT STUD TOOLS 3288 J9121 196 Fig 193 Installing Oil Pump Assembly In Case 1 OIL PUMP 2 PILOT STUD TOOL 3 PILOT STUD TOOL a Attach Adapter 8266 6 to Handle 8266 8 b Attach dial indicator C 3339 to Handle 8266 8 c Install the assembled tool onto the input shaft of the transmission and tighten the retaining screw on Adapter 8266 6 to secure it to the input shaft 42RE AUTOMATIC TRANSMISSION 21 119 d Position the dial indicator plunger against a flat spot on the oil pump and zero the dial indica tor e Move input shaft in and out and record read ing End play should be 0 56 2 31 mm 0 022 0 091 in Adjust as necessary LE 3 D 80507065 Fig 194 Checking Input Shaft End Play 1 TOOL 8266 8 2 TOOL 8266 6 3 TOOL C 3339 30 Install accumulator piston and inner and outer springs Fig 195 31 Verify that valve body solenoid harness is secured in 3 4 accumulator housing cover plate 32 Install valv
216. but should always follow line pressure Some common pressures that can be measured to evaluate pump and dutch performance are the upshift downshift pressures and the garage shift pressures The upshift downshift pressure for all shifts except the 3 4 4 3 and 4 2prime shifts is 120 psi The upshift downshift pressure for the 3 4 4 3 and the 4 2prime shifts is 100 psi The garage shift pressure when performing a N R shift is 220 psi The garage shift pressure for the R N and N 1 shifts is 120 psi AIR TESTING TRANSMISSION CLUTCH OPERATION Air pressure testing can be used to check transmis sion clutch operation The test can be conducted with the transmission either in the vehicle or on the work bench as a final check Air pressure testing requires that the oil pan and valve body be removed from the transmission The dutch apply passages are shown Fig 35 4TH LOW CLUTCH REVERSE 2ND CLUTCH CLUTCH OVERDRIVE CLUTCH A UNDERDRIVE CLUTCH 80b9a594 Fig 35 Air Pressure Test Passages NOTE The air supply which is used must be free of moisture and dirt Use a pressure of 30 psi to test clutch operation Apply air pressure at each port If the clutch is functioning a soft thump will be heard as the clutch is applied The clutch application can also be felt by touching the appropriate element while applying air 21 210 45RFE AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING Continued pressure As the air p
217. cant leaking from 1 Transfer case overfilled transfer case seals or vent restricted 3 Transfer case seals damaged or installed incorrectly 1 Transfer case shift linkage binding 2 Insufficient or incorrect lubricant 2 Transfer case vent closed or 1 Repair or replace linkage as necessary 2 Drain and refill transfer case with the correct type and quantity of lubricant 3 Repair or replace components as necessary 1 Drain and refill transfer case with the correct type and quantity of lubricant 1 Drain lubricant to the correct level 2 Clean or replace vent as necessary 3 Replace suspect seal WJ DIAGNOSIS AND TESTING Continued NV242 TRANSFER CASE 21 277 CONDITION POSSIBLE CAUSE CORRECTION Transfer case will not shift through 4X4 part time torque load range light remains on 2 Incorrect tire pressure 3 Excessive Tire wear 1 Incomplete shift due to drivetrain 1 Momentarily release the accelerator pedal to complete the shift 2 Correct tire pressure as necessary 3 Correct tire condition as necessary 4 Excessive vehicle loading REMOVAL AND INSTALLATION TRANSFER CASE REMOVAL 1 Shift transfer case into Neutral 2 Raise vehide 3 Remove transfer case drain plug and drain transfer case lubricant 4 Mark front and rear propeller shaft yokes for alignment reference 5 Support transmission with jack stand 6 Remove rear crossmember and sk
218. ccomplish this the band retains its holding capacity until the front clutch is applied giving a small amount of overlap between them LOW REVERSE REAR SERVO While in the deenergized state no pressure applied the piston is held up in its bore by the pis ton spring The plug is held down in its bore in the piston by the plug spring When pressure is applied to the top of the piston the plug is forced down in its bore taking up any dearance As the piston moves it causes the plug spring to compress and the piston moves down over the plug The piston continues to move down until it hits the shoulder of the plug and fully applies the band The period of time from the initial application until the piston is against the shoulder of the plug represents a reduced shocking of the band that cushions the shift GEARSHIFT MECHANISM DESCRIPTION The gear shift mechanism provides six shift posi tions which are e Park P Reverse R Neutral N Drive D Manual second 2 Manual low 1 OPERATION Manual low 1 range provides first gear only Overrun braking is also provided in this range Man ual second 2 range provides first and second gear only Drive range provides first second third and over drive fourth gear ranges The shift into overdrive 42RE AUTOMATIC TRANSMISSION 21 47 fourth gear range occurs only after the transmission has completed the shift into D third gear range No further movement of the shift mechan
219. ch chatter can result from the use of improper fluid Mopar ATF Plus 3 Type 7176 automatic trans mission fluid when new is red in color The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze The red color is not permanent and is not an indicator of fluid condition As the vehicle is driven the ATF will begin to look darker in color and may eventually become brown This is normal A dark brown black fluid accompanied with a burnt odor and or deterio ration in shift quality may indicate fluid deteriora tion or transmission component failure FLUID ADDITIVES DaimlerChrysler strongly recommends against the addition of any fluids to the transmission other than those automatic transmission fluids listed above Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks Various special additives and supplements exist that claim to improve shift feel and or quality These additives and others also claim to improve converter clutch operation and inhibit overheating oxidation varnish and sludge These claims have not been sup ported to the satisfaction of DaimlerChrysler and these additives must not be used The use of trans mission sealers should also be avoided since they may adversely affect the integrity of transmission seals OPERATION The automatic transmission fluid is selected based upon several qualities The fluid must pr
220. chain and both sprockets if the chain is stretched distorted or if any of the links bind Replace the bearings if rough or noisy LOW RANGE ANNULUS GEAR Inspect annulus gear condition carefully The gear is only serviced as part of the front case If the gear is damaged it will be necessary to replace the gear and front case as an assembly Do not attempt to remove the gear Fig 107 FRONT REAR CASES AND FRONT RETAINER Inspect the cases and retainer for wear and dam age Clean the sealing surfaces with a scraper and all purpose deaner This will ensure proper sealer adhe sion at assembly Replace the input retainer seal do not reuse it Check case condition If leaks were a problem look for gouges and severe scoring of case sealing sur faces Also make sure the front case mounting studs are in good condition Check the front case mounting studs and vent tube The tube can be secured with Loctite 271 or 680 if loose The stud threads can be deaned up with a die if necessary Also check condition of the fill drain plug threads in the rear case The threads can WJ NV242 TRANSFER CASE 21 305 CLEANING AND INSPECTION Continued 80c070f4 Fig 105 Rear Retainer Components 5 BAND CLAMPS 1 REAR RETAINER 2 REAR BEARING 1 0 RETAINING RING 6 REAR SLINGER 3 REAR SEAL 7 REAR BEARING O D RETAINING RING 4 BOOT 8 REAR BEARING 8001094b Fig 106 Seal Contact Surface Of Yoke Slinger
221. companied with a burnt odor and or deterio ration in shift quality may indicate fluid deteriora tion or transmission component failure FLUID ADDITIVES DaimlerChrysler strongly recommends against the addition of any fluids to the transmission other than those automatic transmission fluids listed above Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks Various special additives and supplements exist that claim to improve shift feel and or quality These additives and others also claim to improve converter clutch operation and inhibit overheating oxidation varnish and sludge These claims have not been sup ported to the satisfaction of DaimlerChrysler and these additives must not be used The use of trans mission sealers should also be avoided since they may adversely affect the integrity of transmission seals OPERATION The automatic transmission fluid is selected based upon several qualities The fluid must provide a high level of protection for the internal components by providing a lubricating film between adjacent metal components The fluid must also be thermally stable so that it can maintain a consistent viscosity through a large temperature range If the viscosity stays con stant through the temperature range of operation transmission operation and shift feel will remain con sistent Transmission fluid must also be a good con ductor of heat The fluid must absorb heat fro
222. compressed and the kickdown valve completely bottomed to obtain correct adjustment Fig 322 Line Pressure Adjustment 1 WRENCH 2 1 5 16 INCH J9521 109 THROTTLE PRESSURE ADJUSTMENT Fig 323 Throttle Pressure Adjustment 1 HEX WRENCH IN THROTTLE LEVER ADJUSTING SCREW Insert Gauge Tool 3763 between the throttle 2 SPECIAL TOOL C 3763 POSITIONED BETWEEN THROTTLE lever cam and the kickdown valve stem Fig 323 LEVER AND KICKDOWN VALVE Push the gauge tool inward to compress the kick down valve against the spring and bottom the throt tle valve 42RE AUTOMATIC TRANSMISSION 21 164 SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS NOILONS 5 amp NI ATILLOYHL 095012 3uVd NI H3A31 01997135 3ATVA 9NINWIL 91 9907 3K TVA 110 NOILVOIH8 YI 12 LNOYS 4 HOLIMS F NOI1VOIlH801 OL H31H3ANOO 3n0uol i 431002 o GION3 IOS dfi4201 AUGHIAO IMYA 1 5 7 5 IMYA FAIVA TILIOHHL gt H SATIVA ONIALL 7 6 3ATVA 13IHS 6 3 o TIANO 75 oU SATIVA 31LLOIHS 3NTVA LdIHS 8
223. condition actually exists 2 Determined the true source of the leak Some suspected converter housing fluid leaks may not be leaks at all They may only be the result of residual fluid in the converter housing or excess fluid spilled during factory fill or fill after repair Converter housing leaks have several potential WJ sources Through careful observation a leak source can be identified before removing the transmission for repair Pump seal leaks tend to move along the drive hub and onto the rear of the converter Pump O ring or pump body leaks follow the same path as a seal leak Fig 69 Pump vent or pump attaching bolt leaks are generally deposited on the inside of the converter housing and not on the converter itself Fig 69 Pump seal or gasket leaks usually travel down the inside of the converter housing Front band lever pin plug leaks are generally deposited on the housing and not on the converter J9021 35 Fig 69 Converter Housing Leak Paths 1 PUMP SEAL 2 PUMP VENT 3 PUMP BOLT 4 PUMP GASKET 5 CONVERTER HOUSING 6 CONVERTER 7 REAR MAIN SEAL LEAK TORQUE CONVERTER LEAK POINTS Possible sources of converter leaks are 1 Leaks at the weld joint around the outside diameter weld Fig 70 2 Leaks at the converter hub weld Fig 70 CONVERTER HOUSING AREA LEAK CORRECTION 1 Remove converter 2 Tighten front band adjusting screw until band is tight around front
224. converter until converter is fully seated in the oil pump gears 6 Check converter seating with a scale and straightedge Fig 83 Surface of converter lugs 42RE AUTOMATIC TRANSMISSION 21 79 should be 1 2 in to rear of straightedge when con verter is fully seated 7 necessary temporarily secure converter with C clamp attached to the converter housing 8 Install the transmission in the vehicle 9 Fill the transmission with the recommended fluid Fig 83 Checking Torque Converter Seating Typical 1 SCALE 2 STRAIGHTEDGE PARK NEUTRAL POSITION SWITCH REM OVAL 1 Raise and position drain pan under switch 2 Disconnec switch wires 3 Remove switch from case INSTALLATION 1 Move shift lever to Park and Neutral positions Verify that switch operating lever fingers are cen tered in switch opening in case Fig 84 2 Install new seal on switch and install switch in case Tighten switch to 34 N m 25 ft Ibs torque 3 Test continuity of new switch with 12V test lamp 4 Connect switch wires and lower vehide 5 Top off transmission fluid level GEARSHIFT CABLE REM OVAL 1 Shift transmission into Park 2 Raise vehicle 21 80 42RE AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION Continued 80b170f4 Fig 84 Park Neutral Position Switch 1 NEUTRAL CONTACT 2 MANUAL LEVER AND SWITCH PLUNGER IN REVERSE POSITION 3 PARK CONTACT 4 SW
225. cored Inspect all of the accumulator springs The springs must be free of distortion warpage or broken coils Inspect all the fluid seals on the valve body Fig 125 Replace any seals that are cracked distorted or damaged in any way These seals pass fluid pressure directly to the clutches Any pressure leak at these points may cause transmission performance prob lems TRANSMISSION GENERAL INFORMATION Heli Coil inserts can be used to repair damaged stripped or worn threads in aluminum parts These inserts are available from most automotive parts suppliers Stainless steel inserts are recommended The use of crocus cloth is permissible where neces sary providing it is used carefully When used on shafts or valves use extreme care to avoid rounding off sharp edges Sharp edges are vital as they pre vent foreign matter from getting between the valve and valve bore UNDERDRIVE 2ND CLUTCH ACCUMULATOR 4TH CLUTCH ACCUMULATOR 2 SPRINGS ACCUMULATOR 2 SPRINGS 2 SPRINGS LOW REVERSE ACCUMULATOR 2 SPRINGS OVERDRIVE ACCUMULATOR 1 SPRING 4TH CLUTCH PASSAGE SEAL 2ND CLUTCH PASSAGE 7 SEAL LOW REVERSE PASSAGE SEAL 80b9a591 Fig 125 Valve Body Seals Do not reuse oil seals gaskets seal rings or O rings during overhaul Replace these parts as a matter of course Also do not reuse snap rings or E dips that are bent or distorted Replace these parts as well Lubr
226. cumulators 7 check balls OPERATION NOTE Refer to the Hydraulic Schematics for a visual aid in determining valve location operation and design SOLENOID SWITCH VALVE The Solenoid Switch Valve SSV controls the direc tion of the transmission fluid when the L R TCC sole noid is energized The Solenoid Switch Valve controls line pressure from the LR TCC solenoid In 1st gear the SSV will be in the downshifted position thus directing fluid to the L R dutch circuit In 2nd 3rd and 4th it will be in the upshifted position and directs the fluid into the torque converter clutch TCC circuit 5 AUTOMATIC TRANSMISSION 21 191 DESCRIPTION AND OPERATION Continued LOW REVERSE ACCUMULATOR LOW REVERSE SWITCH VALVE UPPER VALVE BODY 2C ACCUMULATOR 4C ACCUMULATOR UNDERDRIVE ACCUMULATOR OVERDRIVE ACCUMULATOR SOLENOID SWITCH VALVE 80c07212 Fig 14 Valve Body Components When shifting into 1st gear a special hydraulic sequence is performed to ensure SSV movement into the downshifted position The L R pressure switch is monitored to confirm SSV movement If the move ment is not confirmed the L R pressure switch does not dose 2nd gear is substituted for 1st A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start
227. d converter clutch fault condi tions The hydraulic flow charts in the Schematics and Diagrams section of this group outline fluid flow and hydraulic circuitry Circuit operation is provided for neutral third fourth and reverse gear ranges Nor mal working pressures are also supplied for each of the gear ranges transmission and converter housing 21 60 42RE AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING Continued DIAGNOSIS CHARTS CONDITION POSSIBLE CAUSES CORRECTION HARSH ENGAGEMENT 1 Fluid Level Low 1 Add Fluid FROM NEUTRAL TO DRIVE OR REVERSE 2 Throttle Linkage Misadjusted 2 Adjust linkage setting may be too long 3 Mount and Driveline Bolts Loose 3 Check engine mount transmission mount propeller shaft rear spring to body bolts rear control arms crossmember and axle bolt torque Tighten loose bolts and replace missing bolts 4 U Joint Worn Broken 4 Remove propeller shaft and replace U Joint 5 Axle Backlash Incorrect 5 Check per Service Manual Correct as needed 6 Hydraulic Pressure Incorrect 6 Check pressure Remove overhaul or adjust valve body as needed 7 Band Misadjusted 7 Adjust rear band 8 Valve Body Check Balls Missing 8 Inspect valve body for proper check ball installation 9 Axle Pinion Flange Loose 9 Replace nut and check pinion threads before installing new nut Replace pinion gear if threads are damaged 10 Clutch band or planetary 10 Rem
228. d to complete the shifts by comparing the engine speed when the shifts occur to the optimum speed After each shift the PCM adjusts the shift point until the optimum speed is reached The PCM also considers vehicle loading grade and engine performance changes due to high altitude in determining when to make shifts It does this by measuring vehicle and engine accelera tion and then factoring in the shift time TRANSFER CASE LOW RANGE OPERATION On four wheel drive vehicles operating in low range the engine can accelerate to its peak more rapidly than in Normal range resulting in delayed shifts and undesirable engine flare The low range governor pressure curve is also higher than normal to initiate upshifts sooner The PCM compares elec tronic vehide speed signal used by the speedometer to the transmission output shaft speed signal to determine when the transfer case is in low range OVERDRIVE OFF SWITCH DESCRIPTION The overdrive OFF control switch is located in the shifter handle The switch is a momentary con tact device that signals the PCM to toggle current status of the overdrive function OPERATION At key on overdrive operation is allowed Pressing the switch once causes the overdrive OFF mode to be entered and the overdrive OFF switch lamp to be illuminated Pressing the switch a second time causes normal overdrive operation to be restored and the overdrive lamp to be turned off The overdrive OFF mode default
229. d torque con CASE verter assembly rearward off engine block dowels 29 Hold torque converter in place during trans 42RE ax mission removal 30 Lower transmission and remove assembly Fig 79 Remove NV247 Transfer Case from under the vehicle 31 To remove torque converter carefully slide torque converter out of the transmission 21 78 42RE AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION Continued INSTALLATION 1 Check torque converter hub and hub drive notches for sharp edges burrs scratches or nicks Polish the hub and notches with 320 400 grit paper and crocus doth if necessary The hub must be smooth to avoid damaging pump seal at installation 2 Lubricate oil pump seal lip with transmission fluid 3 Align converter and oil pump 4 Carefully insert converter in oil pump Then rotate converter back and forth until fully seated in pump gears 5 Check converter seating with steel scale and straightedge Fig 82 Surface of converter lugs should be 1 2 in to rear of straightedge when con verter is fully seated 6 Temporarily secure converter with C clamp Fig 82 Typical Method Of Checking Converter Seating 1 SCALE 2 STRAIGHTEDGE 7 Position transmission on jack and secure it with chains 8 Check condition of converter driveplate Replace the plate if cracked distorted or damaged Also be sure transmission dowel pins are seated in engine block and protrude far enough to hold t
230. de is parked for lengthy periods The valve check ball is spring loaded and has an opening pressure of approximately 2 psi The valve is serviced as an assembly it is not repairable Do not dean the valve if restricted or contaminated by sludge or debris If the valve fails or if a transmission malfunction occurs that gener ates significant amounts of sludge and or clutch par tides and metal shavings the valve must be replaced The valve must be removed whenever the cooler and lines are reverse flushed The valve can be flow tested when necessary The procedure is exactly the same as for flow testing a cooler If the valve is restricted installed backwards or in the wrong line it will cause an overheating condition and possible transmission failure CAUTION The drainback valve is a one way flow device It must be properly oriented in terms of flow direction for the cooler to function properly The valve must be installed in the pressure line Other wise flow will be blocked and would cause an over heating condition and eventual transmission failure OIL PUMP VOLUME CHECK Measuring the oil pump output volume will deter mine if sufficient oil flow to the transmission oil cooler exists and whether or not an internal trans mission failure is present Verify that the transmission fluid is at the proper level Refer to the Fluid Level Check procedure in this section If necessary fill the transmission to the proper level wit
231. dip securing the transfer case shift cable into the cable support bracket WJ THROTTLE VALVE CABLE THROTTLE BODY 80ba79c5 Fig 76 Throttle Valve Cable gt s q TRANSFER CASE SHIFT LEVER 1 EK 521 N S Ve e VEA ANC NN L N ars TRANSFER CASE 6 N SHIFT CABLE 80ba79c6 Fig 77 Transfer Case Shift Cable 20 Disconnect transmission fluid cooler lines at transmission fittings and clips 21 Support rear of engine with safety stand or jack 22 Raise transmission slightly with service jack to relieve load on crossmember and supports 2 AUTOMATIC TRANSMISSION 21 77 REMOVAL AND INSTALLATION Continued 23 Remove bolts securing rear support and cush ion to transmission and crossmember Fig 78 24 Remove bolts attaching crossmember to frame and remove crossmember CROSSMEMBER TRANSFER CASE 45RFE 80ba79c8 Fig 80 Remove NV242 Transfer Case 26 Remove bolts holding the upper transmission bending braces to the torque converter housing and the overdrive unit Fig 81 27 Remove all remaining converter housing bolts MOUNT Fig 78 Rear Transmission Crossmember 25 Remove transfer case Fig 79 and Fig 80 80ba79c7 DDS TRANSMISSIO BENDING BRACES 80ba79ca Fig 81 Remove Upper Transmission Bending Braces TRANSFER 28 Carefully work transmission an
232. drive sprocket hub from mainshaft Be sure to retrieve all the drive sprocket hub needle bearings 6 Remove snap ring holding dutch sleeve onto mainshaft 7 Remove range dutch sleeve blockout spring locking dutch and locking clutch spring from main shaft Fig 28 8 Remove shift sector Rotate and tilt sector as needed to remove it Fig 29 WJ 247 TRANSFER CASE 21 317 DISASSEMBLY AND ASSEMBLY Continued REAR HOUSING OUTPUT SHAFT 9 Remove shift sector bushing and Fig ANDSPROCKET 30 A MAINSHAFT AX SPROCKET 8035896 Fig 26 Front Output Shaft Drive Gear And Chain Removal DETENT PLUNGER 19321 22 Fig 27 Detent Plug Spring And Plunger Removal LOCKING BLOCKOUT CLUTCH SPRING SPRING SNAP RING 18921 207 Fig 30 Sector Bushing And O Ring Removal 1 SHIFT SECTOR BUSHING 2 O RING DRIVE N RANGE SPROCKET LOCKING CLUTCH HUB CLUTCH SLEEVE BOba7a52 Fig 28 Range Clutch Sleeve Blockout Spring Locking Clutch and Spring 21 318 NV247 TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued INPUT GEAR LOW RANGE ASSEMBLY REMOVAL 1 Turn front case on side so front bearing retainer is accessible 2 Remove front bearing retainer bolts Fig 31 3 Remove front bearing retainer as follows a Loosen retainer with flat blade screwdriver S to break sealer bead To avoid damaging case lt and retainer position screwdriver bl
233. dutch thrust washer Fig 185 Use additional petroleum jelly to hold washer in place if necessary J9121 352 Fig 181 Rear Band Lever And Pivot Pin Installation 1 REAR BAND LEVER 2 LEVER PIVOT PIN 9121 215 Fig 183 Installing Intermediate Shaft Thrust Plate 1 INTERMEDIATE SHAFT HUB 2 INTERMEDIATE SHAFT THRUST PLATE 19121 217 Fig 182 Installing Planetary Geartrain 1 PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT Fig 184 Input Shaft Seal Ring Location ASSEMBLY 1 INPUT SHAFT 2 TEFLON SEAL RING 3 METAL SEAL RING 4 REAR CLUTCH RETAINER 11 Check seal ring on rear clutch retainer hub and seal rings on input shaft Fig 184 Also verify that shaft seal rings are installed in sequence shown WJ DISASSEMBLY AND ASSEMBLY Continued Fig 185 Installing Rear Clutch Thrust Washer 1 REAR CLUTCH RETAINER 2 REAR CLUTCH THRUST WASHER FIBER 13 Align clutch discs in front clutch and install front clutch on rear clutch Fig 186 Rotate front clutch retainer back and forth until completely seated on rear clutch retainer 14 Coat intermediate shaft thrust washer with petroleum jelly Then install washer in rear dutch hub Fig 187 Use enough petroleum jelly to hold washer in place Be sure grooved side of washer faces rearward toward output shaft as shown Also note that washer only fits one way in clutch hub Note thickness of this wash
234. e DRB Scan Tool Communication Based on the information received from these var ious inputs the TCM determines the appropriate shift schedule and shift points depending on the present operating conditions and driver demand This is possible through the control of various direct and indirect outputs Some examples of TCM direct outputs are Transmission Control Relay e Solenoids Torque Reduction Request Some examples of TCM indirect outputs are e Transmission Temperature to PCM e PRNDL Position to BCM In addition to monitoring inputs and controlling outputs the TCM has other important responsibili ties and functions e Storing and maintaining Clutch Volume Indexes Storing and selecting appropriate Shift Sched ules e System self diagnostics Diagnostic capabilities with DRB scan tool NOTE If the TCM has been replaced the Quick Learn Procedure must be performed Refer to Quick Learn Procedure in Service Procedures of this group CLUTCH VOLUME INDEXES An important function of the TCM is to monitor Clutch Volume Indexes CVI CVIs represent the vol ume of fluid needed to compress a dutch pack 45RFE AUTOMATIC TRANSMISSION 21 201 The TCM monitors gear ratio changes by monitor ing the Input and Output Speed Sensors The Input or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm The Out put Speed Sensor provides the TCM with output sha
235. e reaction area on the right side of the throttle pres sure plug in the regulator valve The higher engine speed and line pressure would open the vent too far and reduce line pressure too much Throttle pressure which increases with engine speed throttle opening is used to oppose the move ment of the pressure valve to help control the meter ing passage at the vent The throttle pressure is combined with spring pressure to reduce the force of the throttle pressure plug on the pressure valve The larger spring at the right closes the regulator valve passage and maintains or increases line pressure The increased line pressure works against the tion area of the line pressure plug and the reaction area left of land 3 simultaneously moves the regu lator valve train to the right and controls the meter ing passage The kickdown valve along with the throttle valve serve to delay upshifts until the correct vehicle and engine speed have been reached It also controls downshifts upon driver demand or increased engine load If these valves were not in place the shift points would be at the same speed for all throttle positions The kickdown valve is actuated by a cam connected to the throttle This is accomplished through either a linkage or a cable The cam forces the kickdown valve toward the throttle valve com pressing the spring between them and moving the throttle valve As the throttle valve land starts to uncover its por
236. e any of the components out or into place The valves and valve body housings will be dam aged if force is used Tag or mark the valve body springs for reference as they are removed Do not allow them to become intermixed 1 Remove fluid filter 2 Disconnect wires from governor pressure sen sor and solenoid 3 Remove screws attaching governor body and retainer plate to transfer plate 4 Remove retainer plate governor body and gas ket from transfer plate 5 Remove governor pressure sensor from gover nor body 6 Remove governor pressure solenoid by pulling it straight out of bore in governor body Remove and discard solenoid O rings if worn cut or torn 7 Remove small shoulder bolt that secures sole noid harness case connector to 3 4 accumulator hous ing Fig 109 Retain shoulder bolt Either tape it to harness or thread it back into accumulator housing after connector removal 8 Unhook overdrive converter solenoid harness from 3 4 accumulator cover plate Fig 110 9 Turn valve body over and remove screws that attach overdrive converter solenoid assembly to valve body Fig 111 10 Remove solenoid and harness assembly from valve body Fig 112 11 Remove boost valve cover Fig 113 12 Remove boost valve retainer valve spring and boost valve Fig 114 21 90 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued Fig 109 Solenoid Harness Case Connector Shoulder Bolt 1
237. e body as follows a Align and carefully insert park rod into pawl Rod will make dick noise as it enters pawl Move rod slightly to check engagement b Align and seat valve body on case Be sure manual lever shaft and overdrive connecor are fully seated in case Also be sure valve body wiring is not pinched or kinked c Install and start all valve body attaching bolts by hand Then tighten bolts evenly in a diag onal pattern to 12 N m 105 in Ibs torque Do not overtighten valve body bolts This could result in distortion and cross leakage after installation CAUTION It is possible for the park rod to displace into a cavity just above the pawl sprag during installation Make sure the rod is actually engaged in the pawl and has not displaced into the cavity 21 120 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued Fig 195 Accumulator Piston And Springs 1 GOVERNOR PRESSURE SENSOR 2 VALVE BODY 3 PARK ROD 4 ACCUMULATOR PISTON 5 GOVERNOR PRESSURE SOLENOID 80c072b8 Fig 196 Installing Manual Lever Shaft Seal 1 15 16 SOCKET 2 SEAL 33 Install new filter on valve body Tighten filter screws to 4 N m 35 in 165 34 Adjust front and rear bands 35 Install seal on park neutral position switch Then install and tighten switch to 34 N m 25 ft Ibs 36 Install magnet in oil pan Magnet goes on small protrusion at corner of pan
238. e on front case Be sure case locating dowels are in place and that main shaft splines are engaged in oil pump inner gear 5 Install and tighten front case to rear case bolts to 41 30 ft 165 torque Be sure to install washer under each bolt used at case dowel locations NV242 LD REAR RETAINER 1 Remove rear bearing in retainer using Installer 8128 and Handle C 4171 2 Install rear bearing in retainer with Tools C 4171 and 5064 Fig 96 800bdfag Fig 96 Installing Rear Bearing In Retainer 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL 5064 3 REAR RETAINER 3 Install rear bearing O D retaining ring with snap ring pliers Fig 97 Be sure retaining ring is fully seated in retainer groove 4 Apply bead of Sealer P N 82300234 or Loctite Ultra Gray to mating surface of rear retainer Sealer bead should be a maximum of 3 16 in 5 Install rear retainer on rear case Tighten retainer bolts to 20 27 N m 15 20 ft 165 torque Install rear bearing retaining ring and Spacer on output shaft 7 Apply liberal quantity of petroleum jelly to new rear seal and to output shaft Petroleum jelly is needed to protect seal lips during installation 8 Slide seal onto Seal Protector 6992 Fig 98 Slide seal protector and seal onto output shaft 9 Slide Installer C 4076 B onto seal protector with the recessed side of the tool toward the seal 21 302 NV242 TRANSFER CASE DISASSEMBL
239. e seated at the bottom of the bore Replace the bearing if worn or roughness is evident Replace both the gear and bearing if the bearing is a loose fit in the bore GEAR CASE AND RETAINERS Examine both case halves and retainers carefully Replace any retainer or case half if wear cracks or other damage is evident Check condition of the low range annulus gear and the shift rail bushing in the front case Fig 78 The low range annulus gear is not a serviceable part Replace the gear and case as an assembly if the gear is loose worn or damaged The shift rail bushing is a serviceable part and can be replaced if necessary 2 E RANGE ANNULUS GEAR 9 Q A 22D Q gt K gt O ELD e RAIL BUSHING J9321 50 Fig 78 Low Range Annulus Gear Location Check the bushing in the rear retainer Replace the bushing if worn or scored Examine the sealing surfaces of both case halves and retainers Small burrs or scratches on these sur faces can be reduced with crocus doth or a fine tooth file Examine condition of the shift rail bushing in the front case If the bushing is worn or damaged it can be removed with a blind hole type puller A replace ment bushing can be installed with a suitable size driver Recess the bushing slightly below the edge of the bore but do not seat it all the into the case GEARTRAIN Inspect the mainshaft splines gear teeth and bear
240. e unit and rebuild clutch pack Snap Rings Damaged 804948 Fig 71 Dipstick Fluid Level Marks Typical 1 DIPSTICK 2 MAXIMUM CORRECT FLUID LEVEL 3 ACCEPTABLE FLUID LEVEL intervals The service fluid fill after a filter change is approximately 3 8 liters 4 0 quarts REMOVAL 1 Hoist and support vehicle on safety stands 2 Place a large diameter shallow drain pan beneath the transmission pan 3 Remove bolts holding front and sides of pan to transmission Fig 72 4 Loosen bolts holding rear of pan to transmis sion 5 Slowly separate front of pan away from trans mission allowing the fluid to drain into drain pan 6 Hold up pan and remove remaining bolt hold ing pan to transmission 7 While holding pan level lower pan away from transmission 8 Pour remaining fluid in pan into drain pan 9 Remove screws holding filter to valve body Fig 73 10 Separate filter from valve body and pour fluid in filter into drain pan 11 Dispose of used trans fluid and filter properly INSPECTION Inspect bottom of pan and magnet for excessive amounts of metal or fiber contamination A light coating of dutch or band material on the bottom of the pan does not indicate a problem unless accompa WJ SERVICE PROCEDURES Continued 80617180 Fig 72 Transmission 1 TRANSMISSION 2 GASKET 3 PAN Ry Amr AES an o A Sage 80b170e8 Fi
241. ealer to set up slightly before proceeding 6 Install extension housing on rear retainer 7 Install extension housing bolts and tighten to 35 46 N m 26 34 ft Ibs WJ DISASSEMBLY AND ASSEMBLY Continued 800bdfae Fig 101 Rear Bearing Retaining Ring Installation 1 REAR BEARING O D RETAINING RING 2 SNAP RING PLIERS RR21F22 Fig 102 Install Output Bearing Snap ring 1 REAR RETAINER 2 SNAP RING 3 REAR BEARING COMPANION FLANGE INSTALLATION 1 Lubricate companion flange hub with transmis sion fluid and install flange on front shaft 2 Install new seal washer on front shaft 3 Install flange on front shaft and tighten nut to 122 176 90 130 ft Ibs CLEANING AND INSPECTION NV242 TRANSFER CASE Clean the transfer case parts with a standard parts deaning solvent Remove all traces of sealer from the cases and retainers with a scraper and all purpose cleaner Use compressed air to remove sol NV242 TRANSFER CASE 21 303 vent residue from oil feed passages in the case halves retainers gears and shafts The oil pickup screen can be cleaned with solvent Shake excess solvent from the screen after deaning and allow it to air dry Do not use compressed air MAINSHAFT SPROCKET HUB INSPECTION Inspect the splines on the hub and shaft and the teeth on the sprocket Minor nicks and scratches can be smoothed with an oilstone However replace any part is damaged Check the co
242. eals 15 O D Check Valve Orifice Failed 15 Check for free movement and secure assembly in piston retainer Check ball bleed orifice 21 70 2 AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION SLIPS IN OVERDRIVE 1 Fluid Level Low 1 Add fluid and check for leaks FOURTH GEAR 2 Overdrive Clutch Pack Worn 2 Remove overdrive unit and rebuild clutch pack 3 Overdrive Piston Retainer Bleed 3 Disassemble transmission remove Orifice Blown Out retainer and replace orifice 4 Overdrive Piston or Seal 4 Remove overdrive unit Replace seals if Malfunction worn Replace piston if damaged If piston retainer is damaged remove and disassemble the transmission 5 3 4 Shift Valve Timing Valve or 5 Remove and overhaul valve Accumulator Malfunction Replace accumulator seals Make sure all valves operate freely in bores and do not bind or stick Make sure valve body screws are correctly tightened and separator plates are properly positioned 6 Overdrive Unit Thrust Bearing 6 Disassemble overdrive unit and replace Failure thrust bearing NO 1 thrust bearing is between overdrive piston and clutch hub NO 2 thrust bearing is between the planetary gear and the direct clutch spring plate NO 3 thrust bearing is between overrunning clutch hub and output shaft 7 O D Check Valve Bleed Orifice 7 Check for function secure orifice inse
243. ed Driven through J 1850 circuits e Oxygen sensor heater relays if equipped e Radiator cooling fan relay pulse width modu lated e Speed control source e Speed control vacuum solenoid e Speed control vent solenoid e Tachometer if equipped Driven through J 1850 circuits e Transmission convertor clutch circuit Transmission 3 4 shift solenoid Transmission relay Transmission temperature lamp if equipped Transmission variable force solenoid WJ DESCRIPTION AND OPERATION Continued ELECTRONIC GOVERNOR DESCRIPTION Governor pressure is controlled electronically Com ponents used for governor pressure control include e Governor body Valve body transfer plate Governor pressure solenoid valve Governor pressure sensor Fluid temperature thermistor Throttle position sensor TPS Transmission speed sensor Powertrain control module PCM GOVERNOR PRESSURE SOLENOID VALVE The solenoid valve is a duty cycle solenoid which regulates the governor pressure needed for upshifts and downshifts It is an electro hydraulic device located in the governor body on the valve body trans fer plate Fig 63 J9321 408A Fig 63 Governor Pressure Solenoid Valve 1 SOLENOID FILTER 2 GOVERNOR PRESSURE SOLENOID GOVERNOR PRESSURE SENSOR The governor pressure sensor measures output pressure of the governor pressure solenoid valve Fig 64 GOVERNOR BODY AND TRANSFER PLATE The transfer plate is designed to
244. ed worn scored burned or charred or if the facing is flaking off Replace the steel plates if heavily scored warped or broken Be sure the driving lugs on the plates are in good condition The lugs must not be bent cracked damaged in any way 42RE AUTOMATIC TRANSMISSION 21 157 Replace the dutch spring and spring retainer if either is distorted warped or broken Check the lug grooves in the dutch retainer The steel plates should slide freely in the slots Replace the retainer if the grooves are worn or damaged Check action of the check ball in the retainer Fig 314 The ball must move freely and not stick NOTE Inspect the clutch retainer bushings care fully Fig 315 The retainer bushings are NOT ser viceable It will be necessary to replace the retainer if either bushing is scored or worn Inspect the piston and retainer seal surfaces for nicks or scratches Minor scratches can be removed with crocus doth However replace the piston and or retainer if the seal surfaces are seriously scored J9121 368 Fig 314 Front Clutch Piston Retainer Check Ball Location 1 RETAINER CHECK BALL J9321 223 Fig 315 Retainer Bushing Location Inspection 1 FRONT CLUTCH RETAINER BUSHINGS NON SERVICEABLE 21 158 42RE AUTOMATIC TRANSMISSION CLEANING AND INSPECTION Continued REAR CLUTCH Clean the dutch components with solvent and dry them with compressed air Do not use rags or shop towels to dr
245. ed ends The rear ring is metal with interlocking ends Check the input shaft for wear or damage Replace the shaft if worn scored or damaged in any way PLANETARY GEARTRAIN Clean the planetary components in solvent and dry them with compressed air Check sun gear and driving shell condition Replace the gear if damaged or if the bushings are scored or worn The bushings are not serviceable Replace the driving shell if worn cracked or dam aged Replace planetary gear sets if gears pinion pins or carrier are damaged in any way Replace the annulus gears and supports if either component is worn or damaged Inspect the geartrain spacers thrust plates snap rings and thrust washers Replace any of these parts that are worn distorted or damaged Do not attempt to reuse these parts The planetary gear thrust washers are different sizes The large diameter washers go on the front WJ planetary and the smaller washers go on the rear planetary All the washers have four locating tabs on them These tabs fit in the holes or slots provided in each planetary gear Inspect the output shaft carefully Pay particular attention to the machined bushing bearing surfaces on the shaft and the governor valve shaft bore at the shaft rear Replace the output shaft if the machined surfaces are scored pitted or damaged in any way Also replace the shaft if the splines are damaged or exhibits cracks at any location especially at the gov er
246. eekly Fluid level is checked with the engine running at curb idle speed the transmission in NEUTRAL and the transmission fluid at normal operating temperature FLUID LEVEL CHECK PROCEDURE 1 Transmission fluid must be at normal operat ing temperature for accurate fluid level check Drive vehide if necessary to bring fluid temperature up to normal hot operating temperature of 82 C 180 F 2 Position vehicle on level surface 3 Start and run engine at curb idle speed 4 Apply parking brakes 5 Shift transmission momentarily into all gear ranges Then shift transmission back to Neutral 6 Clean top of filler tube and dipstick to keep dirt from entering tube 7 Remove dipstick Fig 71 and check fluid level as follows a Correct acceptable level is in crosshatch area b Correct maximum level is to MAX arrow mark c Incorrect level is at or below MIN line d If fluid is low add only enough Mopar ATF Plus 3 to restore correct level Do not overfill CAUTION Do not overfill the transmission Overfill ing may cause leakage out the pump vent which can be mistaken for a pump seal leak Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear train This will significantly reduce fluid life FLUID AND FILTER REPLACEM ENT Refer to the Maintenance Schedules in Group O Lubrication and Maintenance for proper service 1 Overdrive Clutch Discs Plates or 1 Remov
247. ent on the number of teeth on the annulus and sun gears BANDS DESCRIPTION KICKDOWN FRONT BAND The kickdown or front band Fig 59 holds the common sun gear of the planetary gear sets The front kickdown band is made of steel and faced on its inner circumference with a friction type lining 21 46 42RE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued One end of the band is anchored to the transmission case and the other is acted on with a pushing force by a servo piston The front band is a single wrap design the band does not completely encompass wrap the drum that it holds 80a3b192 Fig 59 Front Band 1 FRONT BAND 2 TRANSMISSION HOUSING LOW REVERSE REAR BAND The low reverse band or rear band Fig 60 is similar in appearance and operation to the front band J9121 89 Fig 60 Rear Band 1 REAR BAND 2 BAND LINK OPERATION KICKDOWN FRONT BAND The kickdown band holds the common sun gear of the planetary gear sets by applying and holding the front dutch retainer which is splined to the sun gear driving shell and in turn splined directly to the sun gear The application of the band by the servo is typ ically done by an apply lever and link bar LOW REVERSE REAR BAND The rear band holds the rear planet carrier sta tionary by being mounted around and applied to the low reverse drum SERVOS DESCRIPTION KICKDOWN FRONT SERVO The kickdown
248. er It is a select fit part and is used to control transmission end play 7 2 9121 190 Fig 186 Assembling Front Rear Clutch Units 1 TURN FRONT CLUTCH BACK amp FORTH UNTIL SEATED 2 REAR CLUTCH ASSEMBLY 42RE AUTOMATIC TRANSMISSION 21 117 19121 214 Fig 187 Installing Intermediate Shaft Thrust Plate 1 INTERMEDIATE SHAFT THRUST WASHER 2 INPUT SHAFT 3 REAR CLUTCH RETAINER HUB 15 Align drive teeth on rear clutch discs with small screwdriver Fig 188 This makes installation on front planetary easier 16 Raise front end of transmission upward as far as possible and support case with wood blocks F ront rear dutch and oil pump assemblies are easier to install if transmission is as close to upright position as possible 17 Slide front band into case 18 Install front and rear dutch units as assembly Fig 189 Align rear clutch with front annulus gear and install assembly in driving shell Be sure out put shaft thrust washer and thrust plate are not displaced during installation 19 Carefully work assembled clutches back and forth to engage and seat rear dutch discs on front annulus gear Also be sure front dutch drive lugs are fully engaged in slots of driving shell after installa tion 20 Assemble front band strut 21 Install front band adjuster strut and adjust ing screw Fig 190 22 Tighten band adjusting screw until band just grips clutch retainer
249. er facing the front of the transmission Fig 86 21 230 45RFE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued the annulus gear and the tabs and notches aligned as shown in Fig 87 REACTION PLATE SELECT 80c07359 Fig 85 Install 2C Clutch Pack 30 Install the number 7 bearing onto the reaction sun gear with the flat side against the sun gear Fig 86 Fig 87 Thrust Plate Alignment 31 Install the output shaft selective thrust plate onto the reaction annulus with the oil grooves facing 80c07425 va Z Va BEARING NUMBER 9 BEARING NUMBER 8 REACTION ANNULUS BEARING NUMBER 6 REACTION REACTION PLANETARY SUN GEAR CARRIER BEARING NUMBER 7 THRUST PLATE Fig 86 Install Reaction Annulus and Carrier 80c07031 WJ DISASSEMBLY AND ASSEMBLY Continued 32 Install the number 6 bearing against the out put shaft selective spacer with the flat side against the spacer Fig 86 33 Install the reaction annulus into the reaction planetary gear set Fig 86 34 Install the 4 retainer bulkhead into the transmission case Make sure that the oil feed holes are pointing toward the valve body area Rotate the reaction annulus during the installation of the 4C retainer bulkhead to ease installation 35 Install the 4C retainer oulkhead tapered snap ring into the transmission case Fig 88 Make sure that the open e
250. er on top of piston spring Fig 223 Make sure retainer is properly installed Small raised tabs should be facing upward Semicircular lugs on underside of retainer are for positioning retainer in spring 7 Compress piston spring and retainer with Com pressor Tool C 3575 A Fig 220 Then install new snap ring to secure spring retainer and spring 8 Install dutch plates and discs Fig 219 Install steel plate then disc until all plates and discs are installed The front clutch uses 4 dutch discs and plates in 42RE transmission J9121 146 Fig 221 Front Clutch Piston Installation 1 CLUTCH PISTON 2 FRONT CLUTCH RETAINER J9321 466 Fig 222 Clutch Piston Spring Installation 1 RETAINER 2 CLUTCH SPRING 3 PISTON J9321 224 Fig 223 Correct Spring Retainer Installed Position 1 SMALL TABS ON RETAINER FACE UPWARD 9 Install pressure plate and waved snap ring Fig 219 WJ DISASSEMBLY AND ASSEMBLY Continued 21 129 42RE AUTOMATIC TRANSMISSION 80c070a4 Fig 224 Rear Clutch Components 1 PISTON SPRING 2 REAR CLUTCH PISTON 3 CLUTCH PISTON SEALS 4 OUTPUT SHAFT THRUST WASHER METAL 5 INPUT SHAFT SNAP RING 6 REAR CLUTCH RETAINER 7 INPUT SHAFT 8 REAR CLUTCH THRUST WASHER FIBER 9 CLUTCH PACK SNAP RING SELECTIVE 10 TOP PRESSURE PLATE 11 CLUTCH DISCS 4 12 BOTTOM PRESSURE PLATE 13 WAVE SPRING 14
251. erclockwise direc tion The rear band is holding the low reverse drum which is splined to the rear carrier Since the rear carrier is being held the torque from the planet pin ions is transferred to the rear annulus gear which is splined to the output shaft The output shaft in turn rotates with the annulus gear in a counterclockwise direction giving a reverse gear output The entire transmission of torque is applied to the rear plane tary gearset only Although there is torque input to the front gearset through the sun gear no other member of the gearset is being held During the entire reverse stage of operation the front planetary gears are in an idling condition WJ DESCRIPTION AND OPERATION Continued ANY 21 7 42RE AUTOMATIC TRANSMISSION INPUT OUTPUT STATIONARY MEMBER ROTATING MEMBER REAR PLANETARY 80c070a9 Fig 6 First Gear Powerflow 1 OUTPUT SHAFT 2 OVER RUNNING CLUTCH HOLDING 3 REAR CLUTCH APPLIED 4 OUTPUT SHAFT 5 OVER RUNNING CLUTCH HOLDING 6 INPUT SHAFT 7 REAR CLUTCH APPLIED 8 INPUT SHAFT FIRST GEAR POWERFLOW When the gearshift lever is moved into the drive position the transmission goes into first gear Fig 6 As soon as the transmission is shifted from park or neutral to drive the rear clutch applies applying the rear clutch pack to the front annulus gear Engine torque is now applied to the front annulus gear turn ing it in
252. erified the voltage at the solenoid pack pressure switches is checked After the relay is energized the TCM mon itors the terminals to verify that the voltage is greater than 3 volts PRESSURE SWITCHES DESCRIPTION The pressure switches are located inside the sole noid and pressure switch assembly and are only ser viced by replacing the assembly OPERATION The TCM relies on five pressure switches to moni tor fluid pressure the L R 2C 4 UD and OD hydraulic circuits The primary purpose of these switches is to help the detect when clutch cuit hydraulic failures occur The switches dose at 23 psi and open at 11 psi and simply indicate whether or not pressure exists The switches are continuously monitored by the TCM for the correct states open or closed in each gear as shown in the following chart GEAR L R 2C 4C UD OD R OP OP OP OP OP P N CL OP OP OP OP 1ST CL OP OP CL OP 2ND OP CL OP CL OP 2ND PRIME OP OP CL CL OP D OP OP OP CL CL OD OP OP CL OP CL L R is closed if output speed is below 100 rpm in Drive and Manual 2 L R is open in Manual 1 21 204 45 AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued A Diagnostic Trouble Code DTC will set if the TCM senses any switch open or closed at the wrong time in a given gear INPUT AND OUTPUT SPEED SENSORS DESCRIPTION The Input and Output Speed Sensors are two wire magnetic pickup devices that generate AC sign
253. ering passage at land 2 land 1 being at the far right of the valve in the diagram As fluid leaks past the land it moves into a groove connected to the filter or sump As the land meters the fluid to the sump it causes the pres sure to reduce and the spring decreases the size of the metering passage When the size of the metering passage is reduced the pressure rises again and the size of the land is increased again Pressure is regu lated by this constant balance of hydraulic and spring pressure WJ 42RE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued e SCREEN TORQUE CONVERTER OIL FILTER 21 23 Di a TO LUBRICATION 80c0713f Fig 24 Regulator Valve in Drive Position The metering at land 2 establishes the line pres sure throughout the transmission It is varied accord ing to changes in throttle position engine speed and transmission condition within a range of 57 94 psi except in reverse Fig 24 The regulated line pres sure in reverse Fig 25 is held at much higher pres sures than in the other gear positions 145 280 psi The higher pressure for reverse is achieved by the manual valve blocking the supply of line pressure to the reaction area left of land 4 With this pressure blocked there is less area for pressure to act on to balance the force of the sp
254. ers and asso ciated valve and spring one at a time Fig 105 Fig 106 Mark the combination of components as a group and tag them as to the location from which they were removed ASSEMBLY 1 Clean and inspect all components Make sure that all passages are thoroughly cleaned and are free from dirt or debris Make sure that all valves move freely in their proper bore Make sure that all gear pockets and bushings are free from excessive wear and scoring Replace the oil pump if any excessive wear or scoring is found 2 Coat the gears with Mopar ATF 43 type 7176 and install into their original locations 3 Lubricate the oil pump valves with Mopar ATF 3 type 7176 and install the valve spring and retainer into the appropriate oil pump valve body bore Fig 105 Fig 106 4 Place the separator plate onto the oil pump body Fig 104 WJ DISASSEMBLY AND ASSEMBLY Continued DRIVEN GEAR 2 SEPARATOR PLATE SCREW CHECK 45RFE TRANSMISSION 21 237 DOWEL 2 80c07012 Fig 104 Oil Pump Housing and Gears 5 Install the screws to hold the separator plate onto the oil pump body Fig 104 Tighten the screws to 4 5 N m 40 in Ibs 6 Position the oil pump cover onto the locating dowels Fig 103 7 Seat the two oil pump halves together and install all bolts finger tight 8 Torque all bolts down slowly starting in the center and working outward The correct torque is 4
255. ersal Handle C 4171 Bushing Remover SP 3633 From kit C 3887 J Seal Installer C 4193 A Remover Bushing SP 3551 Dial Caliper C 4962 Installer Bushing SP 5117 21 180 42RE AUTOMATIC TRANSMISSION SPECIAL TOOLS Continued Remover Bushing SP 5324 Installer Bushing SP 5325 Remover 6957 CO Installer 6951 Adapter C 3705 Retainer 6583 45RFE AUTOMATIC TRANSMISSION 21 181 45RFE AUTOMATIC TRANSMISSION TABLE OF CONTENTS DESCRIPTION AND OPERATION 45RFE AUTOMATIC TRANSMISSION FLUID TORQUE CONVERTER ELECTRONICALLY MODULATED CONVERTER CLUTCH ENGAGEMENT OIL PUMP mi wis Berets ei VALVE PISTONS ae baa wee E INPUT CLUTCHES dee HOLDING CLUTCHES PLANETARY GEARTRAIN GEARSHIFT MECHANISM OVERDRIVE OFF SWITCH BRAKE TRANSMISSION SHIFT INTERLOCK 5 TRANSMISSION CONTROL MODULE SOLENOID AND PRESSURE SWITCH ASSEMBLY BATTERY FEED TRANSMISSION CONTROL RELAY PRESSURE 5 5 INPUT AND OUTPUT SPEED SENSORS LINE PRESSURE CONTROL THROTTLE POSITION SENSOR TRANSMISSION RANGE SENSOR
256. es indude driver adaptive shifting and three planetary gear sets to provide wide ratio capability with precise ratio steps for optimum driveability The three planetary gear sets also make available a unique alternate second gear ratio The primary 2nd gear ratio fits between 1st and 3rd gears for normal through gear accelera tions The alternate second gear ratio 2 prime allows smoother 4 2 kickdowns at high speeds to provide 2nd gear passing performance over a wider highway cruising range The hydraulic portion of the transmission consists of the transmission fluid fluid passages hydraulic valves and various line pressure control components The primary mechanical components of the trans mission consist of the following e Three multiple disc input clutches Three multiple disc holding clutches Five hydraulic accumulators Three planetary gear sets Dual Stage Hydraulic oil pump Valve body Solenoid pack The TCM is the heart or brain of the electronic control system and relies on information from vari ous direct and indirect inputs sensors switches etc to determine driver demand and vehide operating conditions With this information the TCM can cal culate and perform timely and quality shifts through various output or control devices solenoid pack transmission control relay etc TRANSMISSION IDENTIFICATION Transmission identification numbers are stamped on the left side of the case just above the oil pan gas ket
257. esults in a cushioned band application After the kickdown servo has become immovable line pressure will finish pushing the accumulator up into its bore When the large end of the accumulator piston is seated in its bore the band or clutch is fully applied NOTE The accumulator is shown in the inverted position for illustrative purposes BOTTOMED AGAINST ACCUMULATOR PLATE LINE PRESSURE NEUTRAL AND DRIVE POSITIONS 80bfe270 Fig 48 Accumulator in Neutral and Drive Positions 42RE AUTOMATIC TRANSMISSION 21 39 FRONT SERVO ACCUMULATOR THROTTLE PLUG SECOND GEAR APPLIED 80bfe271 Fig 49 Accumulator in Second Gear Position 1 BOTTOM IN BORE 2 SHUTTLE VALVE PISTONS DESCRIPTION There are several sizes and types of pistons used in an automatic transmission Some pistons are used to apply clutches while others are used to apply bands They all have in common the fact that they are round or circular in shape located within a smooth walled cylinder which is closed at one end and converts fluid pressure into mechanical movement The fluid pres sure exerted on the piston is contained within the sys tem through the use of piston rings or seals OPERATION The principal which makes this operation possible is known as Pascal s Law Pascal s Law can be stated as Pressure on a confined fluid is transmitted equally in all directions and acts with equal force on equal areas 21 40 42RE AU
258. events transmission lever from returning to closed position cable adjustment will be necessary Throttle Valve Cable Adjustment Procedure 1 Turn ignition switch to OFF position 2 Remove air cleaner if necessary 3 Disconnect cable end from attachment stud Carefully slide cable off stud Do not pry or pull cable off 4 Verify that transmission throttle lever is in fully dosed position Then be sure lever on throttle body is at curb idle position 5 Insert small screwdriver under edge of retaining clip and remove retaining clip 6 Center cable end on attachment stud to within 1 mm 0 039 in NOTE Be sure that as the cable is pulled forward and centered on the throttle lever stud the cable housing moves smoothly with the cable Due to the angle at which the cable housing enters the spring housing the cable housing may bind slightly and create an incorrect adjustment 7 Install retaining dip onto cable housing 8 Check cable adjustment Verify transmission throttle lever and lever on throttle body move simul taneously GEARSHIFT CABLE Check adjustment by starting the engine in Park and Neutral Adjustment is OK if the engine starts only in these positions Adjustment is incorrect if the engine starts in one but not both positions If the engine starts in any position other than Park or Neu tral or if the engine will not start at all the park neutral position switch or TRS may be faulty Gearshift
259. ever and shifter assembly bracket Fig 7 8 Remove the nuts holding the shift cable seal plate to the floor pan Fig 8 9 Pull cable through floor panel opening aise CS gt Ke ARS BLE SS SUD EET B EN r STU lt lt lt yi 80ba79cd Fig 7 Transfer Case Shift Cable at Shifter 1 CLIP 2 SHIFTER 3 TRANSFER CASE SHIFT LEVER PIN 4 TRANSFER CASE SHIFT CABLE 10 Remove transfer case shift cable from vehicle INSTALLATION 1 Route cable through hole in floor pan 2 Install seal plate to studs in floor pan 3 Install nuts to hold seal plate to floor pan Fig 8 Tighten nuts to 7 N m 65 in Ibs 4 Install the transfer case shift cable to the shifter assembly bracket Seat cable in bracket and install clip Fig 7 80 79 Fig 8 Shift Cables at Floor 1 SEAL PLATES 2 TRANSMISSION SHIFT CABLE 3 TRANSFER CASE SHIFT CABLE 5 Verify the transfer case shift lever at console is in the NEUTRAL position 6 Snap the cable onto the shift lever pin Fig 7 7 Raise the vehicle 8 Install the shift cable to the shift cable support bracket and install dip Fig 6 9 Verify that the transfer case is still in the NEUTRAL position 10 Snap the shift cable onto the transfer case shift lever Fig 6 11 Lower vehide 12 Verify correct transfer case operation in all ranges 13
260. ews adjacent to the arrows cast into the bot tom of the transfer plate first 13 Position the detent spring onto the valve body 14 Install the screw to hold the detent spring onto the valve body Tighten the screw to 4 5 N m 40 in Ibs 15 Install new clutch passage seals onto the valve body if necessary OIL PUMP DISASSEMBLY 1 Remove the bolts holding the reaction shaft support to the oil pump Fig 103 2 Remove the reaction shaft support from the oil pump Fig 103 3 Remove all bolts holding the oil pump halves together Fig 103 4 Using suitable prying tools separate the oil pump sections by inserting the tools in the supplied areas and prying the halves apart NOTE The oil pump halves are aligned to each other through the use of two dowels Be sure to pry upward evenly to prevent damage to the oil pump components 21 236 45RFE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued REACTION SHAFT SUPPORT SEAL RING 5 PUMP HOUSING 80 07011 Fig 103 Oil Pump Assembly 5 Remove the screws holding the separator plate onto the oil pump body Fig 104 6 Remove the separator plate from the oil pump body Fig 104 7 Mark all gears for location The gears are select fit and if the oil pump is to be reused the gears must be returned to their original locations 8 Remove the oil pump gears from the oil pump case Fig 104 9 Remove the oil pump valve retain
261. facing upward 12 Using Remover C 4210 and Handle C 4171 drive input shaft bearing into case The bearing locating ring must be fully seated against case sur face Fig 48 13 Remove input gear pilot bearing by inserting a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer Fig 49 14 Install new pilot bearing with Installer 8128 and Handle C 4171 Fig 50 21 322 NV247 TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued J8921 219 Fig 48 Seating Input Shaft Bearing 80298364 1 SNAP RING 2 INPUT SHAFT BEARING Fig 50 Install Input Gear Pilot Bearing 1 HANDLE C 4171 2 INSTALLER 8128 3 INPUT GEAR 80211090 Fig 49 Remove Input Gear Pilot Bearing 1 DRIFT 2 INPUT GEAR J9521 41 Fig 51 Install Front Bearing Retainer Seal 15 Remove front bearing retainer seal with suit 1 FRONT BEARING RETAINER able pry tool 2 SPECIAL TOOL 7884 16 Install new front bearing retainer with Installer 7884 Fig 51 INPUT AND LOW RANGE GEAR ASSEMBLY 1 Lubricate gears and thrust washers Fig 52 with recommended transmission fluid WJ DISASSEMBLY AND ASSEMBLY Continued 2 Install first thrust washer in low range gear Fig 52 Be sure washer tabs are properly aligned in gear notches 3 Install input gear in low range gear Be sure input gear is fully seated 4
262. from ham mer Fig 43 Once seal is started continue tap ping seal into bore until installer tool bottoms against case J9321 52 HANDLE C 4171 6953 80398363 Fig 43 Front Output Seal Installation 1 INSTALLER 6952 A 2 TRANSFER CASE 7 Remove the output shaft rear bearing with the screw and jaws from Remover L 4454 and Cup 8148 Fig 44 8 Install new bearing with Tool Handle C 4171 and Installer 5066 Fig 45 The bearing bore is chamfered at the top Install the bearing so it is flush with the lower edge of this chamfer Fig 46 WJ DISASSEMBLY AND ASSEMBLY Continued 80298366 Fig 44 Output Shaft Rear Bearing Removal 1 REAR CASE 2 SPECIAL TOOL L 4454 1 AND 1 4454 3 3 SPECIAL TOOL 8148 y C 2 5 a fea fe uA ZZ oc e 80 11094 Fig 45 Output Shaft Rear Bearing Installation 1 HANDLE C 4171 2 OUTPUT SHAFT INNER BEARING 3 INSTALLER 5066 NV247 TRANSFER CASE 21 321 Fig 46 Output Shaft Rear Bearing Installation Depth 1 BEARING SEATED AT LOWER EDGE OF CHAMFER 2 CHAMFER 9 Using Remover C 4210 and Handle C 4171 drive input shaft bearing from inside the annulus gear opening in the case Fig 47 N N SSS N VN 19521 43 Fig 47 Input Shaft Bearing Removal 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL C 4210 10 Install locating ring on new bearing 11 Position case so forward end is
263. ft speed information By comparing the two inputs the TCM can deter mine transmission gear position This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur Fig 29 zu THE TCM TIMES HOW LONG IT TAKES TO COMPRESS THE CLUTCH PACK TO CHANGE THE GEAR RATIO 9 8089925 Fig 29 Example of CVI Calculation OUTPUT SPEED SENSOR OUTPUT SHAFT CLUTCH PACK SEPARATOR PLATE FRICTION DISCS INPUT SHAFT INPUT SPEED SENSOR PISTON AND SEAL Gear ratios be determined by using the DRB Scan Tool and reading the Input Output Speed Sen sor values in the Monitors display Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value For example if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm then the TCM can determine that the gear ratio is 2 1 In direct drive 3rd gear the gear ratio changes to 1 1 The gear ratio changes as clutches are applied and released By monitoring the length of time it takes for the gear ratio to change following a shift request the TCM can determine the volume of fluid used to apply or release a friction element 21 202 45RFE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued The volume of transmission fluid needed to apply the friction elements are continuously updated f
264. g 73 Transmission Filter 1 TRANSMISSION 2 FILTER nied by slipping condition or shift lag If fluid and pan are contaminated with excessive amounts or debris refer to the diagnosis section of this group Check the adjustment of the front and rear bands adjust if necessary CLEANING 1 Using a suitable solvent dean pan and mag net 2 Using a suitable gasket scraper dean gasket material from gasket surface of transmission case and the gasket flange around the pan 42RE AUTOMATIC TRANSMISSION 21 173 INSTALLATION 1 Place replacement filter in position on valve body 2 Install screws to hold filter to valve body Fig 73 Tighten screws to 4 35 in 165 torque 3 Place new gasket in position on pan and install pan on transmission 4 Place pan in position on transmission 5 Install screws to hold pan to transmission Fig 72 Tighten bolts to 17 N m 150 in Ibs torque 6 Lower vehide fill transmission with Mopar ATF Plus 3 type 7176 fluid TRANSMISSION FILL PROCEDURE To avoid overfilling transmission after a fluid change or overhaul perform the following procedure 1 Remove dipstick and insert dean funnel in transmission fill tube 2 Add following initial quantity of Mopar ATF Plus 3 to transmission a If only fluid and filter were changed add 3 pints 1 1 2 quarts of ATF Plus 3 to transmis sion b If transmission was completely overhauled torque converte
265. g material are no longer visible Inspect the servo components Replace the springs if collapsed distorted or broken Replace the guide rod and piston if cracked bent or worn Discard the servo snap ring if distorted or warped Check the servo piston bore for wear If the bore is severely scored or damaged it will be necessary to replace the case Replace any servo component if doubt exists about condition Do not reuse suspect parts REAR SERVO Remove and discard the servo piston seal ring Fig 313 Then dean the servo components with solvent and dry with compressed air Replace either spring if collapsed distorted or broken Replace the plug and piston if cracked bent or worn Discard the servo snap rings and use a new ones at assembly OIL PUMP AND REACTION SHAFT SUPPORT 1 Clean pump and support components with sol vent and dry them with compressed air 2 Check condition of the seal rings and thrust washer on the reaction shaft support The seal rings do not need to be replaced unless cracked broken or severely worn 3 Inspect the pump and support components Replace the pump or support if the seal ring grooves or machined surfaces are worn scored pitted or damaged Replace the pump gears if pitted worn chipped or damaged 4 Inspect the pump bushing Then check the reaction shaft support bushing Replace either bush ing only if heavily worn scored or damaged It is not necessary to replace the bushing
266. g rear case to front case Fig 25 Note position of the two black finish bolts at each end of the case These bolts go through the case dowels and require a washer under the bolt head 80010965 Fig 22 Remove Rear Retainer 1 MAINSHAFT 2 REAR RETAINER 8001096 Fig 23 Oil Pump Removal 1 OIL PUMP RR21F27 Fig 24 Pickup Tube O Ring Location 1 OIL PUMP 2 O RING 5 Remove rear case from front case Fig 26 Insert screwdrivers into slots cast into each end of case Then pry upward to break sealer bead and remove rear case WJ DISASSEMBLY AND ASSEMBLY Continued T ING KC A 80010969 Fig 25 Spline And Dowel Bolt Locations 1 DOWEL BOLT AND WASHER 2 2 CASE BOLT 5 3 SPLINE HEAD BOLT 1 CAUTION Do not pry on the sealing surface of either case half as the surfaces will become dam aged Fig 26 Loosening Removing Rear case MAINSHAFT SCREWDRIVER FRONT CASE SCREWDRIVER REAR CASE akon NV242 TRANSFER CASE 21 283 80010979 Fig 27 Oil Pickup Screen Hose And Tube Removal 1 CONNECTING HOSE 2 PICKUP SCREEN 3 PICKUP TUBE 800010957 Fig 28 Yoke Nut Removal 1 IMPACT WRENCH 2 5 3 YOKE 6 Remove oil pickup tube and screen from rear case Fig 27 YOKE AND RANGE LEVER 1 Remove front yoke nut a Move range lever to 4L position
267. g with Tool Han dle C 4171 and Remover C 4210 Install bearing far 19521 43 Fig 60 Input Gear Bearing Removal 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL C 4210 J8921 219 Fig 61 Seating Input Gear Bearing 1 SNAP RING 2 INPUT SHAFT BEARING 80211090 Fig 62 Remove Input Gear Pilot Bearing 1 DRIFT 2 INPUT GEAR 9 Remove the input gear pilot bearing by insert ing a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer Fig 62 10 Install new pilot bearing with Installer 8128 and Handle C 4171 Fig 63 11 Install new seal in front bearing retainer with Installer 7884 Fig 64 80a98364 Fig 63 Install Input Gear Pilot Bearing 1 HANDLE C 4171 2 INSTALLER 8128 3 INPUT GEAR 12 Remove output shaft rear bearing with the screw and jaws from Remover L 4454 and Cup 8148 Fig 65 WJ DISASSEMBLY AND ASSEMBLY Continued n NN gt 19521 41 Fig 64 Front Bearing Retainer Seal Installation 1 FRONT BEARING RETAINER 2 SPECIAL TOOL 7884 13 Install new bearing with Tool Handle C 4171 and Installer 5066 Fig 66 Lubricate bearing after installation 80298366 Fig 65 Remove Front Output Shaft Rear Bearing 1 REAR CASE 2 SPECIAL TOOL L 4454 1 AND L 4454 3 3 SPECIAL TOOL 8148 NV242 TRANSFER CASE 21 293 80a11094 Fig
268. ge is provided by the overdrive unit that contains an overdrive clutch direct clutch planetary gear set and overrunning clutch The transmission contains a front rear and direct clutch which function as the input driving compo nents They also contain the kickdown front and the low reverse rear bands which along with the over WJ REAR CLUTCH iy Rp ERE 158 PLANETARY GEARTRAIN 158 OVERDRIVE 0 158 ADJUSTMENTS BRAKE TRANSMISSION SHIFT INTERLOCK 159 TRANSMISSION THROTTLE VALVE CABLE 159 GEARSHIFT 161 BAND 5 162 VALVE 162 SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS 164 SPECIFICATIONS 5 176 SPECIAL TOOLS RE 5 5 177 running clutch and overdrive clutch serve as the holding components The driving and holding compo nents combine to select the necessary planetary gear components in the front rear or overdrive planetary gear set transfer the engine power from the input shaft through to the output shaft The valve body is mounted to the lower side of the transmission and contains the valves to control pres sure regulation fluid flow control and clutch band application The oil pump is mounted at the f
269. gins to match the speed of the impeller the fluid that was hitting the stator in such as way as to cause it to lock up is no longer doing so In this con dition of operation the stator begins to free wheel and the converter acts as a fluid coupling FLOW IS MORE NEARLY STRAIGHT THROUGH ANGLE IS LESS lt 3 AT STALL CRUISE Fig 16 Stator Operation 1 DIRECTION STATOR WILL FREE WHEEL DUE TO OIL PUSHING ON BACKSIDE OF VANES 2 FRONT OF ENGINE INCREASED ANGLE AS OIL STRIKES VANES 4 DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING AGAINST STATOR VANES 80bfe26e 21 16 42RE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued TORQUE CONVERTER CLUTCH TCC In a standard torque converter the impeller and turbine are rotating at about the same speed and the stator is freewheeling providing no torque multipli cation By applying the turbine s piston to the front cover s friction material a total converter engage ment can be obtained The result of this engagement is a direc 1 1 mechanical link between the engine and the transmission Converter dutch engagement in third or fourth gear range is controlled by sensor inputs to the pow ertrain control module Inputs that determine clutch engagement are coolant temperature engine rpm vehide speed throttle position and manifold vac uum The torque converter dutch is engaged by the dutch solenoid on the valve body T
270. gn governor feed holes in gasket with feed pas sages in case Fig 202 Also install gasket before overdrive piston retainer Center hole in gasket is smaller than retainer and cannot be installed over retainer 7 Position overdrive piston retainer on transmis sion case and align bolt holes in retainer gasket and case Fig 203 Then install and tighten retainer bolts to 17 13 ft Ibs torque 8 Install new seals on over drive piston 9 Stand transmission case upright on bellhousing 21 122 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued S o be J9121 349 Fig 202 Installing Aligning Case Gasket 1 CASE GASKET 2 BE SURE GOVERNOR TUBE FEED HOLES IN CASE AND GASKET ARE ALIGNED gt lt gt SSS 52 gt SS LI 19321 464 Fig 203 Aligning Overdrive Piston Retainer 1 PISTON RETAINER 2 GASKET 3 RETAINER BOLTS WJ 10 Position Guide Ring 8114 1 on outer edge of overdrive piston retainer 11 Position Seal Guide 8114 2 on inner edge of overdrive piston retainer 12 Install 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 Mopar Door Ease or equivalent c Insta
271. gs on governor pressure sole noid and sensor 3 Lubricate solenoid and sensor O rings with dean transmission fluid 4 Install governor pressure sensor in governor body 5 Install governor pressure solenoid in governor body Push solenoid in until it snaps into place in body 6 Position governor plate body gasket on transfer Fig 156 Solenoid Harness Case Connector Shoulder Bolt 1 SOLENOID HARNESS CASE CONNECTOR 2 3 4 ACCUMULATOR HOUSING 4 E AO J J9321 458 Fig 157 Solenoid Harness Routing 1 OVERDRIVE CONVERTER SOLENOID WIRE HARNESS 2 3 4 ACCUMULATOR COVER PLATE 7 Install retainer plate on governor body and around solenoid Be sure solenoid connector is posi tioned in retainer cutout 8 Align screw holes in governor body and trans fer plate Then install and tighten governor body screws to 4 N m 35 16 torque 9 Connect harness wires to governor pressure solenoid and governor pressure sensor 10 Install fluid filter and pan 11 Lower vehide 12 Fill transmission with recommended fluid and road test vehicle to verify repair WJ DISASSEMBLY AND ASSEMBLY Continued TRANSMISSION DISASSEM BLY 1 Clean transmission exterior with steam gun or with solvent Wear eye protection during cleaning operations 2 Place transmission in a vertical position 3 Measure and record input shaft end play read ings 4 Remove shift and thr
272. h ATF 43 type 7176 Auto matic Transmission Fluid 1 Disconnect the To cooler line at the cooler inlet and place a collecting container under the dis connected line CAUTION With the fluid set at the proper level fluid collection should not exceed 1 quart or inter nal damage to the transmission may occur 2 Run the engine at curb idle speed with the shift selector in neutral 3 one quart of transmission fluid is collected in the container in 20 seconds or less oil pump flow vol WJ ume is within acceptable limits If fluid flow is inter mittent or it takes more than 20 seconds to collect one quart of fluid refer to the Hydraulic Pressure tests in this section for further diagnosis 4 Re connect the To cooler line to the transmis sion cooler inlet 5 Refill the transmission to proper level FLUSHING COOLERS AND TUBES When a transmission failure has contaminated the fluid the oil cooler s must be flushed The torque converter must also be replaced This will insure that metal partides or sludged oil are not later trans ferred back into the reconditioned or replaced trans mission The only recommended procedure for flushing cool ers and lines is to use Tool 6906A Cooler Flusher WARNING WEAR PROTECTIVE EYEWEAR THAT MEETS THE REQUIREMENTS OF OSHA AND ANSI 287 1 1968 WEAR STANDARD INDUSTRIAL RUB BER GLOVES KEEP LIGHTED CIGARETTES SPARKS FLAMES AND OTHER IGNITION SOURCES AWA
273. has circulated through the transmission for some time an overhaul may also be necessary especially if shift problems had developed WJ The transmission cooler and lines should be reverse flushed whenever a malfunction generates sludge and or debris The torque converter should also be replaced at the same time Failure to flush the cooler and lines will result in recontamination Flushing applies to auxiliary cool ers as well The torque converter should also be replaced whenever a failure generates sludge and debris This is necessary because normal converter flushing procedures will not remove all contami nants 45RFE AUTOMATIC TRANSMISSION GENERAL DIAGNOSIS CAUTION Before attempting any repair on a 45RFE automatic transmission check for Diagnostic Trou ble Codes with the DRB scan tool Transmission malfunctions may be caused by these general conditions Poor engine performance e Improper adjustments e Hydraulic malfunctions e Mechanical malfunctions e Electronic malfunctions Diagnosis of these problems should always begin by checking the easily accessible variables fluid level and condition gearshift cable adjustment Then per form a road test to determine if the problem has been corrected or if more diagnosis is necessary If the problem persists after the preliminary tests and cor rections are completed hydraulic pressure checks should be performed PRELIMINARY DIAGNOSIS Two basic procedures are requ
274. he PCM uses a temperature sensor in the transmission oil sump to determine when low temperature gover nor pressure is needed NORMAL OPERATION Normal operation is refined through the increased computing power of the PCM and through access to data on engine operating conditions provided by the PCM that were not available with the previous stand alone electronic module This facilitated the development of a load adaptive shift strategy the ability to alter the shift schedule in response to vehi cle load condition One manifestation of this capabil ity is grade hunting prevention the ability of the transmission logic to delay an upshift on a grade if the engine does not have sufficient power to main tain speed in the higher gear The 3 2 downshift and WJ DESCRIPTION AND OPERATION Continued the potential for hunting between gears occurs with a heavily loaded vehicle or on steep grades When hunting occurs it is very objectionable because shifts are frequent and accompanied by large changes in noise and acceleration WIDE OPEN THROTTLE OPERATION In wide open throttle WOT mode adaptive mem ory in the PCM assures that up shifts occur at the preprogrammed optimum speed WOT operation is determined from the throttle position sensor which is also a part of the emission control system The ini tial setting for the WOT upshift is below the opti mum engine speed As WOT shifts are repeated the PCM learns the time require
275. he clutch can be engaged in third and fourth gear ranges depending on overdrive control switch position If the overdrive control switch is the normal ON position the dutch will engage after the shift to fourth gear and above approximately 72 km h 45 mph If the control switch is in the OFF position the dutch will engage after the shift to third gear at approximately 56 km h 35 mph at light throttle OIL PUMP DESCRIPTION The oil pump Fig 17 is located in the pump hous ing inside the bell housing of the transmission case The oil pump consists of an inner and outer gear a housing and a cover that also serves as the reaction shaft support 80be45f7 Fig 17 Oil Pump Assembly 1 OIL SEAL 2 OIL PUMP BODY 3 VENT 4 REACTION SHAFT SUPPORT 5 INNER ROTOR 6 OUTER ROTOR 7 O RING OPERATION As the torque converter rotates the converter hub rotates the inner and outer gears As the gears rotate the clearance between the gear teeth increases in the crescent area and creates a suction at the inlet side of the pump This suction draws fluid through the pump inlet from the oil pan As the clearance between the gear teeth in the crescent area decreases it forces pressurized fluid into the pump outlet and to the valve body WJ DESCRIPTION AND OPERATION Continued 42RE TRANSMISSION 21 17 J9321 155 Fig 18 Upper Housing Control Valve Locations 8
276. he left side of the case just above the oil pan gas ket surface Fig 2 Refer to this information when ordering replacement parts 80b11960 Fig 2 Transmission Part And Serial Number Location 1 PART NUMBER 2 BUILD DATE 3 SERIAL NUMBER GEAR RATIOS The 42RE gear ratios are Ast 2743 2nd 1 54 1 1 00 1 4th 0 69 1 Rev 2 21 OPERATION The application of each driving or holding compo nent is controlled by the valve body based upon the manual lever position and governor pressure The governor pressure is a variable pressure input to the valve body and is one of the signals that a shift is necessary First through fourth gear are obtained by selectively applying and releasing the different clutches and bands Engine power is thereby routed to the various planetary gear assemblies which com bine with the overrunning clutch assemblies to gen erate the different gear ratios The torque converter dutch is hydraulically applied and is released when fluid is vented from the hydraulic circuit by the torque converter control TCC solenoid on the valve body The torque converter dutch is controlled by the Powertrain Control Module PCM The torque con verter dutch engages in fourth gear and in third gear when the O D switch is OFF when the vehide is cruising on a level plane after the vehide has warmed up The torque converter dutch will disen gage momentarily when an increase in engine load is
277. he shift cable support bracket and install clip Fig 11 9 Verify that the transfer case is still in the NEUTRAL position 10 Snap the shift cable onto the transfer case shift lever Fig 11 11 Lower vehicle 12 Verify correct transfer case operation in all ranges 13 Install shift lever bezel and any console parts removed for access to transfer case shift cable DISASSEMBLY AND ASSEMBLY NV242 TRANSFER CASE DISASSEMBLY NV242LD REAR RETAINER 1 Remove output shaft boot Spread band damp that secures boot on slinger with a suitable awl Then slide boot off shaft Fig 14 2 Using puller M D 998056 A remove rear slinger Fig 15 3 Remove rear seal from retainer Fig 16 Use pry tool or collapse seal with punch to remove it 4 Remove rear output bearing I D retaining ring Fig 17 5 Remove speedometer adapter 6 Remove rear retainer bolts f NN 80250351 Fig 14 Output Boot Typical 1 SLINGER 2 BOOT 3 AWL 4 TRANSFER CASE gel 7 oS Fig 15 Rear Slinger Removal 1 TRANSFER CASE 2 SPECIAL TOOL 0998056 3 SLINGER 80250352 7 Remove rear retainer Tap retainer with mallet and pry upward to break sealer bead Then slide retainer off case and output shaft Fig 18 NV242HD REAR RETAINER 1 Remove extension housing bolts 2 Tap extension housing with plastic or rawhide mallet to loosen sealer Fig 19 3 Separate extension housing
278. his type of operation Trailer tow ing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped Such vehicles should have an auxiliary transmission fluid cooler a heavy duty cooling sys tem and the engine axle ratio combination needed to handle heavy loads FLUID CONTAMINATION Transmission fluid contamination is generally a result of e adding incorrect fluid failure to dean dipstick and fill tube when checking level e engine coolant entering the fluid internal failure that generates debris overheat that generates sludge fluid break down e failure to reverse flush cooler and lines after repair failure to replace contaminated converter after repair The use of non recommended fluids can result in transmission failure The usual results are erratic shifts slippage abnormal wear and eventual failure due to fluid breakdown and sludge formation Avoid this condition by using recommended fluids only The dipstick cap and fill tube should be wiped dean before checking fluid level Dirt grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand Take the time to wipe the cap and tube dean before withdraw ing the dipstick Engine coolant in the transmission fluid is gener ally caused by a cooler malfunction The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part If coolant
279. ible in any other gear position 3 With floor shift lever handle push button not depressed and lever in a PARK position Apply forward force on cen ter of handle and remove pressure Engine starts must be possible b PARK position Apply rearward force on ter of handle and remove pressure Engine starts must be possible NEUTRAL position N ormal position Engine starts must be possible d NEUTRAL position Engine running and brakes applied apply forward force on center of shift handle Transmission shall not be able to shift from neutral to reverse THROTTLE VALVE CABLE Transmission throttle valve cable adjustment is extremely important to proper operation This adjust ment positions the throttle valve which controls shift speed quality and part throttle downshift sensitivity If cable setting is too loose early shifts and slip page between shifts may occur If the setting is too tight shifts may be delayed and part throttle down shifts may be very sensitive Refer to the Adjust ments section for the proper adjustment procedure ROAD TESTING Before road testing be sure the fluid level and con cable adjustments have been checked and adjusted if necessary Verify that diagnostic trouble codes have been resolved Observe engine performance during the road test A poorly tuned engine will not allow accurate analy sis of transmission operation Operate the transmission in all gear ranges
280. icate transmission parts with Plus 3 Type 7176 transmission fluid during over haul and assembly Use petroleum jelly Door Ease or Ru Glyde to prelubricate seals O rings and thrust washers Petroleum jelly can also be used to hold parts in place during reassembly TRANSMISSION CASE CLEANING AND INSPECTION Clean the case in a solvent tank Flush the case bores and fluid passages thoroughly with solvent Dry the case and all fluid passages with compressed air Be sure all solvent is removed from the case and that all fluid passages are dear NOTE Do not use shop towels or rags to dry the case or any other transmission component unless they are made from lint free materials Lint will stick to case surfaces and transmission components and circulate throughout the transmission after assem bly A sufficient quantity of lint can block fluid pas sages and interfere with valve body operation Inspect the case for cracks porous spots worn bores or damaged threads Damaged threads can be repaired with Helicoil thread inserts However the case will have to be replaced if it exhibits any type of damage or wear WJ CLEANING AND INSPECTION Continued LOW REVERSE CLUTCH ASSEMBLY Clean the overrunning clutch assembly clutch cam and low reverse dutch retainer Dry them with com pressed air after cleaning Inspect condition of each dutch part after cleaning Replace the overrunning dutch roller and s
281. icking cross leakage and unsatisfactory operation Tighten valve body screws to recom mended torque only LOWER HOUSING 1 Lubricate valves springs and the housing valve and plug bores with clean transmission fluid Fig 137 WJ 2 Install 3 4 timing valve spring and valve in lower housing 3 Install 3 4 quick fill valve in lower housing 4 Install 3 4 quick fill valve spring and plug in housing 5 Install timing valve end plate Tighten end plate screws to 4 N m 35 in Ibs torque 3 4 ACCUMULATOR 1 Lubricate accumulator piston seals and hous ing piston bore with clean transmission fluid Fig 138 2 Install new seal rings on accumulator piston 3 Install piston and spring in housing 4 Install end plate on housing TRANSFER PLATE 1 Install rear clutch and rear servo check balls in transfer plate Fig 139 2 Install filter screen in upper housing separator plate Fig 140 3 Align and position upper housing separator plate on transfer plate Fig 141 4 Install brace plate Fig 141 Tighten brace attaching screws to 4 N m 35 in Ibs torque 5 Install remaining separator plate attaching screws Tighten screws to 4 N m 35 in 165 torque J9321 437 Fig 139 Rear Clutch And Rear Servo Check Ball Locations 1 REAR CLUTCH CHECK BALL 2 REAR SERVO CHECK BALL 3 TRANSFER PLATE WJ DISASSEMBLY AND ASSEMBLY Continued Fig 140 Separator Plate Filter
282. id plate if equipped Fig 4 CROSSMEMBER TRANSMISSION MOUNT y 24 80 79 7 Fig 4 Crossmember Removal Installation 7 Disconnec front rear propeller shafts at trans fer case Refer to Group 3 Differential and Driveline for the correct procedures 8 Disconnect transfer case cable from range lever 9 Disconnect transfer case vent hose Fig 5 and indicator switch harness if necessary 10 Support transfer case with transmission jack 11 Secure transfer case to jack with chains 4 Correct as necessary 12 Remove nuts attaching transfer case to trans mission 13 Pull transfer case and jack rearward to disen gage transfer case 14 Remove transfer case from under vehide TRANSFER CASE 45RFE 80ba79c8 Fig 5 Transfer Case Mounting INSTALLATION 1 Mount transfer case on a transmission jack 2 Secure transfer case to jack with chains 3 Position transfer case under vehicle 4 Align transfer case and transmission shafts and install transfer case on transmission 5 Install and tighten transfer case attaching nuts to 35 N m 26 ft Ibs torque Fig 5 6 Align and connect propeller shafts Refer to Group 3 Differential and Driveline for proper proce dures and specifications 7 Fill transfer case with correct fluid Check transmission fluid level Correct as necessary 8 Install rear crossmember and skid plate if equipped Tighten crossmember bolts to 41
283. ifter operation WJ REMOVAL AND INSTALLATION Continued 16 Install shift lever bezel and any console parts removed for access to shift lever assembly and shift cable SHIFTER REMOVAL 1 Shift transmission into Park 2 Remove shift lever bezel and any necessary console parts for access to shift lever assembly and shifter cables 3 Disconnec the transmission shift cable at shift lever and shifter assembly bracket Fig 57 4 Disconnect the brake transmission interlock cable from the shifter BTSI lever and the shifter assembly bracket 5 Disconnect the transfer case shift cable from the transfer case shift lever pin Fig 59 Remove the clip holding the transfer case shift cable to the shifter assembly bracket 7 Remove the transfer case shift cable from the shifter assembly bracket 8 Disengage all wiring connectors from the shifter assembly 9 Remove all nuts holding the shifter assembly to the floor pan Fig 60 45RFE AUTOMATIC TRANSMISSION 21 221 80ba79cb Fig 57 Transmission Shift Cable at Shifter 1 SHIFT LEVER PIN 2 ADJUSTMENT SCREW 3 SHIFT CABLE 4 SHIFTER ASSEMBLY BRACKET 10 Remove the shifter assembly from the vehicle INSTALLATION 1 Install shifter assembly onto the shifter assem bly studs on the floor pan 80ba79c2 Fig 58 Brake Transmission Interlock Cable 4 STEERING COLUMN ASSEMBLY 5 INTERLOCK CABLE 1 SHIFT MECHA
284. inding worn or damaged 1 Insufficient or incorrect lubricant 1 Transfer case not completely engaged in 4WD LOW possibly from shift to 4L while rolling 2 Shift linkage loose binding or is misadjusted 3 Range fork cracked inserts worn or fork is binding on shift rail 4 Annulus gear or lockplate worn or damaged 1 Transfer case over filled 2 Vent closed or restricted 3 Output shaft seals damaged or installed correctly CORRECTION 1 Reduce speed to 3 4 km h 2 3 mph before attempting to shift 2 Lubricate repair or replace cable or thighten loose components as necessary 3 Drain and refill to edge of fill hole with correct lubricant 4 Disassemble unit and replace worn or damaged components as necessary 1 Drain and refill to edge of fill hole with correct lubricant If unit is still noisy after drain and refill disassembly and inspection may be required to locate source of noise 1 Stop vehicle shift transfer case to neutral then shift back to 4WD LOW 2 Tighten lubricate or repair linkage as necessary Adjust linkage if necessary 3 Disassemble unit and repair as necessary 4 Disassemble unit and repair as necessary 1 Drain to correct level 2 Clear or replace vent if necessary 3 Replace seals Be sure seal lip faces interior of case when installed Also be sure yoke seal surfaces are not scored or nicked Remove scores and nicks with fine sandpaper or replace yoke s
285. ine and bell housing 3 Valve Body Misassembled 3 Remove disassemble inspect valve body Reassemble correctly if necessary Replace assembly if valves or springs are damaged Check for loose bolts or screws 4 Pump Passages Leaking 4 Check pump for porous casting scores on mating surfaces and excess rotor clearance Repair as required Loose pump bolts 5 Cooling System Cooler Plugged 5 Flow check cooler circuit Repair as needed SLIPS IN REVERSE ONLY 5 Overdrive Direct Clutch Worn 5 Disassemble overdrive Repair as needed 6 Hydraulic Pressure Too Low 6 Perform hydraulic pressure tests to determine cause 7 Rear Servo Leaking 7 Air pressure check clutch servo operation 4 Rear Band Worn 4 Replace as required and repair as required 8 Band Linkage Binding 8 Inspect and repair as required 21 66 42RE AUTOMATIC TRANSMISSION v n s W DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION SLIPS IN FORWARD 1 Fluid Level Low 1 Add fluid and check for leaks DRIVE RANGES 2 Fluid Foaming 2 Check for high oil level bad pump gasket or seals dirt between pump halves and loose pump bolts Replace pump if necessary 3 Throttle Linkage Misadjusted 3 Adjust linkage 4 Gearshift Linkage Misadjusted 4 Adjust linkage 5 Rear Clutch Worn 5 Inspect and replace as needed 6 Low Hydraulic Pressure Due to 6 Perform hydraulic and air pressure tests
286. ing over haul and assembly Use petroleum jelly Mopar Door Ease or Ru Glyde to prelubricate seals O rings and thrust washers Petroleum jelly can also be used to hold parts in place during reassembly TRANSMISSION CASE CLEANING AND INSPECTION Clean the case in a solvent tank Flush the case bores and fluid passages thoroughly with solvent 21 156 42RE AUTOMATIC TRANSMISSION CLEANING AND INSPECTION Continued Dry the case and all fluid passages with compressed air Be sure all solvent is removed from the case and that all fluid passages are clear NOTE Do not use shop towels or rags to dry the case or any other transmission component unless they are made from lint free materials Lint will stick to case surfaces and transmission components and circulate throughout the transmission after assem bly A sufficient quantity of lint can block fluid pas sages and interfere with valve body operation Inspect the case for cracks porous spots worn bores or damaged threads Damaged threads can be repaired with Helicoil thread inserts However the case will have to be replaced if it exhibits any type of damage or wear Lubricate the front band adjusting screw threads with petroleum jelly and thread the screw part way into the case Be sure the screw turns freely OVERRUNNING CLUTCH LOW REVERSE DRUM OVERDRIVE PISTON RETAINER Clean the overrunning clutch assembly clutch cam low reverse drum and overdrive piston retainer in
287. input to the TCM The line pressure solenoid moni tors the transmission line pressure and completes the feedback loop to the TCM The TCM uses this infor mation to adjust its control of the pressure control solenoid to achieve the desired line pressure OPERATION The TCM calculates the desired line pressure based upon inputs from the transmission and engine The TCM calculates the torque input to the trans mission and uses that information as the primary WJ input to the calculation The line pressure is set to a predetermined value during shifts and when the transmission is in the PARK and NEUTRAL posi tions This is done to ensure consistent shift quality During all other operation the actual line pressure is compared to the desired line pressure and adjust ments are made to the pressure control solenoid duty cycle THROTTLE POSITION SENSOR OPERATION The Transmission Control Module TCM receives the throttle position signal and its ground from the Throttle Position Sensor TPS The TPS has a 5 volt pull up supplied by the engine controller The throt tle signal is checked by the TCM for out of range as well as intermittence excessive signal changes TRANSMISSION RANGE SENSOR DESCRIPTION The Transmission Range Sensor TRS is mounted to the top of the valve body inside the transmission The Transmission Range Sensor TRS has six switch contacts that Determine shift lever position Supply ground to the St
288. inued 1 DIRECT CLUTCH DISCS 6 CLUTCH PLATES 5 J9321 368 Fig 292 42RE Direct Clutch Pack Components 1 REACTION PLATE 2 PRESSURE PLATE 18 Assemble and install direct clutch pack on c Install first dutch disc followed by a steel hub as follows plate until all discs and plates have been installed a Assemble clutch pack components Fig 292 b Install direct clutch reaction plate on clutch hub first Note that one side of reaction plate is counterbored Be sure this side faces rear ward Splines at rear of hub are raised Install pressure plate This is last dutch pack item to be installed Be sure plate is installed with shoulder side facing upward Fig 294 19 Install dutch hub and dutch pack on direct slightly Counterbore in plate fits over raised splines Plate should be flush with this end of hub Fig 293 dutch spring Fig 295 Be sure hub is started on sun gear splines before proceeding 1 2 AUTOMATIC TRANSMISSION 21 149 DISASSEMBLY AND ASSEMBLY Continued 19121 330 Fig 294 Correct Position Of Direct Clutch Pressure Plate 1 DIRECT CLUTCH PRESSURE PLATE 2 CLUTCH PACK 3 BE SURE SHOULDER SIDE OF PLATE FACES UPWARD 19121 329 Fig 293 Correct Position Of Direct Clutch Reaction Plate 1 REACTION PLATE COUNTERBORE 2 CLUTCH REACTION PLATE FLUSH WITH END OF 3 CLUT
289. ion and repair as required 3 Front or Rear Band Misadjusted 3 Adjust bands 4 Case Leaks Internally 4 Check for leakage between passages in case 5 Servo Band or Linkage 5 Air pressure check servo operation and Malfunction repair as required 6 Overrunning Clutch Worn 6 Remove and inspect clutch Repair as required 7 Planetary Gears Broken 7 Remove inspect and repair as required look for debris in oil pan 8 Converter Clutch Dragging 8 Check for plugged cooler Perform flow check Inspect pump for excessive side clearance Replace pump as required NO 4 3 DOWNSHIFT 1 Circuit Wiring and or Connectors 1 Test wiring and connectors with test lamp Shorted and volt ohmmeter Repair wiring as necessary Replace connectors and or harnesses as required 2 Malfunction 2 Check PCM operation with DRB scan tool Replace PCM only if faulty 4 Lockup Solenoid Not Venting 4 Remove valve body and replace solenoid assembly if plugged or shorted 5 Overdrive Solenoid Not Venting 5 Remove valve body and replace solenoid if plugged or shorted 6 Valve Body Valve Sticking 6 Repair stuck 3 4 shift valve or lockup timing valve NO 4 3 DOWNSHIFT 1 Control Switch Open Shorted 1 Test and replace switch if faulty WHEN CONTROL SWITCH 3 TPS Malfunction 3 Check TPS with DRB scan tool at PCM IS TURNED OFF 2 Overdrive Solenoid Connector 2 Test solenoids and replace if seized or Shorted shorted 3 PC
290. ion or shift lag If fluid and pan are contaminated with excessive amounts or debris refer to the diagnosis section of this group CLEANING 1 Using a suitable solvent dean pan and mag net 2 Using a suitable gasket scraper dean original sealing material from surface of transmission case and the transmission pan INSTALLATION 1 Install a new oil filter seal into the bottom of the oi pump NOTE Do not attempt to install the seal onto the oil filter first and then into the oil pump An unsat isfactory seal between the oil pump and filter will result allowing air to be drawn into the pump 2 Place replacement filter in position on valve body and into the oil pump 3 Install screws to hold filter to valve body Fig 37 Tighten screws to 4 5 N m 40 in Ibs torque 4 Install new cooler return filter onto the trans mission Torque the filter to 14 12 125 in Ibs 5 Place bead of Mopar RTV sealant onto the transmission case sealing surface 6 Place pan in position on transmission 7 Install screws to hold pan to transmission Tighten bolts to 11 8 N m 105 in Ibs torque 8 Lower vehide fill transmission with Mopar ATF Plus 3 type 7176 fluid TRANSMISSION FILL PROCEDURE To avoid overfilling transmission after a fluid change or overhaul perform the following procedure 1 Remove dipstick and insert dean funnel in transmission fill tube 2 Add following initial quantity of
291. ired Body Malfunction or Incorrect Correct valve body pressure adjustments as Hydraulic Control Pressure required Adjustments 4 Governor Circuit Electrical Fault 4 Test with DRB scan tool and repair as required 5 Valve Body Malfunction 5 Perform hydraulic pressure tests to determine cause and repair as required Correct valve body pressure adjustments as required 6 TPS Malfunction 6 Replace sensor check with DRB scan tool 7 Malfunction 7 Check with DRB scan tool and replace if required 8 Valve Body Malfunction 8 Repair sticking 1 2 2 3 shift valves governor plugs 3 4 solenoid 3 4 shift valve 3 4 timing valve STUCK IN LOW GEAR 1 Throttle Linkage Misadjusted 1 Adjust linkage and repair linkage if worn WILL NOT UPSHIFT Stuck or damaged Check for binding cable or missing return spring 2 Gearshift Linkage Misadjusted 2 Adjust linkage and repair linkage if worn or damaged 3 Governor Component Electrical 3 Check operating pressures and test with Fault DRB scan tool repair faulty component 4 Front Band Out of Adjustment 4 Adjust Band 5 Clutch or Servo Malfunction 5 Air pressure check operation of clutches and bands Repair faulty component WJ 2 AUTOMATIC TRANSMISSION 21 65 DIAGNOSIS AND TESTING Continued OREEPS IN NEUTRAL determine cause and repair as required BUZZING NOISE 2 Shift Cable Misassembled 2 Route cable away from eng
292. ired One procedure for vehicles that are drivable and an alternate proce dure for disabled vehicles will not back up or move forward VEHICLE IS DRIVABLE 1 Check for transmission fault codes using DRB scan tool 2 Check fluid level and condition 3 Adjust gearshift cable if complaint was based on delayed erratic or harsh shifts 4 Road test and note how transmission upshifts downshifts and engages 5 Perform stall test if complaint is based on slug gish acceleration Or if abnormal throttle opening is needed to maintain normal speeds with a properly tuned engine 6 Perform hydraulic pressure test if shift prob lems were noted during road test WJ DIAGNOSIS AND TESTING Continued 7 Perform air pressure test to check clutch oper ation VEHICLE IS DISABLED 1 Check fluid level and condition 2 Check for broken or disconnected gearshift cable 3 Check for cracked leaking cooler lines or loose or missing pressure port plugs 4 Raise and support vehicle on safety stands start engine shift transmission into gear and note following If propeller shaft turns but wheels do not problem is with differential or axle shafts b If propeller shaft does not turn and transmis sion is noisy stop engine Remove oil pan and check for debris If pan is dear remove transmis sion and check for damaged driveplate converter oil pump or input shaft If propeller shaft does not turn and
293. is serviced as an assembly CAUTION The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid If the fluid is contaminated flush the fluid cooler and lines 5 80007135 Fig 9 Torque Converter Assembly 1 TURBINE 2 IMPELLER 3 HUB 4 STATOR 5 FRONT COVER 6 CONVERTER CLUTCH DISC 7 DRIVE PLATE 21 12 42RE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued 2 IMPELLER VANE CONSTRUCTION AND CURVATURE 80bfe26a Fig 10 Impeller 1 ENGINE FLEXPLATE 4 ENGINE ROTATION 2 OIL FLOW FROM IMPELLER SECTION INTO TURBINE 5 ENGINE ROTATION SECTION 3 IMPELLER VANES AND COVER ARE INTEGRAL IMPELLER The impeller Fig 10 is an integral part of the converter housing The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter As the con verter housing is rotated by the engine so is the impeller because they are one and the same and are the driving member of the system WJ 2 2 AUTOMATIC TRANSMISSION 21 13 DESCRIPTION AND OPERATION Continued 9 BLADE CONSTRUCTION S0bfe26b Fig 11 Turbine 1 TUR
294. ism is required to complete the 3 4 shift The fourth gear upshift occurs automatically when the overdrive selector switch is in the ON position No upshift to fourth gear will occur if any of the fol lowing are true e The transmission fluid temperature is below 10 50 F or above 121 C 250 F The shift to third is not yet complete e Vehide speed is too low for the 3 4 shift to occur e Battery temperature is below 5 23 F CONVERTER DRAINBACK VALVE DESCRIPTION The drainback valve is located in the transmission cooler outlet pressure line OPERATION The valve prevents fluid from draining from the converter into the cooler and lines when the vehicle is shut down for lengthy periods Production valves have a hose nipple at one end while the opposite end is threaded for a flare fitting All valves have an arrow or similar mark to indicate direction of flow through the valve POWERTRAIN CONTROL MODULE DESCRIPTION The Powertrain Control Module PCM is located in the engine compartment Fig 62 The PCM is referred to as J TEC OPERATION 1 Also refer to Modes of Operation The PCM operates the fuel system The PCM isa pre programmed triple microprocessor digital com puter It regulates ignition timing air fuel ratio emission control devices charging system certain transmission features speed control air conditioning compressor clutch engagement and idle speed The PCM can adap
295. iston Line pressure through the timing valve moves the overdrive piston into contact with the overdrive dutch The direct dutch is disengaged before the overdrive dutch is engaged The boost valve provides increased fluid apply pressure to the overdrive dutch during 3 4 upshifts and when accel erating in fourth gear The 3 4 accumulator cushions overdrive clutch engagement to smooth 3 4 upshifts The accumulator is charged at the same time as apply pressure acts against the overdrive piston RECOMMENDED FLUID NOTE Refer to the Service Procedures section of this Group for fluid level checking procedures FLUID TYPE Mopar ATF Plus 3 Type 7176 automatic trans mission fluid is the recommended fluid for Chrysler automatic transmissions Dexron fluid 15 NOT recommended Clutch chatter can result from the use of improper fluid FLUID ADDITIVES Fluid additives other than approved fluo rescent leak detection dyes are not to be used in this transmission FLUID NOTE Refer to the maintenance schedules in Group 0 Lubrication and Maintenance for the rec WJ ommended maintenance fluid filter change inter vals for this transmission NOTE Refer to Service Procedures in this group for fluid level checking procedures DESCRIPTION Mopar ATF Plus 3 Type 7176 automatic trans mission fluid is the recommended fluid for Daimler Chrysler automatic transmissions Dexron fluid 15 NOT recommended Clut
296. itch park neutral 34 N m 25 ft Ibs Bolt fluid 17 N m 13 ft Ibs Screws fluid filter 4 N m 35 in Ibs Bolt oil pump 20 N m 15 ft Ibs Bolt overrunning clutch cam 17 N m 13 ft Ibs Bolt O D totrans 34 N m 25 ft Ibs Bolt O D piston retainer 17 N m 13 ft Ibs Plug pressure test port 14 N m 10 ft Ibs Bolt reaction shaft support 20 15 ft Ibs Locknut rear band 41 N m 30 ft 165 Bolt speedometer adapter 11 N m 8 ft Ibs Bolt valve body tocase 12 N m 100 in 165 Sensor trans speed 27 N m 20 ft Ibs Screw solenoid wiring connector 4 N m 35 in Ibs Screw solenoid to transfer plate 4 N m 35 in Ibs 2 AUTOMATIC TRANSMISSION 21 177 SPECIFICATIONS Continued THRUST WASHER SPACER SNAP RING DIMENSIONS Front clutch thrust washer reaction shaft 1 55 mm 0 061 in support hub Rear clutch thrust washer clutch retainer 0 061 in Intermediate shaft thrust plate shaft hub pilot 1 5 1 6 mm 0 060 0 063 in Output shaft thrust washer rear clutch hub Select fit to set end play Rear clutch pack snap ring 0 060 in 0 076 in 0 098 in Planetary geartrain snap ring at front of output shaft Select fit three thicknesses avalible Overdrive piston thrust plate Thrust plate and spacer are select fit Refer to
297. k gear and shaft J9121 292 Fig 275 Clutch Drum Inner Retaining Ring Removal 1 INNER RETAINING RING 2 DIRECT CLUTCH DRUM 3 ANNULUS GEAR 9221 46 Fig 277 Marking Annulus Gear Output Shaft For Assembly Alignment 1 OUTPUT SHAFT 2 HAMMER 3 PUNCH 21 144 42 AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued 10 Remove snap ring that secures annulus gear on output shaft Fig 278 Use two screwdrivers to unseat and work snap ring out of groove as shown 11 Remove annulus gear from output shaft Fig 279 Use rawhide or plastic mallet to tap gear off shaft J9321 448 Fig 278 Annulus Gear Snap Ring Removal 1 OUTPUT SHAFT 2 ANNULUS GEAR 3 SNAP RING J9021 288 Fig 279 Annulus Gear Removal 1 OUTPUT SHAFT 2 ANNULUS GEAR GEAR CASE AND PARK LOCK DISASSEM BLY 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 ASSEMBLY GEARTRAIN AND DIRECT CLUTCH ASSEMBLY 1 Soak direct clutch and overdrive clutch discs in Mopar ATF Plus 3 type 7176 transmission fluid Allow discs to soak for 10 20 minutes 2 Install new pilot bushing and dutch hub bush ing in output shaft if necessary Fig 280 Lubricate bushings with petroleum jelly or transmission fluid
298. king gear on the output shaft to the transmission case 80c070a6 Fig 3 Park Powerflow 1 LEVER ENGAGED FOR PARK 2 PARK SPRAG 3 OUTPUT SHAFT 42RE AUTOMATIC TRANSMISSION 21 5 NEUTRAL POWERFLOW With the gear selector in the neutral position Fig 4 the power flow of the transmission is essentially the same as in the park position The only opera tional difference is that the parking sprag has been disengaged unlocking the output shaft from the transmission case and allowing it to move freely 80c070a7 Fig 4 Neutral Powerflow LEVER DISENGAGED FOR NEUTRAL PARK SPRAG OUTPUT SHAFT CAM LEVER 21 6 42RE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued 53 INPUT OUTPUT STATIONARY MEMBER ROTATING MEMBER REAR PLANETARY 80607028 Fig 5 Reverse Powerflow 1 FRONT CLUTCH ENGAGED 2 OUTPUT SHAFT 3 LOW REVERSE BAND APPLIED 4 INPUT SHAFT 5 OUTPUT SHAFT 6 INPUT SHAFT 7 FRONT CLUTCH ENGAGED 8 LOW REVERSE BAND APPLIED REVERSE POWERFLOW When the gear selector is moved into the reverse position Fig 5 the front dutch and the rear band are applied With the application of the front clutch engine torque is applied to the sun gear turning it in a dockwise direction The dockwise rotation of the sun gear causes the rear planet pinions to rotate against engine rotation in a count
299. l too high When the transmssion has too much fluid the WJ geartrain churns up foam and cause the same condi tions which occur with a low fluid level In either case air bubbles can cause overheating and or fluid oxidation and varnishing This interfere with normal valve dutch and accumulator operation Foaming can also result in fluid escaping from the transmission vent where it may be mis taken for a leak Along with fluid level it is important to check the condition of the fluid When the fluid smells burned and is contaminated with metal or friction material particles a complete transmission recondition is needed Be sure to examine the fluid on the dipstick dosely If there is any doubt about its condition drain out a sample for a double check After the fluid has been checked seat the dipstick fully to seal out water and dirt The transmission fluid level should be inspected at least every six months FLUID LEVEL CHECK PROCEDURE The transmission has a dipstick to check oil level It is located on the right side of the engine Be sure to wipe all dirt from dipstick handle before removing The torque converter fills in both the P Park and N Neutral positions Place the selector lever in P Park to be sure that the fluid level check is accurate The engine should be running at idle speed for at least one minute with the vehicle on level ground At normal operating temperature approxi mately 82 C or 180 F
300. lation 6 Install rear bearing locating ring in retainer if ring was removed during overhaul 7 Apply 3 mm 1 8 in wide bead of Mopar gas ket maker or silicone adhesive sealer to mounting surface of rear retainer Allow sealer to set up slightly before proceeding rear 21 328 NV247 TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 8 Slide rear retainer onto mainshaft Fig 75 9 Spread rear bearing locating ring and slide rear retainer into place on rear case Fig 76 10 Install and tighten rear retainer bolts to 27 34 N m 20 25 ft Ibs 11 Install rubber access plug Fig 77 REAR CASE REAR RETAINER 80ba7a37 Fig 75 Rear Retainer Installation PARALLEL 0 JAW SNAP RING PLIERS REAR e s RETAINER EX Y gt gt LEA m Fig 76 Engaging Rear Bearing Locating Ring FINAL ASSEMBLY 1 Install drain plug Tighten plug to 41 54 N m 30 40 ft 165 torque 2 Level transfer case and fill it with Dexron automatic transmission fluid Correct fill level is to bottom edge of fill plug hole 3 Install and tighten fill plug to 41 54 N m 30 40 ft 165 torque 80ba7a36 80ba7a33 Fig 77 Installing Rubber Access Plug CLEANING AND INSPECTION NV247 COMPONENTS GENERAL Clean the transfer case components with parts cleaning solvent Flush the oil passages in the cases and drivetrain components with solvent This will help remo
301. let side of the valve leads to the valve body governor circuit The solenoid valve regulates line pressure to pro duce governor pressure The average current sup plied to the solenoid controls governor pressure One amp current produces zero kPa psi governor pres sure Zero amps sets the maximum governor pres sure The powertrain control module PCM turns on the trans control relay which supplies electrical power to the solenoid valve Operating voltage is 12 volts DC The PCM controls the ground side of the sole noid using the governor pressure solenoid control cir cuit GOVERNOR PRESSURE SENSOR The sensor output signal provides the necessary feedback to the PCM This feedback is needed to ade quately control governor pressure GOVERNOR BODY AND TRANSFER PLATE The transfer plate channels line pressure to the solenoid valve through the governor body It also channels governor pressure from the solenoid valve to the governor circuit It is the solenoid valve that develops the necessary governor pressure TRANSMISSION FLUID TEMPERATURE THERMISTOR The PCM prevents engagement of the converter dutch and overdrive dutch when fluid temperature is below approximately 10 C 50 F If fluid temperature exceeds 126 C 260 F the PCM causes a 4 3 downshift and engage the con verter dutch Engagement is according to the third gear converter dutch engagement schedule WJ The overdrive OFF lamp in the instrument panel illumina
302. ll piston over Seal Guide 8114 2 and inside Guide Ring 8114 1 dj Push overdrive piston retainer e Verify that the locating lugs entered the lug bores in the retainer into position in NOTE INSTALL THE REMAINING TRANSMISSION COMPONENTS AND OVERDRIVE UNIT FRONT SERVO PISTON DISASSEMBLY 1 Remove seal ring from rod guide Fig 204 2 Remove small snap ring from servo piston rod Then remove piston rod spring and washer from piston 3 Remove and discard servo component O ring and seal rings ASSEMBLY Clean and inspect front servo components 1 Lubricate new O ring and seal rings with petro leum jelly and install them on piston guide and rod 2 Install rod in piston Install spring and washer on rod Compress spring and install snap ring Fig 204 3 Set servo components aside for installation dur ing transmission reassembly REAR SERVO PISTON DISASSEMBLY 1 Remove small snap ring and remove plug and spring from servo piston Fig 205 2 Remove and discard servo piston seal ring ASSEMBLY 1 Lubricate piston and guide seals with petro leum jelly Lubricate other servo parts with ATF Plus 3 Type 7176 transmission fluid 2 Install new seal ring on servo piston 3 Assemble piston plug spring and new snap ring 4 Lubricate piston seal lip with petroleum jelly 1 2 AUTOMATIC TRANSMISSION 21 123 DISASSEMBLY AND ASSEMBLY Continued
303. lly by grounding the return wire of the solenoid as necessary When a solenoid is energized the solenoid valve shifts and a fluid passage is opened or closed vented or applied depending on its default operat ing state The result is an apply or release of a fric tional element The MS and UD solenoids are normally applied to allow transmission limp in in the event of an electri cal failure The continuity of the solenoids and circuits are periodically tested Each solenoid is turned on or off depending on its current state An spike should be detected by the TCM during this test If no spike is detected the circuit is tested again to verify the failure In addition to the periodic testing the solenoid circuits are tested if a speed ratio or pres sure switch error occurs SOLENOID SWITCH VALVE DESCRIPTION The Solenoid Switch Valve SSV is located in the valve body controls the direction of the transmission fluid when the L R TCC solenoid is energized OPERATION The Solenoid Switch Valve controls line pressure from the LR TCC solenoid In 1st gear the SSV will be in the downshifted position thus directing fluid to the L R dutch circuit 2nd 3rd and 4th it will be in the upshifted position and directs the fluid into the torque converter clutch TCC circuit When shifting into 1st gear a special hydraulic sequence is performed to ensure SSV movement into the downshifted position The L R pressure s
304. lve Body 11 8 N m 105 in Ibs Screw Valve Body to Transfer Plate 4 5 Nem 40 in Ibs Screw Solenoid Module to Transfer Plate 5 7 N m 50 in Ibs Screw Accumulator Cover 4 5 N m 40 in Ibs Screw Detent Spring 4 5 40 in Ibs Bolt Input Speed Sensor Bolt Output Speed Sensor Bolt Line Pressure Sensor 11 8 N m 105 in 16 11 8 N m 105 in Ibs 11 8 N m 105 in Ibs Bolt Extension Housing 54 40 ft Ibs Fitting Vent 12 N m 100 165 Screw Manual Valve Cam Retaining 4 5 Nem 40 in Ibs Bolt Manual Lever 28 2 N m 250 165 SPECIAL TOOLS 45RFE TRANSMISSION Pressure Gauge C 3292 90114420 Dial Indicator C 3339 21 272 45 AUTOMATIC TRANSMISSION SPECIAL TOOLS Continued Seal Installer C 3860 A Flusher 6906 Spring Compressor 8249 e Spring Compressor 8250 Qi Spring Compressor 8251 Piston Installer 8252 N Seal Installer 8253 5 AUTOMATIC TRANSMISSION 21 273 SPECIAL TOOLS Continued Seal Installer 8254 Pressure Tap Adapter 8258 4 Installer 8255 Line Pressure Adapter 8259 Support Stand 8257 Input Clutch Pressure Fixture 8260 21 274 45RFE AUTOMATIC TRANSMISSION SPECIAL TOOLS Continued Alignment Plate 8261 Bearing Installer 8320 EC
305. lve body to transmis sion case 9 Lower valve body enough to remove accumula tor piston and springs 80c072b2 Fig 98 Valve Body 1 VALVE BODY 2 WIRE HARNESS 3 PARK ROD 4 GOVERNOR PRESSURE SOLENOID 5 GOVERNOR PRESSURE SENSOR INSTALLATION 1 Check condition of O ring seals on valve body harness connector Fig 99 Replace seals on tor body if cut or worn 21 86 42RE AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION Continued 2 Check condition of manual lever shaft seal in transmission case Replace seal if lip is cut or worn Install new seal with 15 16 deep well socket Fig 100 3 Check condition of seals on accumulator piston Fig 101 Install new piston seals if necessary 4 Place valve body manual lever in low 1 posi tion so ball on park lock rod will be easier to install in sprag 5 Lubricate shaft of manual lever with petroleum jelly This will ease inserting shaft through seal in case 6 Lubricate seal rings on valve body harness con nector with petroleum jelly 7 Position valve body in case and work end of park lock rod into and through pawl sprag Turn pro peller shaft to align sprag and park lock teeth if nec essary The rod will click as it enters pawl Move rod to check engagement CAUTION It is possible for the park rod to displace into a cavity just above the pawl sprag during installation Make sure the rod is actually engaged in the
306. ly air pressure through front clutch apply pas sage Piston movement can be felt and a soft thump heard as the clutch applies Governor pressure low at all mph figures Lubrication pressure low at all throttle positions Rear Clutch Air Test Place one or two fingers on the clutch housing and apply air pressure through rear clutch apply passage Piston movement can be felt and a soft thump heard as the clutch applies 21 58 42RE AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING Continued 80b1717e Fig 68 Air Pressure Test Passages LINE PRESSURE TO ACCUMULATOR 2 REAR SERVO APPLY 3 FRONT SERVO APPLY 4 FRONT SERVO RELEASE 5 PUMP SUCTION 6 PUMP PRESSURE 7 FRONT CLUTCH APPLY 8 REAR CLUTCH APPLY 9 TO TORQUE CONVERTOR 10 TO COOLER 11 FROM TORQUE CONVERTER a Front Servo Air Test Apply air pressure to the front servo apply pas sage The servo rod should extend and cause the band to tighten around the drum Spring pressure should release the servo when air pressure is removed Rear Servo Air Test Apply air pressure to the rear servo apply passage The servo rod should extend and cause the band to tighten around the drum Spring pressure should release the servo when air pressure is removed CONVERTER HOUSING FLUID LEAK DIAGNOSIS When diagnosing converter housing fluid leaks two items must be established before repair 1 Verify that a leak
307. m the internal transmission components and transfer that heat to the transmission case TORQUE CONVERTER DESCRIPTION The torque converter Fig 2 is a hydraulic device that couples the engine crankshaft to the transmis sion The torque converter consists of an outer shell with an internal turbine a stator an overrunning clutch an impeller and an electronically applied con verter clutch The converter clutch provides reduced engine speed and greater fuel economy when engaged Clutch engagement also provides reduced transmission fluid temperatures The converter clutch engages in third gear The torque converter hub drives the transmission oil fluid pump and con tains an o ring seal to better control oil flow The torque converter is a sealed welded unit that is not repairable and is serviced as an assembly 21 184 45RFE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued CAUTION The torque converter must be replaced if a transmission failure resulted in large amounts of metal or fiber contamination in the fluid If the fluid is contaminated flush the fluid cooler and lines IMPELLER The impeller Fig 3 is an integral part of the con verter housing The impeller consists of curved blades placed radially along the inside of the housing on the transmission side of the converter As the con verter housing is rotated by the engine so is the impeller because they are one and the same and are the driving member
308. m the input dutch hub 10 Remove the overdrive clutch wave snap ring from the input dutch retainer 11 Remove the UD OD reaction plate tapered snap ring from the input dutch retainer 12 Remove the UD OD reaction plate from the input dutch retainer 13 Remove the UD OD reaction plate flat snap ring from the input dutch retainer Fig 107 14 Remove the underdrive clutch pack from the input dutch retainer Fig 109 15 Using Spring Compressor 8251 compress the UD OD balance piston and remove the snap ring from the input dutch hub Fig 108 16 Remove the UD OD balance piston and piston return spring from the input dutch retainer Fig 109 17 Remove the underdrive piston from the input dutch retainer Fig 109 NOTE Both the UD OD balance piston and the underdrive piston have seals molded onto them If the seal is damaged do not attempt to install a new seal onto the piston The piston seal must be replaced as an assembly 18 Remove the input dutch retainer tapered snap ring 19 Separate input dutch retainer from input dutch hub WJ 45RFE AUTOMATIC TRANSMISSION 21 239 DISASSEMBLY AND ASSEMBLY Continued REV REACTION SNAP RING PLATE SELECT REV 5 d REVISE REACTION PLATE BEARING SNAP RING NUMBER 4 BEARING El NUMBER 3 OD HUB SHAFT BEARING NUMBER 2 SNAP RING FLAT OD CLUTCH SNAP RING TAPER UD OD REACTION PLATE SELECT
309. me speed The front and rear planet pinions do not turn at all in direct drive The only rotation is the input from the engine to the connected parts which are acing as one common unit to the output shaft 21 10 42RE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued FOURTH GEAR POWERFLOW Fourth gear overdrive range is electronically con trolled and hydraulically activated Various sensor inputs are supplied to the powertrain control module to operate the overdrive solenoid on the valve body The solenoid contains a check ball that opens and doses a vent port in the 3 4 shift valve feed passage The overdrive solenoid and check ball are not ener gized in first second third or reverse gear The vent port remains open diverting line pressure from the 2 3 shift valve away from the 3 4 shift valve The overdrive control switch must be in the ON position to transmit overdrive status to the PCM A 3 4 upshift occurs only when the overdrive solenoid is energized by the PCM The PCM energizes the over drive solenoid during the 3 4 upshift This causes the solenoid check ball to dose the vent port allowing line pressure from the 2 3 shift valve to act directly on the 3 4 upshift valve Line pressure on the 3 4 shift valve overcomes valve spring pressure moving the valve to the upshift position This action exposes the feed passages to the 3 4 timing valve 3 4 quick fill valve 3 4 accumulator and ultimately to the overdrive p
310. mid throttle by decreasing the L R Solenoid duty cycle OIL PUMP DESCRIPTION The oil pump Fig 10 is located at the front of the transmission inside the bell housing and behind the transmission front cover The oil pump consists of two independent pumps Fig 11 a number of valves Fig 12 a front seal Fig 13 and a bolt on reaction shaft The converter clutch switch and regulator valves pressure regulator valve and converter pres sure limit valve are all located in the oil pump hous ing OPERATION As the torque converter rotates the converter hub rotates the oil pump drive gear As the drive gear rotates both driven gears the clearance between the gear teeth increases in the crescent area and creates a suction at the inlet side of the pump This suction draws fluid through the pump inlet from the oil pan As the clearance between the gear teeth in the cres cent area decreases it forces pressurized fluid into the pump outlet and to the oil pump valves WJ DESCRIPTION AND OPERATION Continued OIL PUMP TO CASE BOLT 6 VE N SASS 80 07356 80 9 592 Fig 11 Oil Pump Gears 45RFE AUTOMATIC TRANSMISSION 21 189 TORQUE TORQUE TORQUE CONVERTER CONVERTER CONVERTER CLUTCH CLUTCH CLUTCH ACCUMULATOR CONTROL SWITCH VALVE VALVE VALVE e TORQUE CONVERTER CLUTCH LIMIT VALVE PRESSURE REGULATOR PUMP VALVE COVE 80b9a593 Fig 12 Oil Pump Valves
311. moved Spacer goes in groove just rearward of shaft rear splines Fig 104 7 Install thrust bearing in overdrive unit sliding hub Use petroleum jelly to hold bearing in position CAUTION Be sure the shoulder on the inside diam eter of the bearing is facing forward 21 88 42RE AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION Continued J9021 96 Fig 104 Intermediate Shaft Selective Spacer Location 1 SELECTIVE SPACER 2 SPACER GROOVE 3 INTERMEDIATE SHAFT 8 Verify that splines in overdrive planetary gear overrunning dutch 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 dutch 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 dutch splines to rotate out of alignment If this occurs it will be 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 diagon
312. n case Fig 72 29 Remove the 2C dutch pack from the transmis sion case Fig 72 30 Remove the rear selective plate and number 6 bearing from the reaction annulus Fig 73 31 Remove the reaction annulus from the tion planetary carrier Fig 73 32 Remove the number 7 bearing Fig 73 33 Remove the reaction sun gear Fig 73 34 Remove the number 8 bearing from the tion planetary carrier Fig 73 35 Remove the reaction planetary carrier Fig 73 Note that this planetary gear set has three pin ion gears 21 226 45RFE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued My a 9227 RETAINER BULKHEAD 80c07358 Fig 71 Remove 4C Clutch Retainer Bulkhead 36 Remove the number 9 bearing from the reverse planetary gear set Fig 73 37 Remove the snap ring holding the park sprag gear onto the output shaft Fig 74 BEARING NUMBER 8 REACTION ANNULUS BEARING NUMBER 6 BEARING NUMBER 7 THRUST PLATE REACTION SUN GEAR REACTION PLATE SELECT 80c07359 Fig 72 Remove 2C Clutch Pack 38 Remove the park sprag gear from the output shaft Fig 75 39 Remove the input reverse planetary assembly Fig 76 S z BEARING NUMBER 9 REACTION PLANETARY CARRIER 80c07031 Fig 73 Remove Reaction Annulus and Carrier 5 AUTOMATIC TRANSMISSION 21 227 DISA
313. n shafts and install transfer case on transmission 5 Install and tighten transfer case attaching nuts to 35 N m 26 ft Ibs torque Fig 5 6 Connect front propeller shaft and install rear propeller shaft Refer to Group 3 Differential and Driveline for proper procedures and torque specifica tions 7 Fill transfer case with correct fluid Check transmission fluid level Correct as necessary 8 Install rear crossmember Fig 4 and skid plate if equipped Tighten crossmember bolts to 41 N m 30 ft 165 torque 9 Remove transmission jack and support stand 10 Verify transfer case is in Neutral Connect shift cable to transfer case range lever 11 Lower vehicle and verify transfer case shift operation 12 Adjust the transfer case shift cable if neces sary TRANSFER CASE SHIFT CABLE REMOVAL 1 Shift transfer case into neutral 2 Raise vehicle 3 Disconnect the shift cable eyelet from the transfer case shift lever Fig 6 4 Remove shift cable from the cable support bracket 5 Lower vehide 6 Remove shift lever bezel and necessary console parts for access to shift lever assembly and shift cable 21 312 247 TRANSFER CASE REMOVAL AND INSTALLATION Continued AUN WS TRANSFER CASE Sex SHIFT LEVER ve BW E Y MALIS ca TRANSFER CASE SHIFT CABLE 80ba79c6 Fig 6 Transfer Case Shift Cable at Transfer Case 7 Disconnect cable at shift l
314. n spring with Compressor Tool C 3575 A Fig 220 Be sure legs of tool are seated squarely on spring retainer before compress ing spring 3 Remove retainer snap ring and remove com pressor tool 4 Remove spring retainer and dutch spring Note position of retainer on spring for assembly reference 5 Remove dutch piston from dutch retainer Remove piston by rotating it up and out of retainer 6 Remove seals from clutch piston and clutch retainer hub Discard both seals as they are not reus able 21 128 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued LA 49121 147 Fig 220 Compressing Front Clutch Piston Spring 1 FRONT CLUTCH SPRING 2 COMPRESSOR TOOL 3575 3 RETAINER SNAP RING 4 SPRING RETAINER ASSEMBLY 1 Soak clutch discs in transmission fluid while assembling other clutch parts 2 Install new seals on piston and in hub of retainer Be sure lip of each seal faces interior of clutch retainer 3 Lubricate lips of piston and retainer seals with liberal quantity of Mopar Door Ease Then lubricate retainer hub bore and piston with light coat of trans mission fluid 4 Install clutch piston in retainer Fig 221 Use twisting motion to seat piston in bottom of retainer CAUTION Never push the clutch piston straight in This will fold the seals over causing leakage and clutch slip 5 Position spring in clutch piston Fig 222 6 Position spring retain
315. nd are seated against reaction pin J9121 348 Fig 178 Rear Band Installation 1 REAR BAND 42RE AUTOMATIC TRANSMISSION 21 115 Fig 179 Installing Low Reverse Drum 1 REAR BAND 2 LOW REVERSE DRUM 6 Install low reverse drum and check overrun ning dutch operation as follows a Lubricate overrunning dutch race on drum hub with transmission fluid b Guide drum through rear band Tilt drum slightly and start on drum hub into overrunning dutch rollers d Press drum rearward and turn it in dock wise direction until drum seats in overrunning dutch Fig 179 e Turn drum back and forth Drum should rotate freely in clockwise direction and lock counterclockwise direction as viewed from front of case 7 Install snap ring that secures low reverse drum to hub of overdrive piston retainer Fig 180 8 Install rear band lever and pivot pin Fig 181 Align lever with pin bores in case and push pivot pin into place 9 Install planetary geartrain assembly Fig 182 10 Install thrust plate on intermediate shaft hub Fig 183 Use petroleum jelly to hold thrust plate in place J9121 351 Fig 180 Installing Low Reverse Drum Retaining Snap Ring 1 LOW REVERSE DRUM 2 HUB OF OVERDRIVE PISTON RETAINER 3 LOW REVERSE DRUM SNAP RING 21 116 42 AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued 12 Install rear
316. nd the cylinder wall The force exerted is downward gravity however the principle remains the same no matter which direction is taken The pressure created in the fluid is equal to the force applied divided by the piston area If the force is 100 lbs and the piston area is 10 sq in then the pres sure created equals 10 PSI Another interpretation of Pascal s Law is that regardless of container shape or size the pressure will be maintained throughout as long as the fluid is confined In other words the pressure in the fluid is the same everywhere within the container WHEN FLUID PRESSURE IS CREATED IS NOT CONFINED WITH A THERE 15 CONFINED FLUID NO PRESSURE CREATED 80bfe273 Fig 51 Pressure on a Confined Fluid WJ DESCRIPTION AND OPERATION Continued FORCE MULTIPLICATION Using the 10 PSI example used in the illustration Fig 52 a force of 1000 Ibs can be moved with a force of only 100 165 The secret of force multiplica tion in hydraulic systems is the total fluid contact area employed The illustration Fig 52 shows an area that is ten times larger than the original area The pressure created with the smaller 100 input is 10 PSI The concept pressure is the same every where means that the pressure underneath the larger piston is also 10 PSI Pressure is equal to the force applied divided by the contact area Therefore by means of simple algebra the output force may be found This concept is ext
317. nding on the following variables e Shift lever position Current gear range Transmission fluid temperature Engine coolant temperature Input speed Throttle angle Engine speed OPERATION The TCM controls the torque converter by way of internal logic software The programming of the soft ware provides the TCM with control over the L R CC Solenoid There are four output logic states that can be applied as follows e NoEMCC e Partial EMCC e Full EMCC e Gradual to no EMCC NO EMCC Under No EMCC conditions the L R Solenoid is OFF There are several conditions that can result in NO EMCC operations No EMCC can be initiated due to a fault in the transmission or because the TCM does not see the need for EMCC under current driving conditions PARTIAL EMCC Partial EMCC operation modulates the L R Sole noid duty cycle to obtain partial torque converter clutch application Partial EMCC operation is main tained until Full EMCC is called for and actuated During Partial EMCC some slip does occur Partial EMCC will usually occur at low speeds low load and light throttle situations FULL EMCC During Full EMCC operation the TCM increases the L R Solenoid duty cycle to full ON after Partial EMCC control brings the engine speed within the desired slip range of transmission input speed rela tive to engine rpm GRADUAL TO NO EMCC This operation is to soften the change from Full or Partial to This is done at
318. nds of the snap ring are located in the case opening toward the valve body area RETAINER BULKHEAD 80c07358 Fig 88 Install 4C Clutch Retainer Bulkhead 36 Air check the 2C and 4 dutch operation 37 Using Alignment Plate 8261 Adapter 8266 17 from End Play Tool Set 8266 and Dial Indicator C 3339 measure and record the output shaft end play Fig 89 The correct output shaft end play is 0 53 0 78 mm 0 021 0 031 in Adjust as necessary Install the chosen output shaft selective spacer and re measure end play to verify selection 38 Apply a bead of RTV silicone and install the extension adapter housing onto the transmission case 39 Install and torque the bolts to hold the exten sion adapter housing onto the transmission case The correct torque is 54 N m 40 ft Ibs 40 Install the number 5 bearing and spacer onto the 4C retainer bulkhead Fig 90 41 Install the input dutch assembly into the transmission case Fig 90 Make sure that the input dutch assembly is fully installed by performing a visual inspection through the input speed sensor hole If the tone wheel on the input dutch assembly is visible the assembly is fully installed 45RFE AUTOMATIC TRANSMISSION 21 231 80c07353 Fig 89 Measure Output Shaft End Play 42 Install the number 1 bearing with the flat side down in the pocket of the input clutch assembly Fig 90 BEARING NUMBER 5 THRUST PLATE SELECT INPUT CLUT
319. ne starts in any position other than Park or Neu tral or if the engine will not start at all the park neutral position switch or TRS may be faulty Gearshift Adjustment Procedure 1 Shift transmission into Park 2 Remove shift lever bezel and floor console as necessary for access to the shift cable adjustment 3 Loosen the shift cable adjustment screw Fig 127 4 Raise vehicle 5 Unsnap cable eyelet from transmission shift lever Fig 128 WJ ADJ USTMENTS Continued 80ba79cb Fig 127 Shift Cable at the Shifter SHIFT LEVER PIN ADJUSTMENT SCREW SHIFT CABLE SHIFTER ASSEMBLY BRACKET 6 Verify transmission shift lever is in Park detent by moving lever fully rearward Last rearward detent is Park position 7 Verify positive engagement of transmission park lock by attempting to rotate propeller shaft Shaft will not rotate when park lock is engaged 8 Snap cable eyelet onto transmission shift lever 9 Lower vehicle 45RFE AUTOMATIC TRANSMISSION 21 251 10 Tighten the shift cable adjustment screw to 7 N m 65 in 165 11 Verify correct operation 12 Install the shifter bezel and any floor console components removed for access 45RFE MANUAL LEVER 80ba79c4 Fig 128 Shift Cable Attachment At Transmission 45RFE AUTOMATIC TRANSMISSION 21 252 SCHEMATICS AND DIAGRAMS HYDRAULIC SCHEMATICS JILVASHOS 354557 WdH
320. ng CLEANING AND INSPECTION VALVE BODY Clean the valve housings valves plugs springs and separator plates with a standard parts deaning solution only Do not use gasoline kerosene or any type of caustic solution Do not immerse any of the electrical components in cleaning solution Clean the electrical components by wiping them off with dry shop towels only Dry all except the electrical parts with compressed air Make sure all passages are clean and free from obstructions Do not use rags or shop towels to dry or wipe off valve body components Lint from these materials can stick to valve body parts interfere with valve operation and clog filters and fluid passages Inspect all of the valve body mating surfaces for scratches nicks burrs or distortion Use a straight edge to check surface flatness Minor scratches may be removed with crocus doth using only very light pressure Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth Position the crocus cloth on a surface plate sheet of plate glass or equally flat sur face If distortion is severe or any surfaces are heavily scored the valve body will have to be replaced Inspect the valves and plugs Fig 124 for scratches burrs nicks or scores Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands Maintaining sharpne
321. ng surfaces with a scraper and all pur pose deaner This will ensure proper adhesion of the sealer during reassembly Replace the slinger and seal outright do not reuse either part Inspect the retaining rings and washers Replace any part if distorted bent or broken Reuse is not recommended Also replace the boot if cut or torn Replace the boot band damps do not reuse them 21 304 NV242 TRANSFER CASE CLEANING AND INSPECTION Continued 8001b75f Fig 103 Input Gear And Carrier Components 1 PLANETARY CARRIER 2 REAR THRUST WASHER 3 FRONT THRUST WASHER 4 CARRIER LOCK RING 5 CARRIER LOCK RETAINING RING 6 INPUT GEAR Fig 104 Shift forks POS 1 RANGE FORK 2 MODE FORK AND RAIL 3 MODE SPRING REAR OUTPUT SHAFT YOKE DRIVE CHAIN Check condition of the seal contact surfaces of the yoke slinger Fig 106 This surface must be dean and smooth to ensure proper seal life Replace the yoke nut and seal washer as neither part should be reused Inspect the shaft threads sprocket teeth and bear ing surfaces Minor nicks on the teeth can be smoothed with an oilstone Use 320 400 grit emery to smooth minor scratches on the shaft bearing sur faces Rough threads on the shaft can be chased if necessary Replace the shaft if the threads are dam aged bearing surfaces are scored or if any sprocket teeth are cracked or broken Examine the drive chain and shaft bearings Replace the
322. nor valve shaft bore The annulus gears can be removed from their sup ports if necessary J ust remove the snap rings and separate the two parts when replacement is neces sary In addition the annulus gear bushings can be replaced if severely worn or scored However it is not necessary to replace the bushings if they only exhibit normal wear Check bushing fit on the output shaft to be sure OVERDRIVE UNIT 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 Check condition of the park lock components and the overdrive case Replace the case if cracked scored or damaged Replace the park lock pawl plug or spring if worn or damaged Be sure the bullet at the end of the park lock rod is in good condition Replace the rod if
323. not rotate to the LOCK position 3 Shifting out of PARK should be possible when the ignition key cylinder is in the OFF position 4 Shifting out of PARK should not be possible while applying 25 Ib maximum handle pushbutton force and ignition key cylinder is in the RUN or START positions unless the foot brake pedal is depressed approximately 1 2 inch 12 mm 21 54 42 AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING Continued SHIFT LEVER POSITION Drive Range First Second Third Fourth 2 Range Manual Second gt TRANSMISSION CLUTCHES AND BANDS FRONT REAR OVERRUN OVERDRIVE BAND BAND CLUTCH CLUTCH X X X L X X X X X X X X NHPEEN aff i gt gt gt gt OVERDRIVE CLUTCHES OVERRUN CLUTCH J9421 218 Clutch And Band Application Chart 5 Shifting out of PARK should not be possible when the ignition key cylinder is in the ACCESSORY or LOCK positions 6 Shifting between any gears NEUTRAL or into PARK may be done without depressing foot brake pedal with ignition switch RUN or START tions and vehicle stationary or in motion GEARSHIFT CABLE 1 The floor shifter lever and gate positions should be in alignment with all transmission PARK NEUTRAL and gear detent positions 2 Engine starts must be possible with floor shift lever in PARK or NEUTRAL gate positions only Engine starts must not be poss
324. nsmission with Plus 3 Type 7176 fluid TORQUE CONVERTER REMOVAL 1 Remove transmission and torque converter from vehide 2 Place a suitable drain pan under the converter housing end of the transmission CAUTION Verify that transmission is secure on the lifting device or work surface the center of gravity of the transmission will shift when the torque con verter is removed creating an unstable condition The torque converter is a heavy unit Use caution when separating the torque converter from the transmission 3 Pull the torque converter forward until the cen ter hub dears the oil pump seal 4 Separate the torque converter from the trans mission INSTALLATION Check converter hub and drive notches for sharp edges burrs scratches or nicks Polish the hub and notches with 320 400 grit paper or crocus doth if essary The hub must be smooth to avoid damaging the pump seal at installation Check that the torque converter hub o ring on the 45RFE torque converter hub is not damaged Replace if necessary 1 Lubricate oil pump seal lip with transmission fluid 2 Place torque converter in position on transmis sion CAUTION Do not damage oil pump seal or bushing while inserting torque converter into the front of the transmission 3 Align torque converter to oil pump seal open ing 4 Insert torque converter hub into oil pump 5 While pushing torque converter inward rotate
325. nstaller 8128 WJ SPECIAL TOOLS Continued Installer 5066 NB Installer 6952 A Remover L 4454 8148 gt Seal Protector 6992 NV242 TRANSFER CASE 21 307 Installer Input Gear Bearing 7829 A Installer Seal 7884 NC Installer Pump Housing Seal 7888 Installer Bearing 8033 A Installer Boot Clamp C 4975 A 21 308 NV247 TRANSFER CASE NV247 TRANSFER CASE TABLE OF CONTENTS page DESCRIPTION AND OPERATION NV247 TRANSFER CASE 308 TRANSFER CASE IDENTIFICATION 308 RECOMMENDED LUBRICANT AND FILL LEVEL RR pex 309 DIAGNOSIS AND TESTING NV247 DIAGNOSIS 310 REMOVAL AND INSTALLATION TRANSFER CASE 311 TRANSFER CASE SHIFT 311 DESCRIPTION AND OPERATION NV247 TRANSFER CASE DESCRIPTION The NV247 Fig 1 is an on demand 4 wheel drive transfer case with two operating ranges and a neu tral position Operating ranges are 4 high and 4 low The 4 low range is used for extra pulling power in off road situations 80ba7a31 Fig 1 NV247 Transfer Case TRANSFER CASE IDENTIFICATION A circular tag is attached to the rear case of each NV247 transfer case Fig 2 The tag indicates the following information e Model number e Serial number e Assembly number Gear ratio Location of manufacture WJ page FRONT OUTPUT S
326. nt housing with Retainer Tool 6583 Fig 154 WJ DISASSEMBLY AND ASSEMBLY Continued Fig 152 Converter Clutch And 3 4 Shift Valve Springs 1 RIGHT SIDE SCREW 2 3 4 ACCUMULATOR 3 3 4 SHIFT VALVE SPRING 4 CONVERTER CLUTCH VALVE SPRING J9321 160 J9521 180 Fig 153 Seating 3 4 Accumulator On Lower Housing 1 ACCUMULATOR BOX 2 CONVERTER CLUTCH VALVE PLUG 42RE AUTOMATIC TRANSMISSION 21 107 4 Install throttle lever in upper housing Then install manual lever over throttle lever and start manual lever into housing 5 Align manual lever with detent ball and man ual valve Hold throttle lever upward Then press down on manual lever until fully seated Remove detent ball retainer tool after lever is seated 6 Then install manual lever seal washer and E clip 7 Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve Fig 155 8 Position line pressure adjusting screw in adjusting screw bracket 9 Install spring on end of line pressure regulator valve 10 Install switch valve spring on tang at end of adjusting screw bracket 11 Install manual valve 12 Install throttle valve and spring 13 Install kickdown valve and detent 14 Install pressure regulator valve 15 Install switch valve 16 Position adjusting screw bracket on valve body Align valve springs and press bracke
327. ntact surfaces in the sprocket bore and on the mainshaft Minor nicks and scratches can be smoothed with 320 400 grit emery doth but do not try to salvage the shaft if nicks or wear is severe INPUT GEAR AND PLANETARY CARRIER Check the teeth on the gear Fig 103 Minor nicks can be dressed off with an oilstone but replace the gear if any teeth are broken cracked or chipped The bearing surface on the gear can be smoothed with 300 400 grit emery doth if necessary Examine the carrier body and pinion gears for wear or damage The carrier will have to be replaced as an assembly if the body pinion pins or pinion gears are damaged Check the lock ring and both thrust washers for wear or cracks Replace them if necessary Also replace the lock retaining ring if bent distorted or broken SHIFT FORKS HUBS SLEEVES Check condition of the shift forks and mode fork shift rail Fig 104 Minor nicks on the shift rail can be smoothed with 320 400 grit emery cloth Inspect the shift fork wear pads The mode fork pads are serviceable and can be replaced if necessary The range fork pads are also serviceable Check both of the sleeves for wear or damage especially on the interior teeth Replace the sleeves if wear or damage is evident REAR RETAINER BEARING SEAL SLINGER BOOT Inspect the retainer components Fig 105 Replace the bearing if rough or noisy Check the retainer for cracks or wear in the bearing bore Clean the retainer seali
328. nterconnected circuits As fluid is sent through passages to the reg ulator valve the pressure pushes the valve to the right against the large spring It is also sent to the reaction areas on the left side of the throttle pressure plug and the line pressure plug With the gear selec tor in the park position fluid recirculates through the regulator and manual valves back to the sump 21 22 42RE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued Fem dam H nedum valve TORQUE CONVERTER TO LUBRICATION OIL FILTER 80c0713e Fig 23 Regulator Valve in Neutral Position Meanwhile the torque converter is filled slowly In all other gear positions Fig 23 fluid flows between two right side lands to the switch valve and torque converter At low pump speeds the flow is controlled by the pressure valve groove to reduce pressure to the torque converter After the torque converter and switch valve fill with fluid the switch valve becomes the controlling metering device for torque converter pressure The regulator valve then begins to control the line pressure for the other transmission circuits The balance of the fluid pressure pushing the valve to the right and the spring pressure pushing to the left determines the size of the met
329. nut to 122 176 N m 90 130 ft 165 torque Use Tool C 3281 or similar tool to hold flange while tightening yoke nut PROGRESSIVE COUPLER 1 Install coupling on mainshaft Fig 71 2 Install coupling retaining snap ring first Fig Fig 66 Rear Case Installation 71 Be sure snap ring is fully seated before proceed ing WJ NV247 TRANSFER CASE 21 327 DISASSEMBLY AND ASSEMBLY Continued 19321 30 Fig 69 Range Lever Installation Typical 1 RANGE LEVER 2 WASHER 3 LOCKNUT J9321 2 Fig 70 Flange Seal Washer Installation 1 YOKE SEAL WASHER 3 Install oil pump locating snap ring on main shaft Fig 71 VISCOUS COUPLING SNAP RING e J9321 17 Fig 71 Progressive Coupling And Oil Pump Snap Ring Installation REAR RETAINER AND OIL PUMP INSTALLATION 1 Install new O ring on flanged end of oil pickup tube 2 Install oil pump Fig 72 3 Insert oil pickup tube in pump Fig 73 4 Install rear bearing on mainshaft Fig 73 Locating ring groove in bearing goes toward end of mainshaft 5 Install rear bearing retaining snap ring Fig 74 OIL PUMP TUBE O RING OIL e PICKUP TUBE 80ba7a38 Fig 72 Installing Oil Pump REAR BEARING J9321 10 Fig 73 Rear Bearing Installation V REAR SNAP N BEARING o gt PLIERS 70 0 SNAP RING J9321 9 Fig 74 Rear Bearing Snap Ring Instal
330. nward and the dial indicator zeroed the first stop felt when the input shaft is pulled out ward is the movement of the input shaft in the input clutch housing hub This value should not be included in the end play measured value and there fore must be recorded and subtracted from the dial indicator reading 9 Remove the bolts holding the transmission extension adapter housing to the transmission case 10 Remove the extension adapter housing from the transmission case 11 Using Alignment Plate 8261 Adapter 8266 17 from End Play Tool Set 8266 and Dial Indicator WJ C 3339 measure and record the output shaft end play Fig 65 j TOOL 8261 AJ TOOL C3339 80c07353 Fig 65 Measure Output Shaft End Play 12 Remove the bolts holding the transmission oil pan to the transmission case 13 Remove the transmission oil pan from the transmission case 14 Remove the primary oil filter and the oil cooler filter Fig 66 15 Remove the cooler bypass valve COOLER FILTER PRIMARY OIL FILTER BYPASS FILTER VALVE 80b9a595 Fig 66 Remove Primary Oil and Cooler Filters 16 Remove the bolts holding the valve body to the transmission case Fig 67 17 Remove the valve body from the transmission case 18 Remove the outer snap ring securing the transmission front cover into the transmission case Fig 68 19 Remove the inner snap ring securing the transmission front cover
331. o prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless the shifter is fully locked into the PARK position TRANSMISSION CONTROL MODULE DESCRIPTION The Transmission Control Module is located in the engine compartment on the right passenger side and is mounted to the inner fender Fig 28 TRANSMISSION CONTROL CONNECTOR 80ba79cf Fig 28 Transmission Control Module Location OPERATION The TCM is the controlling unit for all electronic operations of the transmission The TCM receives information regarding vehicle operation from both direct and indirect inputs and selects the operational mode of the transmission Direct inputs are hard wired to and used specifically by the TCM Indirect inputs originate from other components modules and WJ DESCRIPTION AND OPERATION Continued are shared with the TCM via the vehicle communica tion bus Some examples of direct inputs to the TCM are Battery B voltage Ignition voltage Transmission Control Relay Switched B Throttle Position Sensor Crankshaft Position Sensor Transmission Range Sensor Pressure Switches Transmission Temperature Sensor Input Shaft Speed Sensor Output Shaft Speed Sensor Line Pressure Sensor Some examples of indirect inputs to the TCM Engine Body Identification Manifold Pressure Target Idle Torque Reduction Confirmation Engine Coolant Temperature Ambient Battery Temperatur
332. ocking the stator s over running dutch to its shaft Fig 9 Under stall conditions the turbine is stationary the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counter clockwise direction When this happens the over run ning dutch of the stator locks and holds the stator from rotating With the stator locked the oil strikes the stator blades and is redirected into a helping direction before it enters the impeller This circula tion of oil from impeller to turbine turbine to stator and stator to impeller can produce a maximum torque multiplication of about 2 4 1 As the turbine begins to match the speed of the impeller the fluid that was hitting the stator in such as way as to cause it to lock up is no longer doing so In this con dition of operation the stator begins to free wheel and the converter acts as a fluid coupling FLOW IS MORE NEARLY STRAIGHT THROUGH ANGLE IS LESS aN 3 AT STALL 1 CRUISE Fig 9 Stator Operation 1 DIRECTION STATOR WILL FREE WHEEL DUE TO OIL PUSHING ON BACKSIDE OF VANES 2 FRONT OF ENGINE 3 INCREASED ANGLE AS OIL STRIKES VANES 4 DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING AGAINST STATOR VANES 80bfe26e 21 188 45RFE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued TORQUE CONVERTER CLUTCH TCC In a standard torque converter the impeller and turbine are rotating at about the
333. ol This program allows the electronic transmission system to recalibrate itself This will provide the best possible transmission operation The quick learn pro cedure should be performed if any of the following procedures are performed e Transmission Assembly Replacement Transmission Control Module Replacement e Solenoid Pack Replacement Clutch Plate and or Seal Replacement e Valve Body Replacement or Recondition To perform the Quick Learn Procedure the follow ing conditions must be met e The brakes must be applied e The engine speed must be above 500 rpm 45RFE AUTOMATIC TRANSMISSION 21 213 e The throttle angle TPS must be less than 3 degrees The shift lever position prompted to shift to overdrive The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the DRB indicates the procedure is complete e The calculated oil temperature must be above 60 and below 200 ALUMINUM THREAD REPAIR Damaged or worn threads in the aluminum trans mission case and valve body can be repaired by the use of Heli Coils or equivalent This repair consists of drilling out the worn out damaged threads Then tap the hole with a special Heli Coil tap or equiva lent and installing a Heli Coil insert or equivalent into the hole This brings the hole back to its original thread size Heli Coil or equivalent tools and inserts are readily available from most automotive parts suppliers mus
334. om mainshaft Fig 21 2 Remove progressive coupling from mainshaft Fig 21 COMPANION FLANGE AND RANGE LEVER REMOVAL 1 Remove front companion flange nut as follows a Move range lever to 4L position b Remove nut with socket and impact wrench 2 Remove companion flange If flange is difficult to remove by hand remove it with bearing splitter or with standard two jaw puller Be sure puller tool is NV247 TRANSFER CASE 21 315 OIL PUMP O RING 80ba7a39 Fig 20 Pick up Tube O ring Location TRANSFER CASE 2 0 MAINSHAFT PROGRESSIVE COUPLING SNAP RINGS 80ba7a50 Fig 21 Progressive Coupling Removal positioned on flange and not on slinger as slinger will be damaged 3 Remove seal washer from front output shaft Discard washer as it should not be reused 4 Remove nut and washer that attach range lever to sector shaft Then move sector to neutral position and remove range lever from shaft NOTE Note position of range lever so it can be re installed correctly FRONT OUTPUT SHAFT AND DRIVE CHAIN REM OVAL 1 Support transfer case so rear case is facing upward 2 Remove bolts holding front case to rear case The case alignment bolt require flat washers Fig 22 3 Loosen rear case with flat blade screwdriver to break sealer bead Insert screwdriver blade only into notches provided at each end of case Fig 23 4 Remove rear case Fig 24 21 316 NV247 TRANSFE
335. ontinued 10121 346 Fig 198 Overrunning Clutch Removal 1 ALIGN MARKS IDENTIFYING NON THREADED HOLE IN CAM AND CASE 2 OVERRUNNING CLUTCH ASSEMBLY 2 Mark location of non threaded hole in dutch cam and blank area in bolt circle with grease pencil 3 Align and install overrunning dutch and cam in case Fig 201 Be sure cam is correctly installed Bolt holes in cam are slightly counter sunk on one side Be sure this side of cam faces rearward toward piston retainer J9121 226 Fig 199 Location Of Non Threaded Hole In Clutch Cam 1 NON THREADED HOLE 2 OVERRUNNING CLUTCH CAM 21 121 42RE AUTOMATIC TRANSMISSION J9121 541 Fig 200 Location Of Blank Area In Clutch Cam Bolt Circle 1 OVERRUNNING CLUTCH CAM SEAT IN CASE 2 NON THREADED HOLE IN CLUTCH CAM ALIGNS HERE BLANK AREA OF SEAT 4 Verify that non threaded hole in clutch cam is properly aligned Check alignment by threading a bolt into each bolt hole Adjust dutch cam position if necessary 5 Install and tighten overrunning clutch bolts to 17 13 ft Ibs torque Note that dutch cam bolts are shorter than piston retainer bolts Fig 201 Overrunning Clutch Installation 1 ALIGN MARKS IDENTIFYING NON THREADED HOLE IN CAM AND CASE 2 OVERRUNNING CLUTCH ASSEMBLY 6 Install new gasket at rear of transmission case Use petroleum jelly to hold gasket in place Be sure to ali
336. or adaptive controls As friction material wears the vol ume of fluid need to apply the element increases Certain mechanical problems within the input dutch assembly broken return springs out of posi tion snap rings excessive clutch pack clearance improper assembly etc can cause inadequate or out of range element volumes Also defective Input Out put Speed Sensors and wiring can cause these conditions The following chart identifies the appro priate clutch volumes and when they are monitored updated SHIFT SCHEDULES As mentioned earlier the TCM has programming that allows it to select a variety of shift schedules Shift schedule selection is dependent on the follow ing e Shift lever position e Throttle position e Engine load CLUTCH VOLUMES Proper Clutch Clutch When Updated 2 1 or 3 1 downshift 4510194 2C 3 2 kickdown 25 to 85 shift OD 23 upshitt 30 to 100 3 4 upshift 30 to 85 4 3 kickdown 30 to 100 shift e Fluid temperature e Software level As driving conditions change the TCM appropri ately adjusts the shift schedule Refer to the follow ing chart to determine the appropriate operation expected depending on driving conditions Extreme Cold Oil temperature above 80 and 240 F Overheat Oil temperature above 240 F engine coolant temperature above 244 temperature below 16 F Super Cold Oil temperature between 12 F and 10 F Oil temperature between
337. ottle levers from valve body manual lever shaft 5 Place transmission in horizontal position 6 Remove transmission oil pan and gasket 7 Remove filter from valve body Fig 158 Keep filter screws separate from other valve body screws Filter screws are longer and should be kept with fil ter 80c072b6 Fig 158 Oil Filler Removal 1 FILTER 2 VALVE BODY 3 SCREWS 2 42RE AUTOMATIC TRANSMISSION 21 109 80c072b7 Fig 159 Valve Body Bolt Locations 1 VALVE BODY BOLTS 2 VALVE BODY BOLTS 8 Remove park neutral position switch 9 Remove hex head bolts attaching valve body to transmission case Fig 159 A total of 10 bolts are used Note different bolt lengths for assembly refer ence 10 Remove valve body assembly Push valve body harness connector out of case Then work park rod and valve body out of case Fig 160 11 Remove accumulator piston and inner and outer springs Fig 161 12 Remove pump oil seal with suitable pry tool or slide hammer mounted screw 13 Loosen front band adjusting screw locknut 4 5 turns Then tighten band adjusting screw until band is tight around front clutch retainer This prevents front rear dutches from coming out with pump and possibly damaging dutch or pump components 14 Remove oil pump bolts 80c072b8 Fig 160 Valve Body Removal 1 GOVERNOR PRESSURE SENSOR 2 VALVE BODY 3 PARK ROD 4 ACCUMULA
338. ousing Then tighten bolts finger tight 11 Tighten support to pump bolts to required torque as follows a Reverse pump assembly and install it in transmission case Position pump so bolts are fac ing out and are accessible b Secure pump assembly in case with 2 or 3 bolts or with pilot studs Tighten support to pump bolts to 20 N m 15 ft 165 d Remove pump assembly from transmission case 12 Install new oil seal in pump with Special Tool C 4193 and Tool Handle C 4171 Fig 218 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 J9321 183 Fig 218 Pump Oil Seal Installation 1 PUMP BODY 2 PUMP SEAL 3 SPECIAL TOOL C 4193 WJ DISASSEMBLY AND ASSEMBLY Continued 42RE AUTOMATIC TRANSMISSION 21 127 J9321 222 Fig 219 42RE Front Clutch Components 7 SNAP RING WAVED 8 CLUTCH PLATES 9 SPRING RETAINER 10 PISTON SEAL 11 FRONT CLUTCH RETAINER 1 RETAINER HUB SEAL 2 CLUTCH PISTON 3 PISTON SPRING 4 SPRING RETAINER SNAP RING 5 CLUTCH DISCS 6 PRESSURE PLATE FRONT CLUTCH NOTE The 42RE transmission uses four plates and discs for the front clutch DISASSEMBLY 1 Remove waved snap ring and remove pressure plate dutch plates and clutch discs Fig 219 2 Compress dutch pisto
339. ove disassemble and repair component damaged transmission as necessary 11 Converter Clutch Faulty 11 Replace converter and flush cooler and line before installing new converter 2 AUTOMATIC TRANSMISSION 21 61 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION DELAYED ENGAGEMENT 1 Fluid Level Low 1 Correct level and check for leaks FROM NEUTRAL TO DRIVE OR REVERSE 2 Filter Clogged 2 2 Change filter 3 Gearshift Linkage Misadjusted 3 E s linkage and repair linkage if worn or damaged 4 Torque Converter Drain Back Cil 4 If vehicle moves normally after 5 drains from torque converter into seconds after shifting into gear no repair is transmission sump necessary If longer inspect pump bushing for wear Replace pump house 5 Rear Band Misadjusted 5 Adjust band 6 Valve Bogy Filter Plugged 6 Replace fluid and filter If oil pan and old fluid were full of clutch disc material and or metal particles overhaul will be necessary 7 Oil Pump Gears Worn Damaged 7 Remove transmission and replace oil pump 8 Governor Circuit and Solenoid 8 Test with DRB scan tool and repair as Valve Electrical Fault required 9 Hydraulic Pressure Incorrect 9 Perform pressure test remove transmission and repair as needed 10 Reaction Shaft Seal Rings 10 Remove transmission remove oil pump Worn Broken and replace seal rings 11 Rear Cl
340. ove and retain overdrive piston thrust bearing Bearing may remain on piston or in dutch hub during removal 14 Position drain pan on workbench 15 Place overdrive unit over drain pan Tilt unit to drain residual fluid from case 42RE AUTOMATIC TRANSMISSION 21 87 16 Examine fluid for clutch material or metal fragments If fluid contains these items overhaul will be necessary 17 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 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 103 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 8921 269 Fig 103 Trimming Overdrive Case Gasket 1 GASKET 2 SHARP KNIFE 6 Install selective spacer on intermediate shaft if re
341. ovide a high level of protection for the internal components by providing a lubricating film between adjacent metal components The fluid must also be thermally stable so that it can maintain a consistent viscosity through a large temperature range If the viscosity stays con stant through the temperature range of operation transmission operation and shift feel will remain con sistent Transmission fluid must also be a good con ductor of heat The fluid must absorb heat from the internal transmission components and transfer that heat to the transmission case WJ 22 AUTOMATIC TRANSMISSION 21 11 DESCRIPTION AND OPERATION Continued TORQUE CONVERTER D DESCRIPTION L The torque converter Fig 9 is a hydraulic device s that couples the engine crankshaft to the transmis sion The torque converter consists of an outer shell 7 with internal turbine a stator overrunning dutch an impeller and an electronically applied con A 3 verter clutch The converter clutch provides reduced im engine speed and greater fuel economy when engaged Clutch engagement also provides reduced transmission fluid temperatures converter dutch engages in third gear The torque converter hub drives the transmission oil fluid pump The torque converter is a sealed welded unit that is not repairable and
342. ow and ice SHIFT MECHANISM Operating ranges are selected with a lever in the floor mounted shifter assembly The shift lever is con 21 276 NV242 TRANSFER CASE DESCRIPTION AND OPERATION Continued D 1 ae 2 A Z Q 80b09a60 Fig 2 Fill Drain Plug And I D Tag Locations 1 10 TAG 2 FILL PLUG 3 DRAIN PLUG nected to the transfer case range lever by an adjust able cable A straight line shift pattern is used Range positions are marked on the shifter bezel LUBRICANT AND FILL LEVEL DESCRIPTION Recommended lubricant for the NV242 transfer case is Mopar Dexron or ATF Plus type 7176 DIAGNOSIS AND TESTING NV242 DIAGNOSIS WJ Approximate lubricant fill capacity is 1 35 liters 2 85 pints The fill and drain plugs are both in the rear case Fig 3 Correct fill level is to the bottom edge of the fill plug hole Be sure the vehicle is level to ensure an accurate fluid level check X lt amp AQ lt ul 76 AGG NS X 3 80b09a60 Fig 3 Fill Drain Plug Locations 1 10 TAG 2 FILL PLUG 3 DRAIN PLUG DIAGNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION Transfer case difficult to shift or will not shift into desired range 3 Internal transfer case components binding worn or damaged Transfer case noisy in all 1 Insufficient or incorrect lubricant drive modes Lubri
343. p seal at installation 2 a replacement transmission is being installed transfer any components necessary such as the manual shift lever and shift cable bracket from the original transmission onto the replacement trans mission 3 Lubricate oil pump seal lip with transmission fluid 45RFE AUTOMATIC TRANSMISSION 21 217 TRANSFER CASE 42RE 80ba79c9 Fig 48 Remove NV247 Transfer Case TRANSFER CASE 45RFE 80ba79c8 Fig 49 Remove NV242 Transfer Case 4 Align converter and oil pump 5 Carefully insert converter in oil pump Then rotate converter back and forth until fully seated in pump gears 6 Check converter seating with steel scale and straightedge Fig 50 Surface of converter lugs should be 1 2 in to rear of straightedge when con verter is fully seated 7 Temporarily secure converter with C damp 8 Position transmission on jack and secure it with chains 9 Check condition of converter driveplate Replace the plate if cracked distorted or damaged Also be sure transmission dowel pins are seated in engine block and protrude far enough to hold transmission in alignment 10 Apply a light coating of Mopar High Temp Grease to the torque converter hub pocket in the rear 11 Raise transmission and align converter with drive plate and converter housing with engine block 21 218 45RFE AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION Continued Fig 50 Typical Method Of
344. press pressure slowly Compress hub and spring far enough to expose dutch hub retaining ring and relieve spring pressure on dutch pack snap ring 2 Fig 267 1 4 Remove direct dutch pack snap ring Fig 268 5 Remove direct dutch hub retaining ring Fig 269 6 Release press load slowly and completely Fig 270 f 4 m 7 Remove Special Tool 6227 1 Then remove A dutch pack from hub Fig 270 8 Mut J9321 364 Fig 268 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 7 9321 398 Fig 267 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 J9321 363 Fig 269 Direct Clutch Hub Retaining Ring Removal 1 SPECIAL TOOL 6227 1 2 CLUTCH HUB RETAINING RING 3 PRESS BED 4 PRESS PLATES 21 142 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued J9321 365 Fig 270 Direct Clutch Pack Removal 1 SPECIAL TOOL 6227 1 2 DIRECT CLUTCH HUB 3 DIRECT CLUTCH PACK J9121 312 Fig 272 Removing Sun Gear Thrust Bearing And Planetary Gear PLANETARY GEAR PLANETARY THRUST BEARING CLUTCH SPRING PLATE SPRING PLATE SNAP RING SUN GEAR Geartrain Di
345. pright 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 Door Ease or equivalent c Install piston over Seal Guide 8114 2 and inside Guide Ring 8114 1 d Push overdrive piston retainer into position in WJ 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 252 CLEANING AND INSPECTION VALVE BODY Clean the valve housings valves plugs springs and separator plates with a standard parts cleaning solution only Do not use gasoline kerosene or any type of caustic solution Do not immerse any of the electrical components in cleaning solution Clean the governor solenoid and sensor and the dual solenoid and harness assembly by wiping them off with dry shop towels only Dry all except the electrical parts with compressed air
346. pring assembly if any rollers or springs are worn or dam aged or if the roller cage is distorted or damaged Replace the cam if worn cracked or damaged Replace the low reverse clutch retainer if the dutch race roller surface or inside diameter is scored worn or damaged ACCUMULATOR Inspect the accumulator piston and seal rings Replace the seal rings if worn or cut Replace the pis ton if chipped or cracked Check condition of the accumulator inner and outer springs Replace the springs if the coils are cracked distorted or collapsed OIL PUMP AND REACTION SHAFT SUPPORT Clean pump and support components with solvent and dry them with compressed air Check condition of the seal rings and thrust washer on the reaction shaft support The seal rings do not need to be replaced unless cracked broken or severely worn Inspect the pump and support components Replace the pump or support if the seal ring grooves or machined surfaces are worn scored pitted or dam aged Replace the pump gears if pitted worn chipped or damaged Inspect the pump bushing Then check the reaction shaft support bushing Replace either bushing only if heavily worn scored or damaged It is not necessary to replace the bushings unless they are actually dam aged Inspect the valves and plugs for scratches burrs nicks or scores Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of
347. r If the transmission slips in third gear either the front dutch or the rear dutch is slipping If the transmission slips in fourth gear but not in third gear the overdrive dutch is slipping By select ing another gear which does not use these clutches the slipping unit can be determined For example if the transmission also slips in Reverse the front dutch is slipping If the transmission does not slip in Reverse the rear dutch is slipping If slippage occurs during the 3 4 shift or only in fourth gear the overdrive clutch is slipping Simi larly if the direct dutch were to fail the transmis sion would lose both reverse gear and overrun braking in 2 position manual second gear If the transmission will not shift to fourth gear the control switch overdrive solenoid or related wiring may also be the problem cause This process of elimination can be used to identify a slipping unit and check operation Proper use of the Clutch and Band Application Chart is the key Although road test analysis will help determine the slipping unit the actual cause of a malfunction usu ally cannot be determined until hydraulic and air pressure tests are performed Practically any condi tion can be caused by leaking hydraulic circuits or sticking valves Unless a malfunction is obvious such as no drive in D range first gear do not disassemble the trans mission Perform the hydraulic and air pressure tests to help determine the probable cau
348. r back out between the input shaft and the reaction shaft and back up to the switch valve From the switch valve the fluid pressure is directed to the transmission cooler and lubrication pressure returns from the cooler to lubricate different portions of the transmis sion 21 36 42RE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued THROTTLE PLUG ACCUMULATOR OVERDRIVE CLUTCH uu 3 4 ACCUMULATOR 2 S EXER Re n B E Ho 4 QUICK FILL VALVE TT m 8 EE TEPPERS 3 4 TIMING VALVE QOL yy 3 4 SHIFT VALVE m TORQUE CONVERTER TO LUBRICATION FRONT CLUTCH LUBRICATION L LJ OVERDRV SOL LOCKUP I UP VALVE k LOCI LOCK UP TIMING VALVE IJ 80c0714b Fig 42 Switch Valve Torque Converter Locked Once the TCC control valve has moved to the left Fig 42 line pressure is directed to the tip of the switch valve forcing the valve to the right The switch valve now vents oil from the front of the pis ton in the torque converter and supplies line pres sure to the rear apply side of the torque converter piston This pressure differential causes the piston to apply against the friction material cutting
349. r must be removed as an assembly to avoid compo nent damage The converter driveplate pump bush ing or oil seal can be damaged if the converter is left attached to the driveplate during removal Be sure to remove the transmission and converter as an assembly REM OVAL 1 Disconnect the negative battery cable 2 Raise and support the 3 Mark propeller shaft and axle yokes for assem bly alignment 4 Remove the rear propeller shaft 5 Remove the front propeller shaft 6 Remove the engine to transmission collar Fig 44 7 Remove the exhaust support bracket from the rear of the transmission 8 Disconnect and lower or remove any necessary exhaust components 9 Remove the starter motor 10 Rotate crankshaft in clockwise direction until converter bolts are accessible Then remove bolts one at a time Rotate crankshaft with socket wrench on dampener bolt 11 Disconnect wires from solenoid and pressure switch assembly input and output speed sensors and line pressure sensor 12 Disconnect gearshift cable from transmission manual valve lever Fig 45 13 Disconnect transfer case shift cable from the transfer case shift lever Fig 46 14 Remove the dip securing the transfer case shift cable into the cable support bracket 15 Disconnect transmission fluid cooler lines at transmission fittings and dips 16 Disconnect the transmission vent hose from the transmission ENG
350. r Piston Components 1 INNER SPRING 2 ACCUMULATOR PISTON 3 OUTER SPRING 4 SEAL RINGS WJ REMOVAL AND INSTALLATION Continued yoke for alignment reference at installation if necc esary 5 Disconnect and remove the rear propeller shaft if necessary 6 Remove transmission oil 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 vehicle speed sensor 10 Remove bolts attaching overdrive unit to transmission Fig 102 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 NT N J9021 83 Fig 102 Overdrive Unit Bolts 1 OVERDRIVE UNIT 2 ATTACHING BOLTS 7 11 Carefully work overdrive unit off intermediate shaft Do not tilt unit during removal Keep it as level as possible 12 If overdrive unit does not require service immediately insert Alignment Tool 6227 2 in splines of planetary gear and overrunning dutch 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 13 Rem
351. r snap ring onto the oil pump Fig 93 INNER SNAP RING 7 C MX TRANSMISSION outer snap COVER RING 80 07355 Fig 93 49 Using Installer 8255 install the inner trans mission front cover snap ring the remainder of the way onto the oil pump Fig 94 80c07417 Fig 94 Seat Snap Ring Using Tool 8255 50 Install the valve body Fig 95 Tighten the valve body to transmission case bolts to 12 N m 105 in Ibs 51 Install the primary oil filter and the oil cooler filter Fig 96 Tighten the screws to hold the pri mary oil filter to the valve body to 4 5 N m 40 in lbs Using Oil Filter Wrench 8321 tighten the cooler return oil filter to the transmission case to 14 N m 125 in Ibs 52 Apply RTV silicone to the oil pan and install the transmission oil Tighten the bolts to 12 105 in 165 WJ DISASSEMBLY AND ASSEMBLY Continued VALVE BODY TO CASE BOLT 6 Fig 95 Install Valve Body Assembly COOLER FILTER FILTER BYPASS PRIMARY OIL 80b9a595 Fig 96 Install Primary Oil and Cooler Filters 53 Install the input output and line pressure sensors Fig 97 Tighten the bolts to 12 N m 105 in Ibs 54 Install the manual shift lever from the trans mission Torque the retaining cross bolt to 16 140 in Ibs VALVE BODY DISASSEMBLY 1 Remove the screws holding the solenoid and pressure switch assembly to the valve body
352. r was replaced or drained and cooler was flushed add 12 pints 6 quarts of ATF Plus 3 to transmission 3 Apply parking brakes 4 Start and run engine at normal curb idle speed 5 Apply service brakes shift transmission through all gear ranges then back to NEUTRAL set parking brake and leave engine running at curb idle speed 6 Remove funnel insert dipstick and check fluid level If level is low add fluid to bring level to MIN mark on dipstick Check to see if the oil level is equal on both sides of the dipstick If one side is noticably higher than the other the dipstick has picked up some oil from the dipstick tube Allow the oil to drain down the dipstick tube and re check 7 Drive vehicle until transmission fluid is at nor mal operating temperature 8 With the engine running at curb idle speed the gear selector in NEUTRAL and the parking brake applied check the transmission fluid level CAUTION Do not overfill transmission fluid foam ing and shifting problems can result 9 Add fluid to bring level up to MAX arrow mark When fluid level is correct shut engine off release park brake remove funnel and install dipstick in fill tube 21 74 42 AUTOMATIC TRANSMISSION SERVICE PROCEDURES Continued CONVERTER DRAINBACK CHECK VALVE SERVICE The converter drainback check valve is located in the cooler outlet pressure line near the radiator tank The valve prevents fluid drainback when the vehi
353. rain end play with feeler gauge Fig 251 Gauge goes between shoulder on output shaft and end of rear annulus support 24 Geartrain end play should be 0 12 to 1 22 mm 0 005 to 0 048 in If end play is incorrect snap ring or thrust washers may have to be replaced Snap ring is available in three different thicknesses for adjustment purposes Fig 246 Installing Front Planetary And Annulus Gears 1 FRONT PLANETARY GEAR 2 FRONT THRUST WASHER 3 FRONT ANNULUS GEAR J9421 179 Fig 247 Positioning Thrust Plate On Front Annulus Support 1 FRONT ANNULUS 2 THRUST PLATE J9121 168 Fig 248 Installing Front Annulus Thrust Washer 1 WASHER FLAT ALIGNS WITH FLAT ON PLANETARY HUB 2 FRONT ANNULUS THRUST WASHER 3 TAB FACES FRONT 2 69 Fig 249 Installing Front Annulus Snap Ring 1 SNAP RING PLIERS 2 FRONT ANNULUS SNAP RING 2 AUTOMATIC TRANSMISSION 21 137 DISASSEMBLY AND ASSEMBLY Continued AK N J9121 170 Fig 250 Installing Planetary Selective Snap Ring 1 SELECTIVE SNAP RING 2 SNAP RING PLIERS 10321 348 Fig 252 Transmission Speed Sensor Removal Installation 1 SOCKET AND WRENCH 2 SPEED SENSOR 3 O RING J9121 171 Fig 251 Checking Planetary Geartrain End Play 1 OUTPUT SHAFT 2 REAR ANNULUS GEAR 3 FEELER GAUGE Fig 253 Overdrive Piston Thrust Be
354. ransmission in alignment 9 Apply a light coating of Mopar High Temp grease to the torque converter hub pocket in the rear of the crankshaft 10 Raise transmission and align converter with drive plate and converter housing with engine block WJ 11 Move transmission forward Then raise lower or tilt transmission to align converter housing with engine block dowels 12 Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft 13 Install two bolts to attach converter housing to engine 14 Install the upper transmission bending braces to the torque converter housing and the overdrive unit Tighten the bolts to 41 N m 30 ft 165 15 Install remaining torque converter housing to engine bolts Tighten to 68 50 ft Ibs 16 Install rear transmission crossmember Tighten crossmember to frame bolts to 68 N m 50 ft Ibs 17 Install rear support to transmission Tighten bolts to 47 35 ft Ibs 18 Lower transmission onto crossmember and install bolts attaching transmission mount to cross member Tighten devis bracket to crossmember bolts to 47 35 ft Ibs Tighten the clevis bracket to rear support bolt to 68 N m 50 ft Ibs 19 Remove engine support fixture 20 Install crankshaft position sensor 21 Install new plastic retainer grommet on any shift cable that was disconnected Grommets should not be reused Use pry tool to
355. rate the inner and outer races of the over running clutch Fig 122 21 246 45RFE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued REACTION PLATE SNAP RING SELECT OVERRUNNING CLUTCH SNAP RING 2 PLATE L R CLUTCH RETAINER PISTON BELLEVILLE S BS Af SNAP RETAINER RING SPRING 80 07033 Fig 121 Low Reverse Clutch Assembly 8 Remove the overrunning clutch lower snap ring Fig 122 9 Using Spring Compressor 8285 and a suitable shop press Fig 123 compress the low reverse pis ton Belleville spring and remove the split retaining ring holding the Belleville spring into the low reverse dutch retainer 10 Remove the low reverse dutch Belleville spring and piston from the low reverse dutch retainer Use 20 psi of air pressure to remove the pis ton if necessary ASSEMBLY 1 Clean and inspect all components Replace any components which show evidence of excessive wear or scoring 2 Check the bleed orifice to ensure that it is not plugged or restricted 3 Install a new seal on the low reverse piston Lubricate the seal with ATF 43 type 7176 prior to installation 4 Install the low reverse piston into the low re verse clutch retainer 5 Position the low reverse piston Belleville spring on the low reverse piston 6 Using Spring Compressor 8285 and a suitable shop press Fig 123 compress the low reverse pis ton
356. rbine within the torque converter case Fig 6 The stator contains an over running dutch which allows the stator to rotate only in a clockwise direction When the stator is locked against the over running dutch the torque multiplication feature of the torque converter is operational SIDE OF STATOR SHOWING VANE CURVATURE VIEW FROM ENGINE SIDE B0bfe26c Fig 5 Stator Components 1 CAM OUTER RACE 2 ROLLER 3 SPRING 4 INNER RACE 80bfe26d Fig 6 Stator Location 1 STATOR 2 IMPELLER 3 FLUID FLOW 4 TURBINE TORQUE CONVERTER CLUTCH TCC The TCC Fig 7 was installed to improve the effi ciency of the torque converter that is lost to the slip page of the fluid coupling Although the fluid coupling provides smooth shock free power transfer it is natural for all fluid couplings to slip If the impeller and turbine were mechanically locked together a zero slippage condition could be obtained A hydraulic piston was added to the turbine and a friction material was added to the inside of the front cover to provide this mechanical lock up OPERATION The converter impeller Fig 8 driving member which is integral to the converter housing and bolted to the engine drive plate rotates at engine speed The converter turbine driven member which reacts from fluid pressure generated by the impeller rotates and turns the transmission input shaft TURBINE As the fluid that was
357. rclockwise the action causes the rollers to roll in the same direction as the race aided by the pushing of the springs As the rollers try to move in the same direction as the inner race they are wedged between the inner and outer races due to the design of the cam In this condition the clutch is locked and acts as one unit PLANETARY GEARSET DESCRIPTION The planetary gearsets Fig 58 are designated as the front rear and overdrive planetary gear assem blies and located in such order A simple planetary gearset consists of three main members 42RE AUTOMATIC TRANSMISSION 21 45 80be4 SS Fig 58 Planetary Gearset 1 ANNULUS GEAR 2 SUN GEAR 3 PLANET CARRIER 4 PLANET PINIONS 4 e The sun gear which is at the center of the sys tem e The planet carrier with planet pinion gears which are free to rotate on their own shafts and are in mesh with the sun gear e The annulus gear which rotates around and is in mesh with the planet pinion gears NOTE The number of pinion gears does not affect the gear ratio only the duty rating OPERATION With any given planetary gearset several condi tions must be met for power to be able to flow e One member must be held e Another member must be driven or used as an input e The third member may be used as an output for power flow e For direct drive to occur two gear members in the front planetary gearset must be driven NOTE Gear ratios are depend
358. re and record OD clutch pack measure 21 242 45RFE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued UNDERDRIVE CLUTCH PACK 80c07440 Fig 114 Measuring UD Clutch Clearance ment in four 4 places 90 apart Take average of four measurements and compare with OD dutch pack clearance specification Verify that the dutch clearance is 1 016 1 65 mm 0 040 0 065 in REACTION PLATE 80c07447 Fig 115 Measuring OD Clutch Clearance 22 Install the reverse clutch pack into the input clutch retainer Fig 107 23 Install the reverse reaction plate into the input clutch retainer 24 Install the reverse reaction plate selective snap ring into the input clutch retainer 25 Mount a dial indicator to the assembly push down on the dutch discs pull up on the reaction planetary plate to ensure the plate is properly seated and zero the indicator against the reverse dutch discs Fig 116 Apply 20 psi of air pressure to the WJ reverse clutch and record the dial indicator reading Measure and record Reverse clutch pack measure ment in four 4 places 90 apart Take average of four measurements and compare with Reverse clutch pack clearance specification The correct clutch clear ance is 0 81 1 24 mm 0 032 0 049 Adjust as necessary Install the chosen snap ring and re mea sure to verify selection TOOL C 3339 S REVERSE CLUTCH PACK 80 07446 Fig 116 Mea
359. remely important as it is also used in the design and operation of all shift valves and limiting valves in the valve body as well as the pistons of the transmission which activate the dutches and bands It is nothing more than using a difference of area to create a difference in pressure to move an object 1000 LBS 100 LBS OUTPUT j L AREA 100 SQ IN AREA 10 SQ IN 80bfe274 Fig 52 Force Multiplication 42RE AUTOMATIC TRANSMISSION 21 41 PISTON TRAVEL The relationship between hydraulic lever and a mechanical lever is the same With a mechanical lever it s a weight to distance output rather than a pressure to area output Using the same forces and areas as in the previous example the smaller piston Fig 53 has to move ten times the distance required to move the larger piston one inch Therefore for every inch the larger piston moves the smaller pis ton moves ten inches This principle is true in other instances also A common garage floor jack is a good example To raise car weighing 2000 Ibs an effort of only 100 165 may be required For every inch the car moves upward the input piston at the jack han dle must move 20 inches downward 80bfe275 Fig 53 Piston Travel 21 42 42 AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued J9321 222 Fig 54 Front Clutch 7 SNAP RING WAVED 8 CLUTCH PLATES 9 SPRING RETAINER 10 PISTON SEAL 11
360. ressure is released the dutch should also release CONVERTER HOUSING FLUID LEAK DIAGNOSIS When diagnosing converter housing fluid leaks two items must be established before repair 1 Verify that a leak condition actually exists 2 Determined the true source of the leak Some suspected converter housing fluid leaks may not be leaks at all They may only be the result of residual fluid in the converter housing or excess fluid spilled during factory fill or fill after repair Converter housing leaks have several potential sources Through careful observation a leak source can be identified before removing the transmission for repair Pump seal leaks tend to move along the drive hub and onto the rear of the converter Pump cover O ring leaks follow the same path as a seal leak TORQUE CONVERTER LEAK POINTS Possible sources of converter leaks are 1 Leaks at the weld joint around the outside diameter weld Fig 36 2 Leaks at the converter hub weld Fig 36 RH254 Fig 36 Converter Leak Points Typical 1 OUTSIDE DIAMETER WELD 2 TORQUE CONVERTER HUB WELD 3 STARTER RING GEAR 4 LUG SERVICE PROCEDURES FLUID LEVEL CHECK Low fluid level can cause a variety of conditions because it allows the pump to take in air along with the fluid As in any hydraulic system air bubbles make the fluid spongy therefore pressures will be low and build up slowly Improper filling can also raise the fluid leve
361. retainer seal 4 Using Remover 6957 remove bushing from rear retainer Fig 11 NV247 TRANSFER CASE 21 313 80298373 Fig 11 Rear Retainer Bushing Removal 1 REMOVER 6957 2 REAR RETAINER BUSHING INSTALLATION 1 Clean fluid residue from sealing surface and inspect for defects 2 Position replacement bushing in rear retainer with fluid port in bushing aligned with slot in retainer 3 Using Installer 8145 drive bushing into retainer until installer seats against case Fig 12 4 Using Installer C 3995 A install seal in rear retainer Fig 13 REAR RETAINER BUSHING INSTALLER 80a9836c Fig 12 Rear Retainer Bushing Install 5 Install rear propeller shaft Refer to Group 3 Differential and Driveline for proper procedures and specifications 6 Verify proper fluid level 7 Lower vehicle 21 314 NV247 TRANSFER CASE REMOVAL AND INSTALLATION Continued 80 983 7 Fig 13 Install Rear Retainer Seal 1 SPECIAL TOOL C 4171 2 SPECIAL TOOL C 3995 A 80ba7a33 Fig 15 Remove Rubber Access Plug b Then slide retainer off mainshaft and rear DISASSEMBLY AND ASSEMBLY bearing Fig 18 NV247 TRANSFER CASE D lt C TOOL DISASSEMBLY 2 lt Position transfer case on shallow drain RETAINER BOSS OA Ex Remove drain plug and drain lubricant remaining in REAR _ case RETAINER SEALER
362. ring on the right This allows line pressure to push the valve train to the right reducing the amount of fluid returned to the pump s inlet increasing line pressure 21 24 2 AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued Le E LLLA und MANUAL VALVE SCREEN TORQUE TO LUBRICATION OIL FILTER 80 07140 Fig 25 Regulator Valve in Reverse Position WJ DESCRIPTION AND OPERATION Continued 42RE AUTOMATIC TRANSMISSION 21 25 ERIC IO IOC IEICE IOS CIC SESE e 2 _ MANUAL VALVE pU 4 E Cia BOOST VALVE J WE J S 80 07141 Fig 26 Kickdown Valve Wide Open Throttle KICKDOWN VALVE When the throttle valve is as far over to the left as it can go the maximum line pressure possible will enter the throttle pressure circuit In this case throt tle pressure will equal line pressure With the kick down valve Fig 26 pushed into the bore as far as it will go fluid initially flows through the annular groove of the 2 3 shift valve which will be in the direct drive position to the right After passing the
363. rocket Snap Ring 80ba7a53 TRANSFER PROGRESSIVE CASE COUPLING 0 MAINSHAFT y N NA 09 Q SNAP RINGS 80ba7a50 Fig 62 Progressive Coupling Installation MILA Q CASE P ook alk OS J9321 73 ASSEMBLY CASE SLOT Fig 63 Oil Pickup Tube Installation 13 Verify that oil pickup tube is still seated in case notch and tube end is pointed toward mainshaft Fig 67 21 326 NV247 TRANSFER CASE h i oq n 9 WJ DISASSEMBLY AND ASSEMBLY Continued CORRECT PICKUP POSITION J9321 76 199415298 Fig 67 Checking Position Of Oil Pickup Tube Fig 64 Installing Case Magnet 14 Install case attaching bolts Alignment bolts 1 MAGNET at each end of case are only ones requiring washers Fig 68 15 Tighten case bolts to 27 34 N m 20 25 ft 165 torque Fig 68 Alignment Bolt Location 1 ALIGNMENT BOLT AND WASHER AT EACH END OF CASE FRONT CASE FLANGE 80ba7a54 COMPANION FLANGE AND RANGE LEVER INSTALLATION 1 Install range lever washer and locknut on sec tor shaft Fig 69 Tighten locknut to 27 34 N m 20 25 ft Ibs torque 2 Install new seal washer on front output shaft Fig 70 3 Lubricate flange hub with transmission fluid and install flange on front shaft 4 Install new seal washer on front shaft 5 Install companion flange and new nut on front output shaft 6 Tighten flange
364. ront of the transmission and is driven by the torque con verter hub The pump supplies the oil pressure nec essary for clutch band actuation and transmission lubrication The 42RE transmission is cooled by an integral fluid cooler inside the radiator 1 2 AUTOMATIC TRANSMISSION 21 3 DESCRIPTION AND OPERATION Continued J9321 407 Fig 1 42RE Transmission 21 4 42 AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued CONVERTER CLUTCH TORQUE CONVERTER OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY FRONT BAND FRONT CLUTCH DRIVING SHELL REAR BAND 8 TRANSMISSION OVERRUNNING CLUTCH 9 OVERDRIVE UNIT 10 PISTON RETAINER 11 OVERDRIVE CLUTCH 12 DIRECT CLUTCH 13 INTERMEDIATE SHAFT 14 FRONT BEARING 15 HOUSING 16 REAR BEARING 17 OUTPUT SHAFT 18 SEAL 19 OVERDRIVE OVERRUNNING CLUTCH 20 OVERDRIVE PLANETARY GEAR 21 DIRECT CLUTCH SPRING 22 OVERDRIVE CLUTCH PISTON VALVE BODY ASSEMBLY 24 FILTER 25 FRONT PLANETARY GEAR REAR CLUTCH 27 TRANSMISSION 28 REAR PLANETARY GEAR IDENTIFICATION Transmission identification numbers are stamped on t
365. rt in Failure O D piston retainer DELAYED 3 4 UPSHIFT 1 Fluid Level Low 1 Add fluid and check for leaks SLOW TO ENGAGE 3 Overdrive Clutch Pack Worn 3 Remove unit and rebuild clutch pack Burnt 4 TPS Faulty 4 Test with DRB scan tool and replace as necessary 5 Overdrive Clutch Bleed Orifice 5 Disassemble transmission and replace Plugged orifice 2 Throttle Valve Cable Misadjusted 2 Adjust throttle valve cable 6 Overdrive Solenoid or Wiring 6 Test solenoid and check wiring for Shorted Open loose corroded connections or shorts grounds Replace solenoid if faulty and repair wiring if necessary 7 Overdrive Excess Clearance 7 Remove unit Measure end play and select proper spacer 8 O D Check Valve Missing or 8 Check for presence of check valve Stuck Repair or replace as required TORQUE CONVERTER Lockup Solenoid Relay or Wiring Test solenoid relay and wiring for LOCKS UP IN SECOND Shorted Open continuity shorts or grounds Replace AND OR THIRD GEAR solenoid and relay if faulty Repair wiring and connectors as necessary HARSH 1 2 2 3 3 4 OR Lockup Solenoid Malfunction Remove valve body and replace solenoid 3 2 SHIFTS assembly 4 2RE AUTOMATIC TRANSMISSION 21 71 DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION NO START IN PARK OR 1 Gearshift Linkage Cable 1 Adjust linkage cable NEUTRAL Misadjusted 2 Neutral Switch Wire Open Cut 2 Check continuity
366. s cycled OFF and ON The normal position for the con trol switch is the ON position The switch must be in this position to energize the solenoid and allow a 3 4 upshift The control switch indicator light illuminates only when the overdrive switch is turned to the OFF position or when illuminated by the transmission control module BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM DESCRIPTION The Brake Transmission Shifter Ignition Interlock BTSI is a cable and solenoid operated system It interconnects the automatic transmission floor mounted shifter to the steering column ignition switch Fig 27 21 200 45RFE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued 80ba79c2 Fig 27 Ignition Interlock Cable 4 STEERING COLUMN ASSEMBLY 5 INTERLOCK CABLE 1 SHIFT MECHANISM 2 SHIFTER BTSI LEVER 3 ADJUSTMENT CLIP OPERATION The system locks the shifter into the PARK posi tion The interlock system is engaged whenever the ignition switch is in the LOCK or ACCESSORY posi tion An additional electrically activated feature will prevent shifting out of the PARK position unless the brake pedal is depressed at least one half an inch A magnetic holding device in line with the park lock cable is energized when the ignition is in the RUN position When the key is in the RUN position and the brake pedal is depressed the shifter is unlocked and will move into any position The interlock system als
367. s or manu facturing tolerances The pressure transducer is affected by barometric pressure as well as temperature Calibration of the zero pressure offset is required to compensate for shifting output due to these factors Normal calibration will be performed when sump temperature is above 50 degrees F or in the absence 21 50 42RE AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued of sump temperature data after the first 10 minutes of vehide operation Calibration of the pressure transducer offset occurs each time the output shaft speed falls below 200 RPM Calibration shall be repeated each 3 seconds the output shaft speed is below 200 RPM A 5 second pulse of 9596 duty cyde is applied to the governor pressure solenoid valve and the transducer output is read during this pulse Averaging of the transducer signal is necessary to reject electrical noise Under cold conditions below 50 degrees F sump the governor pressure solenoid valve response may be too slow to guarantee 0 psi during the 5 second calibration pulse Calibration pulses are continued during this period however the transducer output valves are discarded Transducer offset must be read at key on under conditions which promote a stable reading This value is retained and becomes the off set during the cold period of operation GOVERNOR PRESSURE SOLENOID VALVE The inlet side of the solenoid valve is exposed to normal transmission line pressure The out
368. s to ON after the ignition switch is cyded OFF and ON The normal position for the con trol switch is the ON position The switch must be in this position to energize the solenoid and allow a 3 4 upshift The control switch indicator light illuminates only when the overdrive switch is turned to the OFF 42RE AUTOMATIC TRANSMISSION 21 51 position or when illuminated by the transmission control module BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM DESCRIPTION The Brake Transmission Shifter Ignition Interlock BTSI is a cable and solenoid operated system It interconnects the automatic transmission floor mounted shifter to the steering column ignition switch Fig 66 OPERATION The system locks the shifter into the PARK posi tion The interlock system is engaged whenever the ignition switch is in the LOCK or ACCESSORY posi tion An additional electrically activated feature will prevent shifting out of the PARK position unless the brake pedal is depressed at least one half an inch A magnetic holding device in line with the park lock cable is energized when the ignition is in the RUN position When the key is in the RUN position and the brake pedal is depressed the shifter is unlocked and will move into any position The interlock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position unless the shifter is fully locked into the PARK position DIAGNOSIS AND TESTING AUTOMATIC TRANSMISSION DI
369. s unless they are acually damaged WJ CLEANING AND INSPECTION Continued 0 J9121 64 Fig 313 Rear Servo Components 1 SNAP RING 2 PISTON SEAL 3 PISTON PLUG 4 SPRING RETAINER 5 SNAP RING 6 PISTON SPRING 7 CUSHION SPRING 8 PISTON 5 Install the gears in the pump body and mea sure pump component clearances as follows a Clearance between outer gear and reaction shaft housing should be 0 010 to 0 063 mm 0 0004 to 0 0025 in Clearance between inner gear and reaction shaft housing should be 0 010 to 0 063 mm 0 0004 to 0 0025 in Both clearances can be measured at the same time by Installing the pump gears in the pump housing Position an appropriate piece of Plasti gage across both gears Align the plastigage to a flat area on the reaction shaft housing IV Install the reaction shaft to the pump housing V Separate the reaction shaft housing from the pump housing and measure the Plastigage following the instructions supplied with it b Clearance between inner gear tooth and outer gear should be 0 08 to 0 19 mm 0 0035 to 0 0075 in Measure clearance with an appropriate feeler gauge Clearance between outer gear and pump housing should also be 0 010 to 0 19 mm 0 0035 to 0 0075 in Measure clearance with an appropriate feeler gauge FRONT CLUTCH Clean and inspect the front dutch components Replace the clutch discs if warp
370. sassembly 1 Remove direct dutch hub and spring Fig 271 2 Remove sun gear and spring plate Then remove planetary thrust bearing and planetary gear Fig 272 2 J9121 311 Fig 271 Direct Clutch Hub And Spring Removal 1 DIRECT CLUTCH SPRING 2 DIRECT CLUTCH HUB 3 Remove overrunning dutch assembly with expanding type snap ring pliers Fig 273 Insert pli ers into dutch hub Expand pliers to grip hub splines and remove clutch with counterclockwise twisting moti on 4 Remove thrust dutch hub 5 Remove overrunning clutch from hub 6 Mark position of annulus gear and direct clutch drum for assembly alignment reference Fig 274 Use small center punch or scriber to make alignment marks bearing from overrunning 8921 248 Fig 273 Overrunning Clutch Assembly Removal Installation 1 OVERRUNNING CLUTCH 2 NEEDLE BEARING WJ DISASSEMBLY AND ASSEMBLY Continued 8921 249 Fig 274 Marking Direct Clutch Drum And Annulus Gear For Assembly Alignment 1 DIRECT CLUTCH DRUM 2 HAMMER 3 PUNCH 42RE AUTOMATIC TRANSMISSION 21 143 Fig 276 Clutch Drum Outer Retaining Ring Removal 1 OUTER RETAINING RING 7 Remove direct clutch drum rear retaining ring Fig 275 8 Remove direct clutch drum outer retaining ring Fig 276 9 Mark annulus gear and output shaft for assem bly alignment reference Fig 277 Use punch or scriber to mar
371. se 8 Adapter Extension Gasket 8 Replace gasket Damaged Leaks Damaged 9 Neutral Switch Leaks Damaged 9 Replace switch and gasket 10 Converter Housing Area Leaks 10 Check for leaks at seal caused by worn seal or burr on converter hub cutting seal worn bushing missing oil return oil in front pump housing or hole plugged Check for leaks past O ring seal on pump or past pump to case bolts pump housing porous oil coming out vent due to overfill or leak past front band shaft access plug 11 Pump Seal Leaks Worn 11 Replace seal Damaged 12 Torque Converter Weld 12 Replace converter Leak Cracked Hub 13 Case Porosity Leaks 13 Replace case 21 72 42 AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION NOISY OPERATION IN FOURTH GEAR ONLY 2 Overdrive Piston or Planetary 2 Remove and disassemble unit Replace Thrust Bearing Damaged either thrust bearing if damaged 3 Output Shaft Bearings Scored 3 Remove and disassemble unit Replace Damaged either bearing if damaged 4 Planetary Gears Worn Chipped 4 Remove and overhaul overdrive unit 5 Overdrive Unit Overrunning Clutch 5 Remove and overhaul overdrive unit Rollers Worn Scored SERVICE PROCEDURES FLUID LEVEL CHECK Transmission fluid level should be checked monthly under normal operation If the vehide is used for trailer towing or similar heavy load hauling check fluid level and condition w
372. se HYDRAULIC PRESSURE TEST Hydraulic test pressures range from a low of one psi 6 895 kPa governor pressure to 300 psi 2068 kPa at the rear servo pressure port in reverse 42RE AUTOMATIC TRANSMISSION 21 55 An accurate tachometer and pressure test gauges are required Test Gauge C 3292 has a 100 psi range and is used at the accumulator governor and front servo ports Test Gauge C 3293 SP has a 300 psi range and is used at the rear servo and overdrive ports where pressures exceed 100 psi Pressure Test Port Locations Test ports are located at both sides of the transmis sion case Fig 67 Line pressure is checked at the accumulator port on the right side of the case The front servo pressure port is at the right side of the case just behind the filler tube opening The rear servo and governor pressure ports are at the right rear of the transmission case The overdrive dutch pressure port is at the left rear of the case J9321 137 Fig 67 Pressure Test Port Locations 1 REAR SERVO TEST PORT 2 GOVERNOR TEST PORT 3 ACCUMULATOR TEST PORT 4 FRONT SERVO TEST PORT 5 OVERDRIVE CLUTCH TEST PORT 21 56 2 AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING Continued Test One Transmission In Manual Low NOTE This test checks pump output pressure reg ulation and condition of the rear clutch and servo circuit Both test gauges are required for this test 1 Connect tachometer to engine
373. secures shuttle valve sec ondary spring on valve stem Fig 134 4 Remove throttle plug primary spring shuttle valve secondary spring and spring guides Fig 135 21 96 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued 10 Remove 1 2 shift valve and spring Fig 136 11 Remove 2 3 shift valve and spring from valve body Fig 136 12 Remove pressure plug cover Fig 136 13 Remove line pressure plug sleeve throttle pressure plug and spring Fig 136 mn Fig 131 Upper Housing Separator Plate 1 TRANSFER PLATE 2 UPPER HOUSING SEPARATOR PLATE 3 FILTER SCREEN 4 BRACE J9321 154 Fig 133 Check Ball Locations In Upper Housing 1 SMALL DIAMETER CHECK BALLS 6 2 LARGE DIAMETER CHECK BALL 1 J9321 437 Fig 132 Rear Clutch And Hear Servo Check Ball Locations 1 REAR CLUTCH CHECK BALL 2 REAR SERVO CHECK BALL 3 TRANSFER PLATE 5 Remove boost valve retainer spring and valve if not previously removed 6 Remove throttle plug and 1 2 and 2 3 governor plugs Fig 122 Fig 134 Shuttle Valve E Clip And Secondary Spring 7 Turn upper housing around and remove limit Location valve and shift valve covers Fig 136 1 E CLIP 8 Remove limit valve housing Then remove 2 SECONDARY SPRING AND GUIDES retainer spring limit valve and 2 3 throttle plug 3 SHUTTLE VALVE from limit valve housing Fig
374. sensed by the PCM such as when the vehide begins to go uphill or the throttle pressure is increased The torque converter dutch feature increases fuel econ omy and reduces the transmission fluid temperature Since the overdrive dutch is applied in fourth gear only and the direct clutch is applied in all ranges except fourth gear the transmission operation for park neutral and first through third gear will be described first Once these powerflows are described the third to fourth shift sequence will be described WJ DESCRIPTION AND OPERATION Continued PARK POWERFLOW As the engine is running and the crankshaft is rotating the flexplate and torque converter which are also bolted to it are all rotating in a clockwise direction as viewed from the front of the engine The notched hub of the torque converter is connected to the oil pump s internal gear supplying the transmis sion with oil pressure As the converter turns it turns the input shaft in a clockwise direction As the input shaft is rotating the front clutch hub rear clutch retainer and all their associated parts are also rotating all being directly connected to the input shaft The power flow from the engine through the front clutch hub and rear clutch retainer stops at the rear clutch retainer Therefore no power flow to the output shaft occurs because no clutches are applied The only mechanism in use at this time is the park ing sprag Fig 3 which locks the par
375. shift lever selection This design allows the vehicle to be driven in limp in mode in the event of a electronic control system fail ure or a situation that the Transmission Control Module TCM recognizes as potentially damaging to the transmission The TCM also performs certain self diagnostic functions and provides comprehensive information sensor data DTC s etc which is helpful in proper diagnosis and repair This information can be viewed with the DRB scan tool FLUID NOTE Refer to the maintenance schedules in Group 0 Lubrication and Maintenance for the rec ommended maintenance fluid filter change inter vals for this transmission NOTE Refer to Service Procedures in this group for fluid level checking procedures DESCRIPTION Mopar ATF Plus 3 Type 7176 automatic trans mission fluid is the recommended fluid for Daimler Chrysler automatic transmissions Dexron fluid 15 NOT recommended Clutch chatter can result from the use of improper fluid Mopar ATF Plus 3 Type 7176 automatic trans mission fluid when new is red in color The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze The red color is not permanent and is not an indicator of fluid condition As the vehicle is driven the ATF will begin to look darker in color and may eventually 45RFE AUTOMATIC TRANSMISSION 21 183 become brown This is normal A dark brown black fluid ac
376. shuttle valve into housing c Hold shuttle valve in place d Compress secondary spring and install E dip in groove at end of shuttle valve e Verify that spring and E dip are properly seated before proceeding 8 Install shuttle valve cover plate Tighten cover plate screws to 4 N m 35 in Ibs torque 9 Install 1 2 and 2 3 valve governor plugs in valve body 10 Install throttle plug 11 Align and install governor plug cover Tighten cover screws to 4 35 in Ibs torque shuttle valve primary spring and 2 2 AUTOMATIC TRANSMISSION 21 103 DISASSEMBLY AND ASSEMBLY Continued J9421 217 Fig 146 Shuttle And Boost Valve Components 1 SPRING 8 SHUTTLE VALVE COVER 2 RETAINER 9 SHUTTLE VALVE 3 BOOST VALVE 10 SHUTTLE VALVE PRIMARY SPRING 4 BOOST VALVE PLUG 11 GOVERNOR PLUG COVER 5 SPRING GUIDES 12 THROTTLE PLUG 6 E CLIP 13 UPPER HOUSING 7 SHUTTLE VALVE SECONDARY SPRING 14 BOOST VALVE COVER 21 104 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued J9321 155 Fig 147 Upper Housing Control Valve Locations 1 UPPER HOUSING 8 MANUAL VALVE 2 REGULATOR VALVE 9 1 2 GOVERNOR PLUG 3 SWITCH VALVE 10 GOVERNOR PLUG COVER 4 REGULATOR VALVE SPRING 11 THROTTLE PLUG 5 KICKDOWN VALVE 12 2 3 GOVERNOR PLUG 6 KICKDOWN DETENT 13 SHUTTLE VALVE PRIMARY SPRING 7
377. ss of these edges is vitally important The edges prevent foreign matter from lodging between the valves and plugs and the bore Inspect all the valve and plug bores in the valve body Use a penlight to view the bore interiors Replace the valve body if any bores are distorted or scored Inspect all of the valve body springs The springs must be free of distortion warpage or broken coils Trial fit each valve and plug in its bore to check freedom of operation When clean and dry the valves and plugs should drop freely into the bores Valve body bores do not change dimensionally with use If the valve body functioned correctly when new it will continue to operate properly after cleaning and inspection It should not be necessary to replace 21 248 45RFE AUTOMATIC TRANSMISSION CLEANING AND INSPECTION Continued SOLENOID MANUAL SWITCH 3 s VALVE VALVE H B CHECK i BALLS 7 LOW REVERSE 4TH CLUTCH 2 SWITCH s VALVE OVERDRIVE LOW REVERSE ACCUMULATOR ACCUMULATOR UNDERDRIVE 2 ACCUMULATOR 2ND CLUTCH E E E ACCUMULATOR W 80b9a599 Fig 124 Valve Body Components valve body assembly unless it is damaged in han dling Inspect all the accumulator bores in the valve body Use penlight to view the bore interiors Replace the valve body if any bores are distorted or s
378. ssible in any other gear position 3 With floor shift lever handle push button not depressed and lever in a PARK position Apply forward force on cen ter of handle and remove pressure Engine starts must be possible b PARK position Apply rearward force on cen ter of handle and remove pressure Engine starts must be possible NEUTRAL position Normal position Engine starts must be possible d NEUTRAL position Engine running brakes applied apply forward force on center of shift handle Transmission shall not be able to shift from neutral to reverse ROAD TESTING Before road testing be sure the fluid level and con cable adjustments have been checked and adjusted if necessary Verify that all diagnostic trou ble codes have been resolved Observe engine performance during the road test A poorly tuned engine will not allow accurate analy sis of transmission operation Operate the transmission in all gear ranges Check for shift variations and engine flare which indicates slippage Note if shifts are harsh spongy delayed early or if part throttle downshifts are sensitive Slippage indicated by engine flare usually means dutch or overrunning clutch problems A slipping dutch can often be determined by com paring which internal units are applied in the vari ous gear ranges The Clutch Application chart provides a basis for analyzing road test results 21 208 45RFE AUTOMATIC TRANSMISSION
379. ston if necessary 4 Remove the 4C dutch snap ring from the retainer bulkhead Fig 117 5 Remove the 4C dutch pack from the retainer bulkhead Fig 117 6 Using Spring Compressor 8250 and a suitable shop press compress the 4C piston return spring and remove the snap ring Fig 117 7 Remove the 4C piston return spring and piston from the retainer bulkhead Fig 117 Use 20 psi of air pressure to remove the piston if necessary ASSEM BLY 1 Clean and inspect all components Replace any components which show evidence of excessive wear or scoring 2 Install new seals on the 2C and 4C pistons Fig 117 3 Lubricate all seals with Mopar ATF 43 type 7176 prior to installation 4 Install the 4 piston into the 4C retainer bulk head Fig 117 5 Position the 4 piston return spring onto the 4C piston 6 Using Spring Compressor 8250 and a suitable shop press compress the 4C piston return spring and install the snap ring Fig 118 7 Assemble and install the 4C clutch pack into the retainer bulkhead Fig 117 8 Install the 4C reaction plate and snap ring into the retainer bulkhead Fig 117 The 4C reaction plate is non directional 9 Measure the 4 dutch dearance The correct dutch clearance is 0 81 1 35 mm 0 032 0 053 in The snap ring is selectable Install the chosen snap ring and re measure to verify the selection 10 Install the 2C piston into the retainer bulk head Fig 11
380. supply transmis sion line pressure to the governor pressure solenoid valve and to return governor pressure The governor pressure solenoid valve is mounted in the governor body The body is bolted to the lower side of the transfer plate Fig 64 TRANSMISSION FLUID TEMPERATURE THERMISTOR Transmission fluid temperature readings are sup plied to the transmission control module by the ther mistor The temperature readings are used to control engagement of the fourth gear overdrive dutch the converter dutch and governor pressure Normal resistance value for the thermistor at room tempera ture is approximately 1000 ohms 42RE AUTOMATIC TRANSMISSION 21 49 80 072 Fig 64 Governor Pressure Sensor 1 GOVERNOR BODY 2 GOVERNOR PRESSURE SENSOR TRANSMISSION FLUID TEMPERATURE THERMISTOR The thermistor is part of the governor pressure sensor assembly and is immersed in transmission fluid at all times TRANSMISSION SPEED SENSOR The speed sensor Fig 65 is located in the over drive gear case The sensor is positioned over the park gear and monitors transmission output shaft rotating speed J9321 411 Fig 65 Transmission Output Speed Sensor 1 TRANSMISSION OUTPUT SHAFT SPEED SENSOR 2 SEAL OPERATION Compensation is required for performance varia tions of two of the input devices Though the slope of the transfer functions is tightly controlled offset may vary due to various environmental factor
381. surface Fig 1 Refer to this information when ordering replacement parts A label is attached to the transmission case above the stamped numbers The label gives additional information which may also be necessary for identification purposes IDENTIFICATION NUMBERS STAMPED TITTJ167710161 M MINH P52119099AA 45RF LABEL 80b9a596 Fig 1 Transmission Part And Serial Number Location GEAR RATIOS The 45RFE gear ratios are TSE wa 3 00 1 Pl denies 1 67 1 2 d Prime ee eh dee 1 50 1 Luces dcs xe le aere gc e Q 1 00 1 Ud CYCLE 0 75 1 Reverse aa x e 3 00 1 OPERATION The 45RFE offers full electronic control of all auto matic up and downshifts and features real time adaptive closed loop shift and pressure control Elec tronic shift and torque converter clutch controls help protect the transmission from damage due to high temperatures which can occur under severe operat ing conditions By altering shift schedules line pres sure and converter dutch control these controls reduce heat generation and increase transmission cooling To help reduce efficiency robbing parasitic losses the transmission includes a dual stage transmission fluid pump with electronic output pressure control Under most driving conditions pump output pres sure greatly exceeds that which
382. suring Reverse Clutch Clearance 26 Remove the reverse clutch pack from the input dutch retainer 27 Install the number 2 bearing onto the under drive hub with flat side up forward with petroleum jelly 28 Install the underdrive hub into the input dutch retainer 29 Install the number 3 bearing into the over drive hub with the flat side up forward with petro leum jelly 30 Install the overdrive hub into the input clutch retainer 31 Install the number 4 bearing into the reverse hub with flat side up forward with petroleum jelly 32 Install the reverse hub into the input clutch retainer 33 Install the complete reverse clutch pack 34 Install the reverse reaction plate and snap ring 35 Push up on reaction plate to allow reverse dutch to move freely 4C RETAINER BULKHEAD DISASSEMBLY 1 Remove the 2C piston belleville spring snap ring from the 4C retainer bulkhead Fig 117 WJ DISASSEMBLY AND ASSEMBLY Continued 2C PISTON SEAL sc 4 RETAINER BULKHEAD SEAL 4C PISTON 45RFE AUTOMATIC TRANSMISSION 21 243 E SNAP RING ae BELLEVILLE SPRING DISC SNAP RING SELECT REACTION PLATE RETURN SPRING 80c07032 Fig 117 4C Retainer Bulkhead Components 2 Remove the 2C piston Belleville spring from the retainer bulkhead Fig 117 3 Remove the 2C piston from the retainer bulk head Use 20 psi of air pressure to remove the pi
383. t line pressure is metered out into the circuits and viewed as throttle pressure This increased throttle pressure is metered out into the circuits it is applied to the 1 2 and 2 3 shift valves When the throttle pressure is high enough a 3 2 downshift will occur If the speed is low enough a 2 1 downshift will occur WJ DESCRIPTION AND OPERATION Continued THROTTLE PLUG SHUTTLE VALVE 1 2 SHIFT CONTROL VALVE 42RE AUTOMATIC TRANSMISSION 21 35 ACCUMULATOR OVERDRIVE CLUTCH ja Soa 3 4 QUICK FILL come Som a dette f BOOST VALVE x HB A 4 SHIFT VALVE DES 3 ER OVERDRV 5 SOL TO LUBRICATION CLUTCH LUBRICATION I LOCKUP I 4 LOCK UP TIMING VALVE SOLENOID LT 80c0714a Fig 41 Switch Valve Torque Converter Unlocked SWITCH VALVE When the transmission is in Drive Second just before the TCC application occurs Fig 41 the pres sure regulator valve is supplying torque converter pressure to the switch valve The switch valve directs this pressure through the transmission input shaft into the converter through the converte
384. t into place Install short upper bracket screws first and long bottom screw last Verify that valve springs and bracket are properly aligned Then tighten all three bracket screws to 4 N m 35 in Ibs torque 17 Perform Line Pressure and Throttle Pressure adjustments Refer to adjustment section of this group for proper procedures 18 Lubricate solenoid case connector O rings and shaft of manual lever with light coat of petroleum jelly 19 Attach solenoid case connector to 3 4 accumu lator with shoulder type screw Connector has small locating tang that fits in dimple at top of accumula tor housing Fig 156 Seat tang in dimple before tightening connector screw 20 Install solenoid assembly and gasket Tighten solenoid attaching screws to 8 72 in Ibs torque 21 Verify that solenoid wire harness is properly routed Fig 157 Solenoid harness must be clear of manual lever and park rod and not be pinched between accumulator housing and cover 21 108 42RE AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued J9521 178 Fig 154 Detent Ball Spring 1 SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING J9121 54 Fig 155 Manual And Throttle Lever Alignment 1 THROTTLE LEVER 2 MANUAL LEVER VALVE ARM 3 MANUAL VALVE 4 KICKDOWN VALVE GOVERNOR BODY SENSOR AND SOLENOID 1 Turn valve body assembly over so accumulator side of transfer plate is facing down 2 Install new O rin
385. t its programming to meet changing operating conditions The PCM receives input signals from various switches and sensors Based on these inputs the PCM regulates various engine and vehicle operations through different system components These compo nents are referred to as Powertrain Control Module PCM Outputs The sensors and switches that pro vide inputs to the PCM are considered Powertrain Control Module PCM Inputs 21 48 42 AUTOMATIC TRANSMISSION DESCRIPTION AND OPERATION Continued j FRONT c LL 54 1 EN A Me N 9 3 G Y Fig 62 PCM Location 1 2 COOLANT TANK The PCM adjusts ignition timing based upon inputs it receives from sensors that react to engine rpm manifold absolute pressure engine coolant tem perature throttle position transmission gear selec tion automatic transmission vehicle speed and the brake switch The PCM adjusts idle speed based on inputs it receives from sensors that react to throttle position vehide speed transmission gear selection engine coolant temperature and from inputs it receives from the air conditioning dutch switch and brake switch Based on inputs that it receives the PCM adjusts ignition coil dwell The PCM also adjusts the gener ator charge rate through control of the generator field and provides speed control operation NOTE PCM Inputs request Auto shutdown ASD
386. t stay until REMOVAL AND INSTALLATION INPUT SPEED SENSOR REM OVAL 1 Raise vehicle 2 Place a suitable fluid catch pan under the transmission 3 Remove the wiring connector from the input speed sensor Fig 38 4 Remove the bolt holding the input speed sensor to the transmission case 5 Remove the input speed sensor from the trans mission case OUTPUT SPEED SENSOR LINE PRESSURE SENSOR INPUT SPEED SENSOR Fig 38 Input Speed Sensor 80c07350 21 214 45 AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION Continued INSTALLATION 1 Install the input speed sensor into the trans mission case 2 Install the bolt to hold the input speed sensor into the transmission case Tighten the bolt to 11 9 N m 105 in 165 3 Install the wiring connector onto the input Speed sensor 4 Verify the transmission fluid level Add fluid as necessary 5 Lower vehicle OUTPUT SPEED SENSOR REM OVAL 1 Raise vehide 2 Place a suitable fluid catch pan under the transmission 3 Remove the wiring connector from the output speed sensor Fig 39 4 Remove the bolt holding the output speed sen sor to the transmission case 5 Remove the output speed sensor from the transmission case OUTPUT SPEED SENSOR LINE PRESSURE SENSOR INPUT SPEED SENSOR 80c07350 Fig 39 Output Speed Sensor INSTALLATION 1 Install the output speed sensor into the trans mission case 2 Ins
387. tains front output shaft front bearing in case Fig 56 Then remove bearing Use hammer handle or hammer and brass 18921 273 punch to tap bearing out of Fig 55 Mainshaft And Sprocket Gear Removal 1 MAINSHAFT GEAR 2 SPROCKET GEAR 3 BOTTOM CASE 242 TRANSFER CASE 21 291 DISASSEMBLY AND ASSEMBLY Continued 2 Install new front output shaft front bearing 4 Remove front output shaft seal using an appro with Tool Handle C 4171 and Installer 8033A with priate pry tool Fig 58 or slide hammer mounted the tapered cone upward Fig 57 Screw y 5 Install new front output shaft oil seal with Installer 6952 A Fig 59 e IIN E x D de wl 80 1108 Fig 58 Remove Front Output Shaft Seal 1 OUTPUT SHAFT SEAL 2 PRYBAR J8921 274 Fig 56 Front Output Shaft Front Bearing Snap Ring Removal 1 FRONT BEARING SNAP RING 80398363 Fig 59 Install Front Output Shaft Seal 1 INSTALLER 6952 A 2 TRANSFER CASE Fig 57 Front Output Shaft Front Bearing Installation 6 Remove input gear bearing with Tool Handle 1 SPECIAL TOOL C 4171 SPECIAL TOOL 8033A C 4171 and Remover C 4210 Fig 60 7 Install snap ring on new input gear bearing 3 Install front bearing snap ring Fig 56 21 292 NV242 TRANSFER CASE DISASSEMBLY AND ASSEMBLY Continued 8 Install new input gear bearin
388. tall the bolt to hold the output speed sensor into the transmission case Tighten the bolt to 11 9 N m 105 in 165 3 Install the wiring connector onto the output Speed sensor 4 Verify the transmission fluid level Add fluid as necessary 5 Lower vehicle LINE PRESSURE SENSOR REM OVAL 1 Raise vehicle 2 Place a suitable fluid catch pan under the transmission 3 Remove the wiring connector from the line pressure sensor Fig 40 4 Remove the bolt holding the line pressure sen sor to the transmission 5 Remove the line pressure sensor from the transmission case OUTPUT SPEED SENSOR LINE PRESSURE SENSOR INPUT SPEED SENSOR 80c07350 Fig 40 Line Pressure Sensor INSTALLATION 1 Install the line pressure sensor into the trans mission case 2 Install the bolt to hold the line pressure sensor into the transmission case Tighten the bolt to 11 9 105 in Ibs 3 Install the wiring connector onto the line pres sure sensor 4 Verify the transmission fluid level Add fluid as necessary 5 Lower vehicle VALVE BODY The valve body can be removed for service without having to remove the transmission assembly The valve body can be disassembled for cleaning and inspection of the individual components Refer to Disassembly and Assembly section for proper proce dures REM OVAL 1 Shift transmission into PARK 2 Raise vehicle WJ REMOVAL AND INSTALLATION
389. tes when the shift back to third occurs The transmission will not allow fourth gear operation until fluid temperature decreases to approximately 110 C 230 F TRANSMISSION SPEED SENSOR Speed sensor signals are triggered by the park gear lugs as they rotate past the sensor pickup face Input signals from the sensor are sent to the trans mission control module for processing The vehicle speed sensor also serves as a backup for the trans mission speed sensor Signals from this sensor are shared with the powertrain control module GOVERNOR PRESSURE CURVES DESCRIPTION There are four governor pressure curves pro grammed into the transmission control module The different curves allow the control module to adjust governor pressure for varying conditions One curve is used for operation when fluid temperature is at or below 1 C 309 A second curve is used when fluid temperature is at or above 10 C 50 F during nor mal city or highway driving A third curve is used during wide open throttle operation fourth curve is used when driving with the transfer case in low range OPERATION LOW TRANSMISSION FLUID TEMPERATURE When the transmission fluid is cold the conven tional governor can delay shifts resulting in higher than normal shift speeds and harsh shifts T he elec tronically controlled low temperature governor pres sure curve is higher than normal to make the transmission shift at normal speeds and sooner T
390. tests in this section for further diagnosis 4 Re connect the To cooler line to the transmis sion cooler inlet 5 Refill the transmission to proper level FLUSHING COOLERS AND TUBES When a transmission failure has contaminated the fluid the oil cooler s must be flushed The torque converter must also be replaced This will insure that metal partides or sludged oil are not later trans ferred back into the reconditioned or replaced trans mission The only recommended procedure for flushing cool ers and lines is to use Tool 6906A Cooler Flusher WARNING WEAR PROTECTIVE EYEWEAR THAT MEETS THE REQUIREMENTS OF OSHA AND ANSI Z87 1 1968 WEAR STANDARD INDUSTRIAL RUB BER GLOVES KEEP LIGHTED CIGARETTES SPARKS FLAMES AND OTHER IGNITION SOURCES AWAY FROM THE AREA TO PREVENT THE IGNITION OF COMBUSTI BLE LIQUIDS AND GASES KEEP A CLASS B FIRE EXTINGUISHER IN THE AREA WHERE THE FLUSHER WILL BE USED KEEP THE AREA WELL VENTILATED DO NOT LET FLUSHING SOLVENT COME IN CON TACT WITH YOUR EYES OR SKIN IF EYE CONTAM INATION OCCURS FLUSH EYES WITH WATER FOR 15 TO 20 SECONDS REMOVE CONTAMINATED CLOTHING AND WASH AFFECTED SKIN WITH SOAP AND WATER SEEK MEDICAL ATTENTION WJ SERVICE PROCEDURES Continued COOLER FLUSH USING TOOL 6906A 1 Remove cover plate filler plug on Tool 6906A Fill reservoir 1 2 to 3 4 full of fresh flushing solution Flushing solvents are petroleum based solutions gen erally used to clean automatic
391. the flushing tool 5 Connect the BLUE pressure line to the OUT LET From cooler line 6 Connect the CLEAR return line to the INLET To cooler line 7 Turn pump ON for two to three minutes to flush cooler s and lines 8 Turn pump OFF 9 Disconnect CLEAR suction line from reservoir at cover plate Disconnect CLEAR return line at cover plate and place it in a drain pan 10 Turn pump ON for 30 seconds to flush ing solution from cooler and lines Turn pump OFF 11 Place CLEAR suction line into a one quart container of Plus type 7176 automatic transmission fluid 12 Turn pump ON until all transmission fluid is removed from the one quart container and lines This purges any residual cleaning solvent from the trans mission cooler and lines Turn pump OFF 13 Disconnect alligator clips from battery Recon nect flusher lines to cover plate and remove flushing adapters from cooler lines ALUMINUM THREAD REPAIR Damaged or worn threads in the aluminum trans mission case and valve body can be repaired by the use of Heli Coils or equivalent This repair consists of drilling out the worn out damaged threads Then tap the hole with a special Heli Coil tap or equiva lent and installing a Heli Coil insert or equivalent into the hole This brings the hole back to its original thread size Heli Coil or equivalent tools and inserts are readily available from most automotive parts s
392. the vehide or on the work bench as a final check after overhaul Air pressure testing requires that the oil pan and valve body be removed from the transmission The servo and dutch apply passages are shown Fig 68 42RE AUTOMATIC TRANSMISSION 21 57 PRESSURE TEST ANALYSIS CHART TEST CONDITION INDICATION Line pressure OK during Pump and regulator any one test valve OK Line pressure OK in R Leakage in rear clutch but low in D 2 1 area seal rings clutch seals Overdrive clutch piston seal or check ball problem Pressure OK in 1 2 but Leakage in front clutch low in D3 and R area Pressure OK in 2 but low Leakage in rear servo in R and 1 Front servo pressure low Leakage in servo broken in 2 servo ring or cracked servo piston Pressure low in D Fourth Gear Range Pressure low in all positions Clogged filter stuck regulator valve worn or faulty pump low oil level Governor pressure too high at idle speed Governor pressure solenoid valve system fault Refer to diagnostic book Faulty governor pressure solenoid transmission control module or governor pressure sensor Clogged fluid cooler or lines seal rings leaking worn pump bushings pump clutch retainer or clogged filter Line pressure high Output shaft plugged sticky regulator valve Line pressure low Sticky regulator valve clogged filter worn pump Front Clutch Air Test Place one or two fingers on the clutch housing and app
393. the fluid level is correct if it is in the HOT region cross hatched area on the oil level indicator The fluid level will be approximately at the upper COLD hole of the dipstick at 70 F fluid temperature NOTE Engine and Transmission should be at nor mal operating temperature before performing this procedure 1 Start engine and apply parking brake 2 Shift the transmission into Drive for approxi mately 2 seconds 3 Shift the transmission into Reverse for approx imately 2 seconds 4 Shift the transmission into Park 5 Hook up DRB scan tool and select transmis sion Select sensors 7 Read the transmission temperature value 8 Compare the fluid temperature value with the chart 9 Adjust transmission fluid level shown on the dipstick according to the chart WJ SERVICE PROCEDURES Continued FLUID LEVEL 45RFE AUTOMATIC TRANSMISSION 21 211 2 7 2 4 2 1 1 8 1 5 FLUID LEVEL IN 1 2 0 9 0 6 0 3 ADD 0 70 80 90 100110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 TEMPERATURE F 80c072fc Transmission Fluid Temperature Chart NOTE After adding any fluid to the transmission wait a minimum of 2 minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level 10 Check transmission for leaks FLUID AND FILTER REPLACEMENT Refer to the Maintenance Schedules in Group 0
394. the valve or plug lands Maintaining sharpness of these edges is vitally important The edges prevent foreign matter from lodging between the valves and plugs and the bore Inspect all the valve and plug bores in the oil pump cover Use a penlight to view the bore interi ors Replace the oil pump if any bores are distorted or scored Inspect all of the valve springs The springs must be free of distortion warpage or broken coils Trial fit each valve and plug in its bore to check freedom of operation When clean and dry the valves and plugs should drop freely into the bores 45RFE AUTOMATIC TRANSMISSION 21 249 PLANETARY GEARTRAIN Clean the planetary components in solvent and dry them with compressed air Check sun gear and driving shell condition Replace the gear if damaged or if the bushings are scored or worn The bushings are not serviceable Replace the driving shell if worn cracked or dam aged Replace planetary gear sets if gears pinion pins or carrier are damaged in any way Replace the annulus gears and supports if either component is worn or damaged Replace the output shaft if the machined surfaces are scored pitted or damaged in any way Also replace the shaft if the splines are damaged or exhibits cracks at any location ADJ USTMENTS BRAKE TRANSMISSION SHIFT INTERLOCK The park interlock cable is part of the brake shift lever interlock system Correct cable adjustment is important to proper interlock oper
395. throttle lever forward and gradually increase to 90 96 psi 621 662 kPa as lever is moved rearward Test Three Transmission In D Range Third Gear NOTE This test checks pressure regulation and condition of the clutch circuits Both test gauges are required for this test 1 Turn OD switch off 2 Leave vehide on hoist and leave Gauge C 3292 in place at accumulator port WJ 3 Move Gauge C 3293 SP over to front servo port for this test 4 Have helper start and run engine at 1600 rpm for this test 5 Move transmission shift lever two detents rear ward from full forward position This is D range 6 Read pressures on both gauges as transmission throttle lever is gradually moved from full forward to full rearward position e Line pressure at accumulator in D range third gear should be 54 60 psi 372 414 kPa with throttle lever forward and increase as lever is moved rear ward e Front servo pressure in D range third gear should be within 3 psi 21 kPa of line pressure up to kickdown point Test Four Transmission In Reverse NOTE This test checks pump output pressure reg ulation and the front clutch and rear servo circuits Use 300 psi Test Gauge C 3293 SP for this test 1 Leave vehicle hoist and leave gauge C 3292 in place at accumulator port 2 Move 300 psi Gauge C 3293 SP back to rear servo port 3 Have helper start and run engine at 1600 rpm for test 4 Move transmission shift lever
396. tion to the TCM PRESSURE CONTROL SOLENOID SOLENOID PACK TRANSMISSION RANGE 23 WAY SENSOR CONNECTOR 8069 590 Fig 30 SOLENOID AND PRESSURE SWITCH ASSEMBLY OPERATION The solenoids within the assembly are supplied voltage by the Transmission Control Relay The sole noids are energized when the TCM grounds the return wire for the solenoid that is needed The pres sure switches simply tell the whether or not pressure exists within a dutch circuit BATTERY FEED TCM DESCRIPTION A fused direct battery feed to the TCM is used for continuous power OPERATION This battery voltage is necessary to retain adaptive learn values in the TCM s RAM Random Access Memory When the battery is disconnected this memory is lost When the battery B is restored 45RFE AUTOMATIC TRANSMISSION 21 203 this memory loss is detected by the TCM and a Diag nostic Trouble Code DTC is set TRANSMISSION CONTROL RELAY DESCRIPTION The relay is supplied fused B voltage energized by the TCM and is used to supply power to the sole noid pack when the transmission is in normal oper ating mode OPERATION When the relay is off no power is supplied to the solenoid pack and the transmission is in limp in mode After a controller reset the TCM energizes the relay Prior to this the TCM verifies that the con tacts are open by checking for no voltage at the switched battery terminals After this is v
397. to cushion the application of the clutch assem bly When the dutch is in the process of being released by the release spring fluid flows through a vent and one way ball check valve located in the dutch retainer The check valve is needed to elimi nate the possibility of plate drag caused by centrifu gal force acting on the residual fluid trapped in the dutch piston retainer OVERDRIVE CLUTCH DESCRIPTION The overdrive clutch Fig 56 is composed of the pressure plate two clutch plates three holding discs overdrive piston retainer piston piston spacer and snap rings The overdrive dutch is the forwardmost component in the transmission overdrive unit and is considered a holding component The overdrive pis ton retainer piston and piston spacer are located on the rear of the main transmission case NOTE The number of discs and plates may vary with each engine and vehicle combination OPERATION To apply the clutch pressure is applied between the piston retainer and piston The fluid pressure is provided by the oil pump transferred through the control valves and passageways and enters the dutch through passages at the lower rear portion of the valve body area With pressure applied between the piston retainer and piston the piston moves away from the piston retainer and compresses the dutch pack This action applies the dutch pack allowing torque to flow through the intermediate shaft into the overdrive planetary gear set
398. ts into place The transmission components and subassemblies are easily installed by hand when properly aligned If a part seems extremely difficult to install it is either misaligned or incorrectly assembled Also ver ify that thrust washers thrust plates and seal rings are correctly positioned before assembly These parts can interfere with proper assembly if mis positioned 6 5 4 The planetary geartrain front rear clutch assem blies and oil pump are all much easier to install when the transmission case is upright Fig 176 Front Servo Components 1 Install rear servo piston spring and retainer 1 PISTON SEAL RINGS Fig 175 Install spring on top of servo piston and 2 SERVO PISTON J9121 344 install retainer on top of spring 3 SNAP RING 2 Install front servo piston assembly servo 4 ROD GUIDE spring and rod guide Fig 176 2 3 Compress front rear servo springs with Valve Spring Compressor C 3422 B and install each servo snap ring Fig 177 39121 343 Fig 175 Rear Servo Components 1 SERVO PISTON 2 PISTON SPRING 80be44b7 3 SNAP RING 4 Fig 177 Compressing Front Rear Servo Springs 5 PISTON SEAL 1 SPRING COMPRESSOR TOOL C 3422 B 2 ROD GUIDE SNAP RING WJ DISASSEMBLY AND ASSEMBLY Continued 4 Lubricate clutch cam rollers with transmission fluid 5 Install rear band in case Fig 178 sure twin lugs on ba
399. ul Bushing condition is important as worn scored bush ings contribute to low pressures dutch slip and accelerated wear of other components However do not replace bushings as a matter of course Replace bushings only when they are actually worn or scored Use recommended tools to replace bushings The tools are sized and designed to remove install and seat bushings correctly The bushing replacement tools are included in Bushing Tool Set C 3887 B Pre sized service bushings are available for replacement purposes Only the sun gear bushings are not serviced Low cost of the sun gear assembly makes it easier to simply replace the gear and bush ings as an assembly Heli Coil inserts can be used to repair damaged stripped or worn threads in aluminum parts These inserts are available from most automotive parts suppliers Stainless steel inserts are recommended The use of crocus cloth is permissible where neces sary providing it is used carefully When used on shafts or valves use extreme care to avoid rounding off sharp edges Sharp edges are vital as they pre vent foreign matter from getting between the valve and valve bore Do not reuse oil seals gaskets seal rings or O rings during overhaul Replace these parts as a matter of course Also do not reuse snap rings or E dips that are bent or distorted Replace these parts as well Lubricate transmission parts with Plus 3 Type 7176 transmission fluid dur
400. units aside for overhaul 3 J9121 124 Fig 165 Removing Front Rear Clutch Assemblies 1 INPUT SHAFT 2 FRONT CLUTCH 3 REAR CLUTCH 42RE AUTOMATIC TRANSMISSION 21 111 J9121 125 Fig 166 Separating Front Rear Clutch Assemblies 1 FRONT CLUTCH 2 REAR CLUTCH 24 Remove intermediate shaft thrust washer from front end of shaft or from rear dutch hub Fig 167 25 Remove output shaft thrust plate from inter mediate shaft hub Fig 168 26 Slide front band off driving shell Fig 169 and remove band from case 27 Remove planetary geartrain as assembly Fig 170 Support geartrain with both hands during removal Do not allow machined surfaces on interme diate shaft or overdrive piston retainer to become nicked or scratched 28 If overdrive unit is not to be serviced install Alignment Shaft 6227 2 into the overdrive unit to prevent misalignment of the overdrive clutches dur ing service of main transmission components 29 Loosen rear band adjusting screw 4 5 turns 30 Remove low reverse drum snap ring Fig 171 2 J9121 214 Fig 167 Removing Intermediate Shaft Thrust Washer 1 INTERMEDIATE SHAFT THRUST WASHER 2 INPUT SHAFT 3 REAR CLUTCH RETAINER HUB 21 112 42RE AUTOMATIC TRANSMISSION nt v W DISASSEMBLY AND ASSEMBLY Continued J9121 215 Fig 168 Removing Intermediate Shaft Thrust Plate 1 INTERMEDIATE SHAFT HUB J9121 217 2
401. uppli ers REMOVAL AND INSTALLATION TRANSMISSION The overdrive unit can be removed and serviced separately It is not necessary to remove the entire transmission assembly to perform overdrive unit repairs If only the overdrive unit requires service refer to the overdrive unit removal and installation proce dures 42RE AUTOMATIC TRANSMISSION 21 175 CAUTION The transmission and torque converter must be removed as an assembly to avoid compo nent damage The converter driveplate pump bush ing or oil seal can be damaged if the converter is left attached to the driveplate during removal Be sure to remove the transmission and converter as an assembly REM OVAL 1 Disconnect battery negative cable 2 Disconnect and lower or remove necessary exhaust components 3 Disconnect fluid cooler lines at transmission 4 Remove starter motor 5 Disconnect and remove crankshaft position sen sor Retain sensor attaching bolts CAUTION The crankshaft position sensor will be damaged if the transmission is removed or installed while the sensor is still bolted to the engine block or transmission 4 0L only To avoid damage be sure to remove the sensor before removing the transmission 6 Remove the bolts holding the bell brace to the transmission 7 Remove nut holding the bell housing brace to the engine to transmission bending brace 8 Remove the bell housing brace from the trans mission Fig 74 9 Remo
402. ure 3 Using a suitable pry tool or slide hammer mounted screw remove the rear retainer seal 80398363 Fig 7 Front Output Seal Installation 1 INSTALLER 6952 A 2 TRANSFER CASE 4 Using Remover 6957 remove bushing from rear retainer Fig 8 X 80a98373 Fig 8 Rear Retainer Bushing Removal 1 REMOVER 6957 2 REAR RETAINER BUSHING INSTALLATION 1 Clean fluid residue from sealing surface and inspect for defects 2 Position replacement bushing in rear retainer with fluid port in bushing aligned with slot in retainer 3 Using Installer 8160 drive bushing into retainer until installer seats against case Fig 9 4 Using Installer C 3995 A install seal in rear retainer Fig 10 5 Install propeller shaft 6 Verify proper fluid level 7 Lower vehicle WJ REMOVAL AND INSTALLATION Continued 80a9b39f Fig 9 Rear Retainer Bushing Install 1 REAR RETAINER BUSHING 2 INSTALLER 8160 80 983 7 Fig 10 Install Rear Retainer Seal 1 SPECIAL TOOL 4171 2 SPECIAL TOOL C 3995 A TRANSFER CASE SHIFT CABLE REMOVAL 1 Shift transfer case into neutral 2 Raise vehicle 3 Disconnect the shift cable eyelet from the transfer case shift lever Fig 11 4 Remove shift cable from the cable support bracket 5 Lower vehicle 6 Remove shift lever bezel and necessary console parts for access to shift lever assembly and shift cable 7
403. ure that the ends of the two rings are offset from each other NOTE The 42RE transmission has 5 baas clutch discs and 2 plates LA 3 Assemble overdrive clutch pack Fig 306 Fig 305 Overdrive Clutch Wave Spring Installation 1 WAVE SPRING E 7 3921 356 Fig 304 Overdrive Clutch Reaction Ring Installation 1 REACTION RING 2 CLUTCH HUB OVERDRIVE CLUTCH 2 DISCS 3 CLUTCH PLATES 2 J9321 369 Fig 306 42RE Overdrive Clutch Components 1 REACTION PLATE 2 PRESSURE PLATE WJ DISASSEMBLY AND ASSEMBLY Continued 4 Install overdrive clutch reaction plate first 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 dutch pack wire type retaining ring Fig 307 J9321 352 Fig 307 Overdrive Clutch Pack Retaining Ring Installation 1 OVERDRIVE CLUTCH PACK RETAINING RING 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
404. utch This allows the system to disregard the normal speed differences between axles that result from variations in front to rear loading and typical cornering Transfer case operating ranges are selected with a floor mounted shift lever The shift lever is connected to the transfer case range lever by an adjustable cable Range positions are marked on the shifter bezel plate RECOMMENDED LUBRICANT AND FILL LEVEL DESCRIPTION Mopar Transfer Case Lubricant is the only lubri cant recommended for the NV247 transfer case Approximate fluid refill capacity is approximately 1 6 liters 3 4 pints The fill and drain plugs are both in the rear case Correct fill level is to the bottom edge of the fill plug hole Be sure that the vehicle is level to ensure an accurate fluid level check NV247 TRANSFER CASE 21 309 h Fig Progressive Coupling 21 310 NV247 TRANSFER CASE DIAGNOSIS AND TESTING NV247 DIAGNOSIS CONDITION TRANSFER CASE DIFFICULT TO SHIFT OR WILL NOT SHIFT INTO DESIRED RANGE TRANSFER CASE NOISY IN ALL MODES NOISY IN OR JUMPS OUT OF 4WD LOW RANGE LUBRICANT LEAKING FROM OUTPUT SHAFT SEALS OR FROM VENT POSSIBLE CAUSE 1 Vehicle speed too great to permit shifting 2 Transfer case external shift cable binding 3 Insufficient or incorrect lubricant 4 Internal components b
405. utch Input Shaft Rear 11 Remove and disassemble transmission Clutch Seal Rings Damaged and repair as necessary 12 Regulator Valve Stuck 12 Clean 13 Cooler Plugged 13 Transfer case failure can plug cooler NO DRIVE RANGE 1 Fluid Level Low 1 Add fluid and check for leaks if drive is REVERSE OK restored 2 Gearshift Linkage Cable 2 Repair or replace linkage components Loose Misadjusted 3 Rear Clutch Burnt 3 Remove and disassemble transmission and rear clutch and seals Repair replace worn or damaged parts as needed 4 Valve Body Malfunction 4 Remove and disassemble valve body Replace assembly if any valves or bores are damaged 5 Transmission Overrunning Clutch 5 Remove and disassemble transmission Broken Replace overrunning clutch 6 Input Shaft Seal Rings Worn 6 Remove and disassemble transmission Damaged Replace seal rings and any other worn or damaged parts 7 Front Planetary Failed Broken 7 Remove and repair 21 62 2 AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING Continued CONDITION POSSIBLE CAUSES CORRECTION NO DRIVE OR REVERSE 1 Fluid Level Low 1 Add fluid and check for leaks if drive is VEHICLE WILL NOT restored MOVE 2 Gearshift Linkage Cable 2 Inspect adjust and reassemble linkage Loose Misadjusted as needed Replace worn damaged parts 3 U Joint Axle Transfer Case 3 Perform preliminary inspection procedure Broken for vehicle
406. valve body 2C ACCUMULATOR 4C ACCUMULATOR UNDERDRIVE ACCUMULATOR OVERDRIVE ACCUMULATOR WJ 10 Remove the screws holding the valve body to the valve body transfer plate 11 Remove the transfer plate from the valve body Note the location of all check balls Fig 101 12 Remove the check balls from the valve body 7 5 80c072f1 Fig 101 Check Ball Locations 13 Remove the retainers securing the solenoid switch valve manual valve and the low reverse switch valve into the valve body and remove the assodated valve and spring Tag each valve and LOW REVERSE ACCUMULATOR LOW REVERSE SWITCH VALVE UPPER VALVE BODY SOLENOID SWITCH VALVE 80c072f2 Fig 100 Valve Body Components WJ DISASSEMBLY AND ASSEMBLY Continued spring combination with location information to aid in assembly SOLENOID 2 MANUAL SWITCH n VALVE l BALLS 7 LOW REVERSE CLUTCH SWITCH
407. ve dirt and particles from these passages Dry the transfer case components with compressed air or allow them to air dry on dean shop towels Apply compressed air through all oil passages in the cases and gear components to dear them of any residue MAINSHAFT Examine the mainshaft components carefully for evidence of wear or damage Replace the thrust washers if worn or damaged Replace the mainshaft and sprocket gears if the teeth or gear bores are worn or damaged Replace the mainshaft bearings if worn flat spot ted brinelled or damaged in any way Replace the mainshaft if it is bent exhibits wear or damage to the bearing surfaces splines or gear teeth INPUT AND LOW RANGE GEARS Inspect the low range gear pinions and pinion pins Replace the low range gear if any of the pins or pin ions are worn or damaged Inspect the thrust washers retainer and snap ring Replace the snap ring if bent or distorted Replace the thrust washers and retainer if worn cracked or damaged in any way Examine the input gear carefully Be sure the gear teeth and bearing surfaces are in good condition Replace the gear if wear or damage is evident Check the input gear pilot bearing Rotate the bear ing and check for roughness or noise Also check bear WJ CLEANING AND INSPECTION Continued ing position in the bore The bearing should be recessed approximately 2 5 mm 0 100 in below the top edge of the bore The bearing should not b
408. ve rear servo spring and piston 38 Inspect transmission components NOTE TO SERVICE THE OVERRUNNING CLUTCH CAM OR OVERDRIVE PISTON RETAINER REFER TO OVERRUNNING CLUTCH CAM SERVICE IN THIS SECTION J9121 345 Fig 174 Compressing Rear Servo Spring 1 FRONT SERVO SNAP RING 2 REAR SERVO SNAP RING 3 SPECIAL TOOL ASSEMBLY Do not allow dirt grease or foreign material to enter the case or transmission components during assembly Keep the transmission case and compo nents clean Also make sure the tools and workbench area used for assembly operations are equally clean Shop towels used for wiping off tools and hands must be made from lint free material Lint will stick to transmission parts and could interfere with valve operation or even restrict fluid passages Lubricate the transmission components with Mopar transmission fluid during reassembly Use Mopar Door Ease or Ru Glyde on seals and O rings to ease installation Petroleum jelly can also be used to hold thrust washers thrust plates and gaskets in position during 21 114 42 AUTOMATIC TRANSMISSION WJ DISASSEMBLY AND ASSEMBLY Continued assembly H owever do not use chassis grease bear ing grease white grease or similar lubricants on transmission part These types of lubricants can eventually block or restrict fluid passages and inter fere with valve operation Use petroleum jelly only Do not force par
409. ve the bolt holding the torque converter cover to the transmission 10 Remove the torque converter cover from the transmission housing TRANSMISSION 2 Pom BELL HOUSING BRACE TORQUE CONVERTER COVER 80ba79c3 Fig 74 Bell Housing Brace and Converter Cover 11 If transmission is being removed for overhaul remove transmission oil pan drain fluid and reinstall pan 21 76 42RE AUTOMATIC TRANSMISSION REMOVAL AND INSTALLATION Continued 12 Remove fill tube bracket bolts and pull tube out of transmission Retain fill tube seal 4 x 4 models it will also be necessary to remove bolt attaching transfer case vent tube to converter hous ing 13 Rotate crankshaft in clockwise direction until converter bolts are accessible Then remove bolts one at a time Rotate crankshaft with socket wrench on dampener bolt 14 Mark propeller shaft and axle yokes for assembly alignment Then disconnect and remove propeller shaft On 4 x 4 models remove both propel ler shafts 15 Disconnect wires from park neutral position switch and transmission solenoid 16 Disconnect gearshift cable from transmission manual valve lever Fig 75 MANUAL LEVER 80ba79c4 Fig 75 Transmission Shift Cable 17 Disconnect throttle valve cable from transmis sion bracket and throttle valve lever Fig 76 18 Disconnect transfer case shift cable from the transfer case shift lever Fig 77 19 Remove the
410. ver drive case Then position Dial Caliper C 4962 over gauge tool Fig 310 b Measure distance to dutch hub thrust bear ing seat at four points 90 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 311 3 Leave Alignment Tool 6227 2 in place Tool will keep planetary and dutch 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 21 154 42 AUTOMATIC TRANSMISSION DISASSEMBLY AND ASSEMBLY Continued J9221 48 Fig 310 Overdrive Piston Thrust Plate Measurement 1 SPECIAL TOOL 6311 2 DIRECT CLUTCH HUB THRUST BEARING SEAT 3 SPECIAL TOOL C 4962 End Play Measure Spacer Thickness ment Inches Inches 1 7500 1 7649 108 110 1 7650 1 7799 123 125 1 7800 1 7949 138 140 1 7950 1 8099 153 155 1 8100 1 8249 168 170 1 8250 1 8399 183 185 1 8400 1 8549 198 200 1 8550 1 8699 213 215 1 8700 1 8849 228 230 1 8850 1 8999 243 245 J9121 342 Fig 311 Overdrive Piston Thrust Plate Selection OVERDRIVE PISTON ASSEMBLY 1 Install new seals on over drive piston 2 Stand transmission case u
411. witch is monitored to confirm SSV movement If the move ment is not confirmed the L R pressure switch does not dose 2nd gear is substituted for 1st A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start DIAGNOSIS AND TESTING EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid Air in the fluid will cause fluid pressures to be low and develop slower than normal If the transmission is overfilled the gears churn the fluid into foam This aerates the fluid and causing the same conditions occurring with a low level In either case air bubbles cause fluid overheating oxi 21 206 45RFE AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING Continued dation and varnish buildup which interferes with valve dutch and servo operation Foaming also causes fluid expansion which can result in fluid over flow from the transmission vent or fill tube Fluid overflow can easily be mistaken for a leak if inspec tion is not careful CAUSES OF BURNT FLUID Burnt discolored fluid is a result of overheating which has two primary causes 1 A result of restricted fluid flow through the main and or auxiliary cooler This condition is usu ally the result of a faulty or damaged main auxiliary cooler or severe restrictions in the coolers and lines caused by debris or kinked lines 2 Heavy duty operation with a vehicle not erly equipped for t
412. with test lamp Repair as required 3 Neutral Switch Faulty 3 Refer to service section for test and replacement procedure 4 Neutral Switch Connect Faulty 4 Connectors spread open Repair 5 Valve Body Manual Lever 5 Inspect lever assembly and replace if Assembly Bent Worn Broken damaged NO REVERSE OR SLIPS 1 Direct Clutch Pack front clutch 1 Disassemble unit and rebuild clutch IN REVERSE Worn pack 2 Rear Band Misadjusted 2 Adjust band 3 Front Clutch Malfunctioned 3 Air pressure test clutch operation Burned Remove and rebuild if necessary 4 Overdrive Thrust Bearing Failure 4 Disassemble geartrain and replace bearings 5 Direct Clutch Spring Collapsed 5 Remove and disassemble unit Check Broken clutch position and replace spring OIL LEAKS 1 Fluid Lines and Fittings Loose 1 Tighten fittings If leaks persist replace Leaks Damaged fittings and lines if necessary 2 Fill Tube where tube enters case 2 Replace tube seal Inspect tube for Leaks Damaged cracks in fill tube 3 Pressure Port Plug Loose 3 Tighten to correct torque Replace plug Loose Damaged or reseal if leak persists 4 Pan Gasket Leaks 4 Tighten pan screws 150 in 16 If leaks persist replace gasket 5 Valve Body Manual Lever Shaft 5 Replace shaft seal Seal Leaks Worn 6 Rear Bearing Access Plate Leaks 6 Replace gasket Tighten screws 7 Gasket Damaged or Bolts are 7 Replace bolts or gasket or tighten both Loo
413. y any of the clutch parts Lint from such materials will adhere to component surfaces and could restrict or block fluid passages after assembly Replace the dutch discs if warped worn scored burned charred the lugs are damaged or if the fac ing is flaking off Replace the top and bottom pres sure plates if scored warped or cracked Be sure the driving lugs on the pressure and dutch plates are also in good condition The lugs must not be bent cracked or damaged in any way Replace the piston spring and wave spring if either part is distorted warped or broken Check the lug grooves in the clutch retainer The dutch and pressure plates should slide freely in the slots Replace the retainer if the grooves are worn or damaged Also check action of the check balls in the retainer and piston Each check ball must move freely and not stick Replace the retainer bushing if worn scored or doubt exists about bushing condition Inspect the piston and retainer seal surfaces for nicks or scratches Minor scratches can be removed with crocus cloth However replace the piston and or retainer if the seal surfaces are seriously scored Check condition of the fiber thrust washer and metal output shaft thrust washer Replace either washer if worn or damaged Check condition of the seal rings on the input shaft and dutch retainer hub Replace the seal rings only if worn distorted or damaged The input shaft front seal ring is teflon with chamfer
414. y geartrain is located behind the 4C retainer bulkhead toward the rear of the transmis sion The planetary geartrain consists of three pri mary assemblies Reaction Fig 25 Reverse Fig 26 Input Fig 26 OPERATION REACTION PLANETARY GEARTRAIN The reaction planetary carrier and reverse sun gear of the reaction planetary geartrain are a single component which is held by the 2C dutch when required The reaction annulus gear is a stand alone component that can be driven by the reverse dutch or held by the 4C dutch The reaction sun gear is driven by the overdrive dutch REVERSE PLANETARY GEARTRAIN The reverse planetary geartrain is the middle of the three planetary sets The reverse planetary carrier can be driven by the overdrive dutch as required The reverse planetary carrier is also splined to the input annulus gear which can be held by the low reverse dutch The reverse planetary annulus input planetary carrier and output shaft are all one piece INPUT PLANETARY GEARTRAIN The input sun gear of the input planetary geartrain is driven by the underdrive clutch GEARSHIFT MECHANISM DESCRIPTION The gear shift mechanism provides six shift posi tions which are e Park P Reverse R Neutral N Drive D Manual second 2 Manual low 1 WJ DESCRIPTION AND OPERATION Continued BEARING BEARING NUMBER 10 NUMBER 11 INPUT SUN 45RFE AUTOMATIC TRANSMISSION 21 199
415. y on the 3 4 upshift valve Line pressure on the 3 4 shift valve overcomes valve spring pressure moving the valve to the upshift position Fig 35 This action exposes the feed passages to the 3 4 timing valve 3 4 quick fill valve 3 4 accumulator and ultimately to the over drive piston OVERDRIVE CLUTCH 6 4 SLE pum 3 4 QUICK FILL VALVE 2 M a AANE 3 4 TIMING VALVE 2 4 SHIFT VALVE Tm OVERDRV SOL 80c0714d Fig 34 3 4 Shift Valve Before Shift 42RE AUTOMATIC TRANSMISSION OVERDRIVE CLUTCH 3 4 ACCUMULATOR TIMING VALVE ni SOL Fig 35 3 4 Shift Valve After Shift gt 3 4 SHIFT VALVE 21 31 80c0714e 21 32 42RE AUTOMATIC TRANSMISSION n T W DESCRIPTION AND OPERATION Continued 3 4 TIMING VALVE OVERDRIVE CLUTCH The 3 4 timing valve is moved by line pressure coming through the 3 4 shift valve Fig 36 The tim ing valve holds the 2 3 shift valve in an upshift posi tion The purpose is to prevent the 2 3 valve from up or downshifting before the 3 4 valve Fig 37 ACCUMULATOR OVERDRIVE CLUTCH 3 4 ACCUMULATOR

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