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automatic transmission—42re

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2. NOISSIWSNVUL LI 5 1 rm UWE o N 5 INOW 14 14VHS 104110 INOW 2 1514 anya Jose LINN AIGWASSV 18044065 14 5 NOISSIWSNVUL dWNd 110 2 TORQUE CONVERTER A three element torque converter is used for all applications Fig 1 Converter elements consist of the turbine stator and impeller The converter also con tains an overrunning clutch and a converter clutch mechanism The converter clutch is an electronically controlled mechanism The clutch provides reduced engine speed and greater fuel economy when engaged Clutch en gagement also provides reduced transmission fluid temperatures The converter clutch is engaged in fourth gear and in third gear when the overdrive control switch is in the OFF position The overrunning dutch is mounted in the stator hub This one way clutch prevents the stator from rotating in a direction opposite to engine rotation This retains the torque multiplication feature of the converter The torque converter is not a serviceable component It shou
3. 56 Transmission Installation 2 Wheel Drive 57 Overdrive Unit Installation 2 Wheel Drive 63 Transmission Installation 4 Wheel Drive 59 Overdrive Unit Installation 4 Wheel Drive 61 Transmission Removal 2 Wheel Drive 55 Overdrive Unit Removal 2 Wheel Drive 62 Transmission Removal 4 Wheel Drive 55 Overdrive Unit Removal 4 Wheel Drive 60 GENERAL INFORMATION The overdrive unit can be removed for service with out having to remove the entire transmission assembly However if the transmission torque converter con verter driveplate or oil pump requires service the complete transmission assembly must be removed for access to these components If only the overdrive unit must be removed refer to the Overdrive Unit nstallation procedures If the complete transmission assembly must be removed refer to the Transmission Removal l nstallation proce dures TRANSMISSION REMOVAL 2 WHEEL DRIVE 1 Disconnect battery negative cable 2 Raise vehicle on hoist 3 Remove skid plate if equipped 4 11 transmission is being removed for repair re move oil pan drain fluid and reinstall pan on case 5 Mark propeller shaft for installation reference Then disconnect and remove propeller shaft 6 Disconnect vehicle speed sensor wires transmis sion solenoid wires and park neutral position switch wires 7 Disconnect wires from tra
4. SHAFT WASHER FRONT FIBER SEAL SHAFT REAR RING SEAL TEFLON CLUTCH RING PACK METAL RETAINER SEAL RING PRESSURE PLATE CLUTCH DISCS 4 PRESSURE 9121 539 REAR CLUTCH RETAINER PRESS TOOL 29121 150 Fig 62 Removing Input Shaft From Rear Clutch Re tainer 5 Install new seals on clutch piston Be sure lip of each seal faces interior of clutch retainer 6 Lubricate lip of piston seals with liberal quantity of Door Eze or petroleum jelly Then lubricate retainer hub and bore with transmission fluid 7 Install clutch piston in retainer Use twisting motion to seat piston in bottom of retainer Do not attempt to push the piston straight in This could fold the seals over causing leakage and clutch slip 21 80 TRANSMISSION OVERHAUL 42RE J9121 538 Fig 63 Installing Rear Clutch Retainer And Input Shaft Seal Rings BE SURE RING ENDS ARE HOOKED TOGETHER AFTER INSTALLATION METAL REAR SEAL RING TEFLON FRONT SEAL RING SQUEEZE RING TOGETHER SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT 9121 151 Fig 64 Input Shaft Seal Ring Identification 8 Install piston spring in retainer and on top of piston Fig 56 Concave side of spring faces up as shown 9 Install wave spring in retainer Fig 66 Be sure spring is completely seated in retainer groove 10 Install bottom pressure plate
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6. gt lt gt RETAINER GASKET RETAINER BOLTS 29321 464 Fig 149 Aligning Overdrive Piston Retainer LOW REVERSE DRUM OVERDRIVE PISTON RETAINER Y LOW REVERSE DRUM SNAP RING J9121 351 Fig 150 Installing Low Reverse Drum Retaining Snap Ring joined and ends of metal ring are correctly hooked together Also verify that shaft seal rings installed in sequence shown 20 Check rear dutch thrust washer Fig 155 Use additional petroleum jelly to hold washer in place if necessary 21 Align dutch discs in front clutch and install front dutch on rear dutch Fig 156 Rotate front dutch retainer back and forth until completely seated on rear clutch 21 106 TRANSMISSION OVERHAUL 42RE REAR BAND LEVER LEVER PIVOT PIN PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT ASSEMBLY 19121 217 Fig 152 Installing Planetary Geartrain 22 Coat intermediate shaft thrust washer with petroleum jelly Then install washer in rear clutch hub Fig 157 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 washer It is a select fit part and is used to control transmission end play 23 Align drive teeth on rear clutch discs with small screwdriver Fig 158 This makes installation on front planetary easier 24 Raise
7. 18 Install front thrust washer on front planetary gear Fig 81 Use enough petroleum jelly to hold washer in place on gear and be sure washer tabs are seated 19 Assemble front annulus gear and support Be sure support snap ring is seated 20 Install front annulus thrust washer Fig 82 Align flat on washer with flat on planetary hub Also be sure washer tab is facing forward 2 FRONT THRUST PLATE ANNULUS GEAR SUPPORT 29221 28 Fig 80 Installing Thrust Plate On Front Annulus Support 29121 167 Fig 81 Installing Front Planetary And Annulus Gears WASHER FRONT FLAT ANNULUS ALIGNS THRUST WITH FLAT WASHER TAB FACES FRONT J9121 168 Fig 82 Installing Front Annulus Thrust Washer 2 21 Install front annulus snap ring Fig 83 Use snap ring pliers to avoid distorting ring during instal lation Also be sure ring is fully seated Fig 83 Installing Front Annulus Snap Ring 22 Install planetary selective snap ring with snap ring pliers Fig 84 Be sure ring is fully seated SELECTIVE SNAP RING 2 NN SNAP RING PLIERS J9121 170 Fig 84 Installing Planetary Selective Snap Ring 23 Turn planetary geartrain assembly over so dri v ing shell is facing workbench Then support geartrain on wood block positioned under forward end of output shaft This is necessary so geartrain components will move forward for accurate end p
8. TORQUE CONVERTER HUB WELD OUTSIDE DIAMETER WELD RH254 STARTER RING GEAR Fig 9 Converter Potential Leak Points LEAK TESTING WITH AIR PRESSURE This test involves closing off all openings and pres surizing the transmission to 8 psi with Air Pump 7700 2 A soapy water solution is applied to suspected leak points before and during the pressure test Leaks will be indicated by the presence of air bubbles coming through the solution Some transmission openings such as the fill tube and front cooler line fitting can be closed off with a rubber plug or similar device Plugs can secured with wire or duct tape The transmission rear output shaft opening is closed off simply by leaving the transfer case bolted in place However if the transfer case has been removed a shipping plug can used to close off this opening The torque converter hub opening in the pump and the pump vent require special tools to close them off The converter hub seal is made from thin wall tube and a 3 17 mm 1 8 in thick disc Fig 10 A retaining strap is needed to secure the seal cup for testing The strap can be made from 31 75 mm 1 1 4 in wide stock Fig 11 The strap attaching hole positions are ap proxi mate only Measure hole position on the converter housing before drilling The pump vent tool is made from 6 35 mm 1 4 in rod and 4 76 mm 3 16 in plate Fig 12 The fabricated tools can all be made from mild steel or al
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10. THROTTLE VALVE CABLE ADJ USTMENT PRO CEDURE 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 closed position Then be sure lever on throttle body is at curb idle position 5 Press cable lock button inward to release cable Fig 4 Lock button only has to move about 2 mm 0 070 to release cable in adjuster head 6 Center cable end on attachment stud to within 1 mm 0 039 in and release lock button 7 Check cable adjustment Be sure transmission throttle lever and lever on throttle body move simulta neously as described in cable adjustment checking procedure 2 TRANSMISSION THROTTLE VALVE CABLE ACCELERATOR CABLE CABLE ENGINE BRACKET THROTTLE VALVE CABLE THROTTLE BRACKET VALVE SHIFT CABLE LEVER BRACKET J9321 414 Fig 3 Throttle Cable Attachment At Transmission CABLE LOCK CABLE BRACKET THROTTLE BODY LEVER THROTTLE VALVE ALIGN CABLE AND STUD TO WITHIN 1 MM 0 039 IN OF CENTER J9321 415 Fig 4 Throttle Cable Adjustment Components IN VEHICLE SERVICE 42RE 21 45 GEARSHIFT CABLE ADJUSTMENT Check adjustment by starting the enginein Park and Neutral Adjustment is OK if the engine starts only in these positions Adjustment is incorrect if the engine starts i
11. 19121 219 Fig 25 Overdrive Piston Retainer Bolt Location REAR BAND REACTION PIN J9121 220 Fig 26 Rear Band And Lever Pin Location LOW REVERSE OVERRUNNING DRUM CLUTCH RACE 29121 218 Fig 27 Low Reverse Drum And Rear Band Removal 45 Compress rear servo spring retainer about 1 16 C 3422 B 21 70 TRANSMISSION OVERHAUL 42RE ASSEMBLY J9121 222 Fig 29 Overrunning Clutch Assembly Removal SPRING COMPRESSOR TOOL C 3422 B J9121 136 Fig 30 Compressing Front Servo Rod Guide Fig 31 A C damp and Tool C 4470 or SP 5560 can also be used to compress spring retainer 46 Remove rear servo spring retainer snap ring Then remove compressor tools and remove rear servo spring and piston FRONT 14 SERVO SNAP RING SPECIAL TOOL SERVO SX 22 L Fig 31 Compressing Rear Servo Spring 29121 345 47 Inspect transmission and overdrive compo nents If major components such as the overdrive unit front clutch or oil pump require service refer to appropriate overhaul procedure OVERHAUL SERVICE INFORMATION Inspect the transmission bushings during overhaul Bushing condition is important as worn scored bush ings contribute to low pressures clutch slip and accel erated wear of other components However do not replace bushings as a matter of course Replace bush ings only when they are actually worn or scored Use recommended tools to replace bushings
12. 9 Turn upper housing around and remove limit valve and shift valve covers Fig 123 UPPER HOUSING 1 2 SHIFT VALVE AND SPRING 2 3 SHIFT VALVE 5 AND SPRING PLUG LIMIT VALVE HOUSING THROTTLE PRESSURE SPRING AND SG AND SPRIN PLUG E m PRESSURE 7 v ar O Sw PLUG LIMIT PRESSURE VALVE LIMIT PLUG RETAINER AND VALVE COVER SPRING COVER J9321 157 Fig 123 Shift Valve And Pressure Plug Locations In Upper Housing 2 10 Remove limit valve housing Then remove tainer spring limit valve and 2 3 throttle plug from limit valve housing Fig 123 11 Remove 1 2 shift control valve and spring Fig 123 12 Remove 1 2 shift valve and spring Fig 123 13 Remove 2 3 shift valve and spring from valve body Fig 123 14 Remove pressure plug cover Fig 123 15 Remove line pressure plug sleeve throttle pres sure plug and spring Fig 123 VALVE BODY LOWER HOUSING DISASSEM BLY FIG 124 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 clutch valve spring and plug 6 Remove converter clutch timing valve retainer and valve spring 3 4 ACCUMULATOR HOUSING DISASSEMBLY FIG 125 1 Remove end plate from housing 2 Remove piston spring 3 Remove piston Remove and discard piston
13. Ibs torque with inch pound Torque Wrench C 3380 A a 3 in extension and 5 16 socket Fig 7 CAUTION If Adapter C 3705 is needed to reach the adjusting screw Fig 8 tighten the screw to only 5 Nem 47 50 in Ibs torque 4 Back off band adjusting screw 3 5 8 turns 5 Hold adjuster screw in position and tighten lock nut to 41 Nem 30 ft Ibs torque 6 Lower vehicle EXTENSION INCH POUND TORQUE WRENCH C 3380 A LOCKNUT BAND ADJUSTING SCREW Fig 7 Front Band Adjustment 5 16 SOCKET INCH POUND WRENCH ADAPTER C 3705 TIGHTEN ADJUSTING SCREW TO ONLY 5 N m 50 IN LBS IF ADAPTER IS USED 29121 233 Fig 8 Using Band Adjustment Adapter Tool 3705 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 2 3 Loosen band adjusting screw locknut 5 6 turns Besure adjusting screw turns freely in lever Lubricate screw threads if necessary 4 Tighten adjusting screw to 8 Nem 72 in Ibs torque Fig 9 Use inch pound Torque Wrench C 3380 A for adjustment 5 Back off band adjusting screw 4 turns 6 Hold adjusting screw in place and tighten lock nut to 34 Nem 25 ft 105 torque 7 Clean oil pan pan magnet and gasket surface of case Also inspect and replace fluid filter if necessary 8 Position new gasket on oil pan and install pan
14. page page Front Clutch Overhaul 76 Rear Clutch Overhaul 78 Front Servo and Band Overhaul 85 Rear Servo and Band Overhaul 86 Oil Pump and Reaction Shaft Support Overhaul 72 Transmission Assembly and Adjustment 102 Overhaul Service Information 70 Transmission Case Cleaning and Inspection 71 Overrunning Clutch Low Reverse Drum and Overdrive Transmission Disassembly 64 Piston Retainer Inspection and Overhaul 71 Valve Body Cleaning and Inspection 96 Planetary Gear Train and Intermediate Shaft Overhaul 81 Valve Body Service and Adjustment 87 TRANSMISSION DISASSEM BLY 1 Remove torque converter if not previously re moved 2 Clean transmission exterior with steam gun or with solvent Wear eye protection during deaning operations 3 Remove shift and throttle levers from valve body manual lever shaft 4 Remove transmission speed sensor and O ring seal from overdrive unit Fig 1 SOCKET AND WRENCH fel SPEED SENSOR O RING J9321 348 Fig 1 Transmission Speed Sensor Removal Installation 5 Place transmission in upright position Fig 2 6 Remove bolts attaching overdrive unit to trans mission case Fig 2 An 11 mm socket is required Note position of all wiring clips for installation refer ence 7 Lift overdrive unit up and off transmission
15. position 21 60 TRANSFER CASE ADAPTER 820198 Fig 7 Transfer Case Attachment 34 Align and install remaining exhaust compo nents Tighten all clamp and bracket bolts and nuts securely Be sure exhaust components are clear of all chassis and driveline components 35 Align and install front and rear propeller shafts Tighten U joint clamp bolts to 19 Nem 170 in Ibs torque 36 Verify that all linkage components hoses and electrical wires have been connected 37 Check transfer case fluid level Add Mopar ATF Plus or Dexron fluid if necessary Correct level is to edge of fill plug hole Be sure transfer case is level before checking or adding fluid 38 Install transfer case skid plate if equipped 39 Lower vehicle 40 Connect battery negative cable 41 Refill transmission with Mopar ATF Plus type 7176 fluid 42 Check and adjust engine oil level as necessary 43 Check and adjust transmission and transfer case shift linkage if necessary 44 Check and adjust transmission shift and throttle valve cables if necessary OVERDRIVE UNIT REMOVAL 4 WHEEL DRIVE 1 Disconnect battery negative cable 2 Raise vehicle on hoist 3 Remove transfer case skid plate if equipped 4 Mark front and rear propeller shafts and U joints for alignment reference Fig 1 5 Disconnect and remove both propeller shafts 6 Disconnect vehicle speed sensor and transmis sion speed sensor wires
16. 7 Disconnect vacuum switch hoses at transfer case if equipped 8 Disconnect transfer case shift linkage at transfer case range lever Then remove linkage bracket bolts and remove linkage and bracket from transfer case Move linkage aside for clearance TRANSMISSION OVERDRIVE REMOVAL AND INSTALLATION 42RE 2 9 Remove nuts attaching transfer case to overdrive unit 10 Remove transfer case Support transfer case with transmission jack Secure transfer case to jack with safety chains Then move transfer case rearward and off overdrive case 11 Remove transfer case from jack and position it on bench 12 Support transmission with adjustable jack stand Position wood block between jack and transmission case 13 Remove nuts and bolts attaching transmission mount to center crossmember 14 Remove nuts and bolts attaching crossmember to frame rails 15 Rotate crossmember diagonally to clear frame rails and remove crossmember 16 Support overdrive unit with transmission jack 17 Remove bolts attaching overdrive unit to trans mission Fig 8 CAUTION The overdrive unit must be fully supported during removal This is necessary to prevent damaging the intermediate shaft Do not allow the shaft to support the entire weight of the overdrive unit 18 Carefully slide overdrive unit off intermediate shaft Do not tilt overdrive unit during removal Keep it as level as possibl
17. Fig 27 Marking Direct Clutch Drum And Annulus Gear For Assembly Alignment 7 Remove direct clutch drum rear retaining ring Fig 28 RE RETAININ RING ANNULUS GEAR 9121 292 Fig 28 Clutch Drum Inner Retaining Ring Removal 8 Remove direct clutch drum outer retaining ring Fig 29 9 Mark annulus gear and output shaft for assem bly alignment reference Fig 30 Use punch or scriber to mark gear and shaft 10 Remove snap ring that secures annulus gear on output shaft Fig 31 Use two screwdrivers to unseat and work snap ring out of groove as shown 11 Remove annulus gear from output shaft Fig 32 Use rawhide or plastic mallet to tap gear off shaft GEAR CASE AND PARK LOCK DISASSEMBLY 1 Remove locating ring from gear case 2 Remove park pawl shaft retaining bolt and re move shaft pawl and spring 21 118 OVERDRIVE UNIT OVERHAUL 42RE SNAP OUTPUT SHAFT RING FRONT BEARING J9021 89 Fig 29 Clutch Drum Outer Retaining Ring Removal OUTPUT SHAFT _ p E PUNCH J9221 46 Fig 30 Marking Annulus Gear And Output Shaft For Assembly Alignment OUTPUT SHAFT ANNULUS GEAR J9321 448 Fig 31 Removing Annulus Gear Snap Ring 3 Remove reaction plug snap ring and remove reaction plug OUTPUT SHAFT ANNULUS GEAR J9021 288 Fig 32 Annulus Gear Removal 4 Remove output shaft seal Use punch or tool similar to Seal Remover C
18. Remove brace plate from lower housing separa tor plate and transfer plate Fig 116 21 92 TRANSMISSION OVERHAUL 42RE Z LOWER VALVE HOUSING BODY SCREWS 13 SEPARATOR TRANSFER J9321 150 PLATE PLATE Fig 116 Brace Plate Removal BRACE J9321 148 Fig 113 Valve Body Screw And Tube Brace Loca TRANSFER UPPER tion PLATE HOUSING SEPARATOR OVERDRIVE TRANSFER PLATE LOWER SEPARATOR PLATE AND HOUSING PLATE UPPER HOUSING FILTER SCREEN BRACE 19321 151 Tm Fig 117 Upper Housing Separator Plate Removal HOUSING REAR SERVO CHECK BALL TRANSFER J9321 152 Fig 115 Removing Transfer Plate From Upper Hous ing 31 Remove upper housing separator plate from Fig 118 Rear Clutch And Rear Servo Check Ball Locations transfer plate Fig 117 Note position of filter in separator plate for assembly reference 32 Remove rear clutch and rear servo check balls from transfer plate Note check ball location for assembly reference before removing it Fig 118 J9321 437 SMALL DIAMETER CHECK BALLS 6 LARGE DIAMETER CHECK 1 J9321 154 Fig 119 Check Ball Locations In Upper Housing VALVE BODY UPPER HOUSING DISASSEMBLY 1 Note location of check balls in valve body upper housing Fig 119 Then remove the one large diameter and the six smaller diameter check balls with pencil magnet TRANSMISSION OVERH
19. 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 replace ment purposes Only the sun gear bushings are not serviced The sun gear is replaced as an assembly if the bushings are damaged Heli Coil inserts can be used to repair damaged stripped or worn threads in aluminum parts These inserts are available from most automotive jobbers 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 prevent 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 2 matter of course Also do not reuse snap rings E clips that are bent or distorted Replace these parts as well Lubricate transmission parts with Mopar ATF Plus Type 7176 Dexron II transmission fluid during overhaul and assembly Use Ru Glyde Door Eze or similar products to prelubricate seals O rings and thrust washers Petroleum jelly can also be used to lubricate and hold parts in place during reassembly TRANSMISSION CASE CLEANING AND INSPEC TION Clean the a solvent tank Flush the case bores and fluid passage
20. damaged Overdrive piston or planetary thrust bearing brinnelled installed wrong or damaged Output shaft bearings brinnelled scored damaged Planetary gears worn chipped damaged Overdrive unit overrunning clutch rollers rough scored or output bushings are worn Remove unit and rebuild clutch pack Remove and disassemble unit replace either thrust bearing if damaged Remove and disassemble unit replace either bearing if damaged Remove and overhaul overdrive unit Remove and overhaul overdrive unit J9321 344 21 30 42RE TRANSMISSION DIAGNOSIS Z OVERDRIVE DIAGNOSIS NO REVERSE OR SLIPS IN Direct clutch spring collapsed or broken Remove and disassemble unit check clutch REVERSE pack and replace spring Direct clutch pack worn Disassemble unit and rebuild clutch pack Rear band out of adjustment Adjust band Front clutch malfunction Air pressure test clutch operation remove and rebuild if necessary Overdrive thrust bearing failure Disassemble geartrain and replace bearings 1 2 OR 2 3 UPSHIFT Governor fault Test governor components with DRB 1 scan HAS LOW AND REVERSE tool and repair as needed ONLY 19321 345 4 742 8 15510 DIAGNOSIS 21 31 TORQUE CONVERTER CLUTCH DIAGNOSIS POSSIBLE CAUSE FAULTY OIL PUMP STICKING GOVE
21. hold dutch units together and remove them from case Fig 18 FRONT CLUTCH INPUT SHAFT J9121 124 Fig 18 Removing Front Rear Clutch Assemblies 29 Lift front dutch off rear dutch Fig 19 Set clutch units aside for overhaul 30 Remove intermediate shaft thrust washer from front end of shaft or from rear clutch hub Fig 20 31 Remove output shaft thrust plate from interme diate shaft hub Fig 21 32 Slide front band off driving shell Fig 22 and remove band from case 21 68 TRANSMISSION OVERHAUL 42RE FRONT CLUTCH CLUTCH J9121 125 Fig 19 Separating Front Rear Clutch Assemblies INTERMEDIATE SHAFT THRUST ASHER REAR CLUTCH RETAINER HUB INPUT SHAFT J9121 214 Fig 20 Removing Intermediate Shaft Thrust Washer 33 Remove planetary geartrain as assembly Fig 23 Support geartrain with both hands during re moval Do not allow machined surfaces on intermedi ate shaft or overdrive piston retainer to become nicked or scratched 34 Loosen rear band adjusting screw 4 5 turns 35 Remove low reverse drum snap ring Fig 24 36 Remove bolts attaching overdrive piston re tainer to rear of case Fig 25 Then remove piston retainer and gasket Ke INTERMEDIATE plis THRUST PLATE J9121 215 Fig 21 Removing Intermediate Shaft Thrust Plate 27 79 Te DRIVING L ON Fig 22 Front Band Removal installation 37 Remove rear ban
22. overdrive bolts are tightened The rod will then have to be replaced because it is not repairable c Work overdrive unit forward on intermediate shaft until seated against transmission case If unit is not fully seated tighten overdrive bolts to draw unit against transmission case 12 Apply Mopar Lock N Seal or Loctite 242 to threads of overdrive attaching bolts 13 Install and tighten overdrive unit attaching bolts to 34 Nem 25 ft 105 14 Install transfer case Tighten attaching nuts to 41 Nem 30 ft Ibs torque 15 Connect transmission throttle valve and gear shift cables and connect transfer case shift linkage 16 Install crossmember and rear mount 17 Connect all necessary electrical wires 18 Install and index speedometer adapter and pin ion if removed Refer to Service section for indexing procedure 19 Align and connect propeller shafts Tighten U joint damp bolts to 19 Nem 170 in Ibs torque 20 Check and adjust fluid level in transfer case Use Mopar ATF Plus type 7176 Mopar Dexron can be used if ATF Plus is not readily available 21 Install skid plate if equipped 22 Check and adjust transmission and transfer case shift linkage if necessary 23 Lower vehide 24 Check and adjust transmission fluid level Use Mopar ATF Plus type 7176 fluid Do not use Mopar Dexron unless ATF Plus is not available OVERDRIVE UNIT REMOVAL 2 WHEEL DRIVE 1 Disc
23. to obtain required distance setting The 33 4 mm 1 5 16 inch setting is an approxi mate setting Because of manufacturing toler ances it may be 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 Turning the adjusting screw counterclockwise increases pres sure while turning the screw clockwise decreases pres sure Throttle Pressure Adjustment Insert Gauge C 3763 between the throttle lever cam and the kickdown valve stem Fig 138 Push the gauge tool inward to compress the kick down valve against the spring and bottom the throttle valve Maintain pressure against kickdown valve spring Turn throttle lever stop screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge tool The kickdown valve spring must be fully com pressed and the kickdown valve completely bot tomed to obtain correct adjustment SPECIAL TOOL C 3763 J9121 542 Fig 138 Throttle Pressure Adjustment TRANSMISSION ASSEMBLY AND ADJUSTMENT Assembly Tips Do not allow dirt grease or foreign material to enter the case or transmission components during assembly Keep the transmission case and components dean Also make sure the tools and workbench area used for assembly operations are equally dean Shop towels used for wiping off tools and hands must be made from lint free material Lint will stick to
24. transmission parts and could interfere with valve op eration or even restrict fluid passages Lubricate the transmission components with Mopar transmission fluid during reassembly Use petroleum jelly Door Eze 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 assembly H owever do not use chassis grease bearing grease white grease or similar lubricants on any transmission part These types of lubricants can even tually block or restrict fluid passages and interfere with valve operation Use petroleum jelly only 2 Do not force parts into place The transmission components and sub assemblies are easily installed by hand when properly aligned If a part seems extremely difficult to install it is either misaligned or incorrectly assembled Also verify that thrust washers thrust plates and seal rings are correctly positioned before assembly These parts can interfere with proper assembly if mispositioned or left out by accident The planetary geartrain front rear clutch assem blies and oil pump are all much easier to install when the transmission case is upright or as close to this position as possible Either tilt the case upward with wood blocks or cut a hole the bench large enough for the output shaft Then lower the shaft through the hole and support the transmission case directly on the bench TRANSMI
25. 10 psi Do not exceed specified pressure 5 Pressurize transmission to 8 psi with air pump 6 Observe suspected leak areas Air bubbles ap pearing in soapy water solution indicate leak points 7 Remove test tools and plugs after test completion and make necessary repairs as described in Leak Correction procedure CONVERTER HOUSING AREA LEAK CORREC TION 1 Remove converter 42RE TRANSMISSION DIAGNOSIS 21 15 VENT PLUG RETAINER RETAINER 4 72 ta TORQUE CONVERTER HUB SEAL CUP RH255 PLUG MADE FRO OLD FILLER TUBE Fig 13 Vent Plug And Hub Seal Cup Installation FLARE CAP HOSE CLAMP FLARED TUBE ON COOLER LINE FITTING RY254 Fig 14 Typical Method Of Pressurizing Transmis sion 2 Tighten front band adjusting screw until band is tight around front 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 obstruc tions 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 if scoring is severe 5 Install new pump seal O ring gasket bushing Replace oil pump if cracked porous or damaged in any way 6 Loosen kickdown lever pin access plug three turns Apply Permatex No 2 or equivalent to plug thread
26. 106 Hold bracket firmly against spring tension while removing last screw 19 Remove adjusting screw bracket line pressure adjusting screw pressure regulator valve spring and switch valve spring Fig 107 Do not remove throttle pressure adjusting screw from bracket and do not disturb setting of either adjusting screw during removal 20 Loosen left side 3 4 accumulator housing at taching screw about 2 3 threads Then remove center and right side housing attaching screws Fig 108 21 Carefully rotate 3 4 accumulator housing up ward and remove 3 4 shift valve spring and converter clutch valve plug and spring Fig 109 2 REMOVE THIS SCREW LAST J9321 430 BRACKET Fig 106 Removing Installing Adjusting Screw Bracket Fasteners SWITCH VALVE 4 SPRING m LINE PRESSURE SCREW THROTTLE PRESSURE ADJUSTING SCREW PRESSURE ADJUSTING REGULATOR BRACKET SCREW VALVE SPRING J9321 431 Fig 107 Adjusting Screw Bracket And Spring Removal LOOSEN REMOVE THIS THESE SCREW SCREWS 3 4 ACCUMULATOR HOUSING J9321 432 Fig 108 Accumulator Housing Screw Locations 2 AS CONVERTER CLUTCH VALVE SPRING 33 SHIFT CLUTCH VALVE SPRING a PLUG 39321 433 Fig 109 Removing 3 4 Shift And Converter Clutch Valve Springs And Plug 22 Remove left side screw and remove 3 4 accumu lator housing from valve body Fig 110 CONVERTER CLUTCH 34 VALV
27. 17 Install strut brackets that secure transmission to engine block and front axle 18 Install and connect crankshaft position sensor Be sure sensor grommet is securely in place 19 Install transmission fill tube Install new O ring seal on tube before installation Fig 6 20 Connect exhaust Y pi peto engine exhaust mani folds 21 Install shift linkage torque bracket 22 Connect shift linkage to transmission 23 Connect solenoid and park neutral switch wires 24 Connect wires to transmission speed sensor and vehicle speed sensor 25 Install crossmember on frame rails Place cross member at 45 angle to rails Insert crossmember between rails and rotate crossmember into place 26 Install bolts nuts attaching transmission to rear mount 27 Install bolts nuts attaching crossmember to frame rails 28 Remove transmission jack 29 Install transfer case Fig 7 Align and position transfer case with transmission jack or with aid of helper Tilt case upward and work into position on transmission mounting studs 30 Install and tighten transfer case attaching nuts to 47 Nem 35 ft Ibs torque 31 Install damper on transfer case rear retainer if removed Tighten damper nuts to 54 Nem 40 ft Ibs torque 32 Install and connect transfer case shift linkage 33 Connect transmission cooler lines to quick dis connect fittings on transmission case Refer to In Vehicle service section for procedures
28. 33155334 FILLOYHL ETP LES isd 09 0 33155334 YONYIAOD isd 021 6 31665354 INN YOLVINWNDDV m YOLVINWNDSY ONHS INOX 38 CIONTIOS LON 21 12 YALYAANOD 14 DITINVYGAH 39 21 42RE TRANSMISSION DIAGNOSIS 8ZE LCE SL 5 dWNd isd 09 33155384 2 isd 001 0 341155334 FILLOYHL isd 09 0 33155334 YONYIAOD isd OF 1 66 33155334 83144 H L p 01247185 wo CA p goose EAS 95558 Xr A TIETY Jt 0 E YOLVINWNDOY E 3 E oO Os oj HILMO 4NO33 HOLMD avid GIONTIOS UI YOLVINWNDIV ONIS OARS 1 12 H3LH3ANOO 3AIHG MOT4 42RE TRANSMISSION DIAGNOSIS 21 40 626 1266 435010 1594 1 ASI 123135 84 6 0
29. 393 Fig 37 Installing Clutch Drum And Outer Retaining Ring ANNULUS GEAR CLUTCH DRUM J9321 394 Fig 38 Installing Clutch Drum Inner Retaining Ring 7 Install rear bearing and snap ring on output shaft Fig 39 Be sure locating ring groove in bearing is toward rear OVERDRIVE UNIT OVERHAUL 42RE 21 121 REAR BEARING J9321 370 Fig 39 Rear Bearing And Snap Ring Installation 8 Install overrunning dutch on hub Fig 40 Note that clutch only fits one way Shoulder on clutch should seat in small recess at edge of hub 9 Install thrust bearing on overrunning clutch hub Fig 41 Use generous amount of petroleum jelly to hold bearingin place for installation Bearing fits one way only Be sure bearing is seated squarely against hub Reinstall bearing if it does not seat squarely CLUTCH HUB OVERRUNNING CLUTCH J9121 322 Fig 40 Assembling Overrunning Clutch And Hub 10 Install overrunning clutch in output shaft Fig 42 Insert snap ring pliers in hub splines Expand pliers to grip hub Then install assembly with counter clockwise twisting motion 11 Install planetary gear in annulus gear Fig 43 Be sure planetary pinions are fully seated in annulus gear before proceeding 12 Install direct clutch spring plate on sun gear Shoulder side of plate should face outward and toward front Then secure plate to sun gear with snap ring Fig 44 13 Coat planetary thrust bearing and bear
30. 3981 OVERDRIVE COMPONENT CLEANING AND INSPEC TION Clean the geartrain Fig 33 and case components Fig 34 with solvent Dry all parts except the bearings with compressed 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 suffi cient 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 reusable 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 components do not try to salvage them Check condition of the park lock components and the overdrive gear case Fig 34 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 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 21 119 OVERDRIVE UNIT OVERHAUL 42RE 99 LCE6f ONIN dVNS 3V
31. 7176 fluid 19 Check and adjust gearshift and throttle linkage if necessary SERVICING TRANSMISSION COOLER LINE FIT TINGS The transmission cooler lines are attached to the transmission and radiator main cooler with quick disconnect fittings Fig 18 The transmission case fitting consists of a fitting body a plastic insert and a wire retainer clip Fig 19 There are two fitting styles that will be used Current production type 1 fittings have the retainer clip exposed as shown in Figures 18 and 19 Future production type 11 fittings will have the fitting body and wire retainer clip covered by a shrink wrap material Fig 20 tool is needed with the type II fittings to spread the retainer clip for cooler line removal A small plastic re moval tool will be attached to each type fitting for this purpose Special service tools are not required The fitting in some cooler line hoses is swedged into the hose Only the insert and retainer clip are service able on this fitting A flange on the cooler line serves as the sealing mechanism The wire retainer clip holds the cooler line in the fitting The clip fits behind the cooler line flange to hold the line in place The plastic insert is not a seating or sealing device The insert is used to indicate when the cooler line is properly seated in the fitting QUICK DISCONNECT FITTING SERVICE The type transmission fitting wire retainer clip and plastic insert are ser
32. Fig 75 11 Position wood block on bench and support sun gear on block Fig 76 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 12 Align rear thrust plate on driving shell and install sun gear lock ring Besure ring is fully seated in sun gear ring groove Fig 77 13 Install assembled driving shell and sun gear on intermediate shaft Fig 78 TRANSMISSION OVERHAUL 42RE 21 83 SUN GEAR DRIVING SHELL REAR THRUST PLATE 9121 162 Fig 75 Installing Sun Gear And Rear Thrust Plate In Driving Shell SUN DRIVING SHELL 39121164 Fig 77 Installing Sun Gear Lock Ring 21 84 TRANSMISSION OVERHAUL 42RE SUN GEAR DRIVING SHELL ASSEMBLY INTERMEDIATE SHAFT J9121 276 Fig 78 Installing Assembled Sun Gear And Driving Shell On Intermediate Shaft 14 Install rear thrust washer on front planetary gear Fig 79 Use enough petroleum jelly to hold washer on gear and be sure washer tabs are all properly seated FRONT PLANETARY J9121 166 Fig 79 Installing Rear Thrust Washer On Front Planetary Gear 15 Assemble front annulus gear and support if necessary 16 Position thrust plate on front annulus gear support Fig 80 Use liberal quantity of petroleum jelly to hold plate in place 17 Install front planetary gear on intermediate shaft and in driving shell Fig 81
33. J9321 409 Fig 127 Governor Pressure Sensor O Ring Location edge to check surface flatness Minor scratches may be removed with crocus cloth using only very light pres sure 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 surface 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 aluminum Fig 128 Aluminum components are identified by the dark color of the special coating applied to the surface or by testing with a magnet DO NOT polish or sand aluminum valves or plugs under any circum stances This practice could damage the special coating Inspect the valves and plugs for scratches burrs nicks or scores Minor surface scratches can be re moved with crocus cloth 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 nspect all of the valve body springs The springs must
34. Remove overdrive dutch reaction snap ring Fig 12 Note that snap ring is located in same groove as wave spring 3 Remove Torx head screws that attach access cover and gasket to overdrive case Fig 13 AT25 size Torx head bit is required 4 Remove access cover and gasket Fig 14 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 15 REACTION RING CLUTCH HUB J9321 356 Fig 12 Removing Installing Overdrive Clutch Heac tion Snap Ring TORX SCREWDRIVER T25 ACCESS COVER SCREWS J9321 357 Fig 13 Removing Installing Access Cover Screws ACCESS COVER AND GASKET J9321 358 Fig 14 Removing Installing Access Cover And Gas ket EXPAND BEARING LOCATING RING WITH SNAP Q RING PLIERS Fig 15 Releasing Bearing From Locating Ring 2 6 Lift gear case up and off geartrain assembly Fig 16 GEARTRAIN ASSEMBLY 19321 360 Fig 16 Removing Gear Case From Geartrain Assembly 7 Remove snap ring that retains rear bearing on output shaft Fig 17 OUTPUT SHAFT J9321 361 Fig 17 Rear Bearing Snap Ring Removal Installation 8 Remove rear bearing from output shaft Fig 18 J9321 362 Fig 18 Rear Bearing Removal OVERDRIVE UNIT OVERHAUL 42RE 21 115 DIRECT CLUTCH HUB AND SPRING RE MOVAL WARNING THE NEXT STEP IN DISASSEMBLY IN VOLVES COMPRESS
35. T P S malfunction Valve body malfunction Transmission control module malfunction Test connector and wiring for loose connections shorts or ground and repair as needed 2 Replace solenoid Test sensor at TCM with DRB II scan tool and replace as necessary 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 Test module with DRB scan tool and replace if faulty J9321 342 21 28 Condition 42RE TRANSMISSION DIAGNOSIS OVERDRIVE DIAGNOSIS Possible Cause Correction NO 4 3 DOWNSHIFT NO 4 3 DOWNSHIFT WHEN CONTROL SWITCH IS TURNED OFF OVERDRIVE OFF AND LAMP IS ILLUMINATED NO 4 3 DOWNSHIFT WHEN OVERDRIVE OFF SWITCH IS TURNED OFF OVERDRIVE OFF AND LAMP NOT ILLUMINATED Circuit wiring and or connectors shorted Converter clutch solenoid not venting Overdrive solenoid not venting 3 4 shift or accumulator malfunction Transmission control module malfunction T P S malfunction Test wiring and connectors with test lamp and volt ohmmeter repair wiring as necessary replace connectors and or harness as required Remove valve body and replace solenoid if seized or shorted Remove valve body and replace solenoid if seized or shorted Remove valve body remove and disassemble lower housing and 3 4 accumulator housing r
36. Upper Housing Valve And Plug Installation Figs 122 123 124 1 Lubricate valves plugs springs with clean trans mission 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 Nem 35 in 165 torque 3 Install 1 2 and 2 3 shift valves and springs 4 Install 1 2 shift control valve and spring 5 Install shift valve cover plate 6 Install shuttle valve as follows a Insert plastic guides in shuttle valve secondary spring and install spring on end of valve b Hold shuttle valve in place Compress secondary spring and install E clip in groove at end of shuttle valve d Verify that spring and E dip are properly seated before proceeding 7 Install shuttle valve cover plate Tighten cover plate screws to 4 Nem 35 in 165 torque 8 Install 1 2 and 2 3 valve governor plugs in valve body 9 Install shuttle valve primary spring and throttle plug 10 Align and install governor plug cover Tighten Cover screws to 4 Nem 35 in 165 torque 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 Boost Valve Tube Installation Fig 133 1 Position valve body assembly so lower housing is facing upward 2 2 Lubricate tube ends and housing ports with
37. 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 Disassemble transmission remove retainer and replace orifice Disassemble overdrive unit and replace thrust bearing 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 J9321 341 Condition 42RE TRANSMISSION DIAGNOSIS 21 27 OVERDRIVE DIAGNOSIS Possible Cause Correction DELAYED 3 4 UPSHIFT SLOW TO ENGAGE low fluid level Overdrive solenoid or wiring is faulty Overdrive piston spacer too thin Overdrive clutch pack worn T P S faulty 6 Overdrive clutch bleed orifice in retainer plugged or blown out 1 Add fluid and check for leaks Test solenoid and check wiring for loose corroded connections or shorts ground replace solenoid if faulty and repair wiring if necessary Remove unit measure end play and select proper spacer Remove unit and rebuild clutch pack Replace T P S Disassemble transmission and replace orifice 3 4 UPSHIFT OCCURS BEFORE COMPLETION OF 2 3 UPSHIFT Overdrive solenoid connector or wiring problem Overdrive solenoid malfunction Coolant temperature or
38. assembly refer ence Fig 35 5 Set assembly aside for final installation after overhaul is complete 21 72 TRANSMISSION OVERHAUL 42RE LOW REVERSE DRUM OVERRUNNING CLUTCH CAM ROLLER AND SPRING ASSEMBLY CLUTCH RACE J9121 140 Fig 34 Checking Overrunning Clutch Installation NON THREADED HOLE J9121 313 Fig 35 Marking Location Of Non Threaded Hole In Clutch Cam OIL PUMP AND REACTION SHAFT SUPPORT OVERHAUL PUMP AND SUPPORT DISASSEMBLY 1 Remove seal from around pump housing Fig 36 2 Loosen bolts that attach pump body to support Fig 37 3 Remove pump to support bolts and separate sup port from pump housing Fig 38 4 Remove inner and outer gears from reaction shaft support Fig 39 5 If pump seal was not removed during transmis sion disassembly remove seal with punch and ham mer 6 Remove front clutch thrust washer from support PUMP HOUSING PUMP 19321 212 Fig 37 Loosening Pump Support Bolts REACTION SHAFT SUPPORT PUMP HOUSING J9321 213 Fig 38 Separating Pump Housing From Reaction Shaft Support REACTION SHAFT SUPPORT INNER OUTER GEAR GEAR J9321 214 Fig 39 Pump Gear Removal hub Fig 40 Note position of chamfer on washer inside diameter for installation reference Chamfer side faces pump OIL SEAL O RING SEAL OUTER GEAR PUMP HOUSING TRANSMISSION OVERHAUL 42RE 21 73 REACTION SHAFT GASKET SUPPO
39. be free of distortion warpage or broken coils Check the two separator plates for distortion or damage 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 2 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 valve body assembly unless it is damaged in handling The only serviceable valve body components are listed below The remaining valve body components are serviced only as part of a complete valve body assem bly Serviceable parts are e dual solenoid and harness assembly TRANSMISSION OVERHAUL 42RE 21 97 solenoid gasket Solenoid case connector O rings and shoulder bolt switch valve and spring pressure adjusting screw and bracket assembly throttle lever manual lever and shaft seal throttle lever shaft seal washer and E dip fluid filter and screws detent ball and spring valve body screws governor pressure solenoid governor pressure sensor and retaining dip park lock rod
40. completely Fig 22 8 Remove Special Tool 6227 1 Then remove dutch pack from hub Fig 22 GEARTRAIN DISASSEMBLY 1 Remove direct dutch hub and spring Fig 23 2 Remove sun gear and spring plate Then remove planetary thrust bearing and planetary gear Fig 24 Z SPECIAL TOOL 6227 1 DIRECT CLUTCH HUB DIRECT CLUTCH PACK J9321 365 Fig 22 Direct Clutch Pack Removal DIRECT DIRECT CLUTCH CLUTCH NI SPRING HUB JE du J9121 311 Fig 23 Direct Clutch Hub And Spring Removal PLANETARY PLANETARY CLUTCH GEAR THRUST SPRING BEARING PLATE SPRING PLATE SNAP RING J9121 312 Fig 24 Removing Sun Gear Thrust Bearing And Planetary Gear 2 3 Remove overrunning clutch assembly with ex panding type snap ring pliers Fig 25 Insert pliers into clutch hub Expand pliers to grip hub splines and remove clutch with counterclockwise twisting motion OVERRUNNING CLUTCH NEEDLE BEARING 8921 248 Fig 25 Overrunning Clutch Assembly Removal Installation 4 Remove thrust bearing from overrunning dutch hub Fig 26 5 Remove overrunning dutch from hub Fig 26 OVERRUNNING C THRUST BEARING J9121 320 Fig 26 Overrunning Clutch Components OVERDRIVE UNIT OVERHAUL 42RE 21 117 6 Mark position of annulus gear and direct clutch drum for assembly alignment reference Fig 27 Use small center punch or scriber to make alignment marks DIRECT PUNCH 8921 249
41. ft 105 NEUTRAL SWITCH SWITCH J9121 106 Fig 170 Park Neutral Position Switch Seal Position 57 Install magnet in oil pan Magnet goes on small protrusion at corner of pan 58 Position new oil pan gasket on case and install oil pan Tighten pan bolts to 17 Nem 13 ft Ibs 59 Install new valve body manual shaft seal in case Fig 171 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 60 Install throttle valve and shift selector levers on valve body manual lever shaft 15 16 Fig 171 Installing Manual Lever Shaft Seal 61 Cap or cover transmission openings cooler line fittings filler tube bore etc to prevent dirt entry TRANSMISSION OVERHAUL 42RE 21 111 62 Install torque converter Use C damp or metal strap to hold converter in place for installation 63 Install transmission speed sensor in overdrive case Fig 1 64 Mount transmission on jack for installation in vehicle 65 Apply dielectric grease to terminal pins of sole noid case connector and neutral switch CAUTION The transmission cooler and lines must be reverse flushed if overhaul corrected a malfunction that generated sludge metal particles or clutch fric tion material The torque converter should also be replaced if contaminated by the same malfunction Debris and residue not flushed from the cooler and lines
42. inter mediate shaft Fig 3 a If overdrive unit does not require service in sert Alignment Tool 6227 2 in overrunning clutch OVERDRIVE BOLTS 7 Bolts OVERDRIVE UNIT TRANSMISSION CASE Fig 3 Overdrive Unit Removal and planetary gear splines to maintain alignment Fig 4 If clutch and gear splines rotate out of 2 alignment overdrive unit may have to be dis assembled in order to realign splines b If overdrive unit does requires service refer to Overdrive Unit Overhaul section SPECIAL TOOL J9321 133 Fig 4 Overdrive Spline Alignment Tool Installation 8 Remove thrust bearing and thrust plate from overdrive piston Fig 5 THRUST BEARING OVERDRIVE PISTON THRUST Fig 5 Thrust Bearing And Plate Removal 9 Place transmission in horizontal position 10 Remove transmission oil pan and gasket 11 Remove oil filter from valve body Fig 6 Keep filter screws separate from other valve body screws Filter screws are longer and should be kept with filter 12 Remove overdrive piston from retainer Fig 7 13 Remove pump oil seal with Special C 3981 Fig 8 Be sure to tighten tool threads completely into seal before using puller bolt to withdraw seal 14 Remove park neutral position switch Fig 9 15 Remove hex head bolts attaching valve body to transmission case Fig 10 A total of 10 bolts are used Note different bolt lengths for assembly re
43. intermediate shaft pilot bushing The large bushing is the overrunning clutch hub bush ing Replace either bushing if scored pitted cracked or worn Remove the annulus gear from the output shaft if bushing replacement is required This will provide more working room and make bushing replace ment easier The bushings can be removed with blind hole puller tools such as Snap On set CG40CB for small bushings and set CG46 for large bushings New bushings can be installed with tools from an all purpose installer kit such as the Snap On A257 bushing driver set OUTPUT 19121 321 Fig 35 Output Shaft Bushing Location OVERDRIVE UNIT ASSEMBLY AND ADJUSTMENT GEARTRAIN AND DIRECT CLUTCH ASSEM BLY 1 Soak direct clutch and overdrive clutch discs in Mopar ATF Plus transmission fluid Allow discs to soak for 10 20 minutes 2 Install new pilot bushing and clutch hub bushing in output shaft if necessary Fig 34 Lubricate new or old bushings with petroleum jelly or transmission fluid 3 Install annulus gear on output shaft if removed Then install annulus gear retaining snap ring Fig 36 4 Align and install clutch drum on annulus gear Fig 37 Be sure drum is engaged in annulus gear lugs 5 Install dutch drum outer retaining ring Fig 37 6 Slide clutch drum forward and install inner re taining ring Fig 38 2 SNAP OUTPUT SHAFT RING FRONT BEARING J9021 89 ANNULUS CLUTCH DRUM J9321
44. 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 cloth However replace the piston and or retainer if the seal surfaces are seriously scored RETAINER CHECK BALL 19121 368 Fig 54 Front Clutch Piston Retainer Check Ball Lo cation FRONT CLUTCH 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 Door Eze or petroleum jelly Then lubricate retainer hub bore and piston with transmis sion fluid 4 Install clutch piston in retainer Fig 56 Use twisting motion to seat piston in bottom of retainer Do not attempt to push the piston straight in This could fold the seals over causing leakage and clutch slip TRANSMISSION OVERHAUL 42RE 21 77 BUSHINGS NON SERVICEABLE J9321 223 Fig 55 Retainer Bushing Locations FRONT CLUTCH RETAINER CLUTCH PISTON 19121 146 Fig 56 Front Clutch Piston Installation 5 Position spring in clutch piston Fig 57 RETAINER CLUTCH SPRING PISTON J9321 466 Fig 57 Clutch Spring Installation 6 Position spring retainer on top of piston spring Fig 58 Make sure retainer is properly insta
45. noid and sensor Figs 126 and 127 3 Lubricate solenoid and sensor O rings with clean transmission fluid 21 102 TRANSMISSION OVERHAUL 42RE 4 Install governor pressure sensor in governor body Then secure sensor with M shaped retaining clip Fig 93 5 Install governor pressure solenoid in governor body Fig 94 Push solenoid in until it snaps into place in body 6 Position governor body gasket on transfer plate Fig 92 7 Install retainer plate on governor body and around solenoid Fig 90 Be sure solenoid connector is positioned in retainer cutout 8 Align screw holes in governor body and transfer plate Then install and tighten governor body screws to 4 35 in 165 torque 9 Connect harness wires to governor pressure 50 lenoid and governor pressure sensor Fig 90 VALVE BODY CONTROL PRESSURE ADJ UST MENTS There are two control pressure adjustments on the valve body which are line pressure and throttle pres sure Line and throttle pressure work together as each affects shift quality and timing Both adjustments must be performed properly and in the correct se quence Line pressure is adjusted first and throttle pressure is adjusted last Line Pressure Adjustment Measure distance from the valve body to the inner edge of the adjusting screw with an accurate steel scale Fig 137 Distance should be 33 4 mm 1 5 16 inch If adjustment is required turn the adjusting screw in or out
46. oil pump Fig 164 Align and position pump on pilot studs Slide pump down studs and work it into front dutch hub and case by hand Then install 2 or 3 pump bolts to hold pump in place 37 Remove pilot stud tools and install remaining oil pump bolts Tighten bolts alternately in diagonal pattern to 20 Nem 15 ft Ibs y T BAND SEAL RINGS J9121 194 9121 196 Fig 164 1 lli il P A Fig 162 Reaction Shaft Support Seal Rings And Front Clutch Thrust Washer Position 38 Install new seals on overdrive piston Then bolt holes in oil pump flange Fig 163 a seals with Ru Glyde Door Eze or petroleum detalla purnip gasket F 1g T64 39 Install overdrive piston in retainer Align lo cating lugs on piston in locating bores in re Z 5 _ TRANSMISSION OVERHAUL 42RE 21 109 tainer Fig 165 Usethin plastic strip or feeler gauge to help guide piston outer seal into retainer OVERDRIVE OVERDRIVE lt gt RETAINER PISTON LUG AS THRUST BORES E 9121 354 Fig 166 Installing Overdrive Piston Thrust Plate 7 o BE SURE THIS SHOULDER ACES FORWARD PISTON Pies d OVERDRIVE 7 PISTON THRUST BEARING DIRECT CLUTCH 19121 353 Fig 165 Overdrive Piston Alignment 40 Install spacer on intermediate shaft if not pre viously installed 41 Install overdrive piston thrust plate Fig 166
47. out of adjustment Transmission clutches slipping 4 Overrunning clutch in converter stator not holding Converter stator overrunning clutch seized contamination occurred shortly after overhaul fluid cooler and lines were not flushed and flow tested This is especially true when original overhaul was to correct a problem that generated a large amount of debris such as a gear failure or a clutch pack failure Note Flushing the cooler and lines is mandatory after a failure of the converter clutch Incorrect fluid used in transmission 3 Main cooler in radiator is cracked allowing engine coolant to enter transmission Severe overload results in overheat fluid breakdown and accelerated wear especially in high ambient temperatures Most frequent causes are Vehicle is not properly equipped for heavy duty service Tow vehicle and boat or trailer are both overloaded Trailer or boat are too large for tow vehicle lead exceeds rated capacity of tow vehicle 21 25 Correction Adjust linkage Check continuity with test lamp repair as required Refer to service section for test and replacement procedure Inspect lever assembly and replace if damaged 1 Check engine and repair as required Adjust as needed Perform stall test and repair as required 4 Perform stall test and replace converter if clutch has failed Replace converter as assembl
48. rearward 3 Install rear thrust washer on rear planetary gear Fig 70 Use enough petroleum jelly to hold washer in place Also be sure washer tabs are properly engaged in gear slots 4 Install rear annulus over and ontorear planetary gear Fig 70 5 Install assembled rear planetary and annulus gear on intermediate shaft Fig 71 Verify that assem bly is fully seated on shaft 6 Install front thrust washer on rear planetary gear Fig 72 Use enough petroleum jelly to hold washer on gear 7 Install spacer on sun gear Fig 73 2 REAR ANNULUS GEAR TABBED THRUST WASHER REAR PLANETARY J9121 156 Fig 70 Assembling Rear Annulus And Planetary Gear REAR ANNULUS AND PLANETARY GEAR ASSEMBLY INTERMEDIATE SHAFT J9121 275 Fig 71 Installing Assembled Rear Annulus And Planetary Gear On Intermediate Shaft FRONT TABBED THRUST WASHER PLANETARY GEAR J9121 158 Fig 72 Installing Rear Planetary Front Thrust Washer 2 8 Install thrust plate over sun gear and on top of spacer Fig 74 Note that thrust plates are inter changeable Use either plate on sun gear and rear of driving shell SUN GEAR SUN GEAR SPACER J9121 159 THRUST PLATE J9121 161 Fig 74 Installing Spacer And Thrust Plate On Sun Gear 9 Insert sun gear into driving shell Fig 75 10 Hold sun gear in position and install rear thrust plate Plate goes over sun gear at rear of driving shell
49. reassembly Overtighten ing can distort the housings resulting in valve stick ing cross leakage and unsatisfactory operation Tighten valve body screws to recommended torque only Lower Housing Assembly Fig 124 1 Lubricate valves springs and the housing valve and plug bores with clean transmission fluid 2 Install 3 4 timing valve spring and valve 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 Nem 35 in Ibs torque 6 Install 3 4 shift valve and spring 7 Install converter clutch valve spring and plug 8 Install converter clutch timing valve and spring 3 4 Accumulator Assembly Fig 125 1 Lubricate accumulator piston seals and housing piston bore with clean transmission fluid 2 Install new seal rings on accumulator piston 3 Install piston and spring in housing 4 Install end plate on housing Transfer Plate Assembly 1 Install rear clutch and rear servo check balls in transfer plate Fig 118 2 Install filter screen in upper housing separator plate Fig 129 UPPER FILTER HOUSING SEPARATOR PLATE Fig 129 Separator Plate Filter Screen Installation 3 Align and position upper housing separator plate on transfer plate Fig 116 4 Install brace plate Fig 116 Tighten brace at taching screws to 4 35 in 16
50. right rear of the transmission case The overdrive dutch pressure port is at the left rear of the case Fig 3 An accurate tachometer and two test gauges required for the pressure test Test Gauge C 3292 has a 100 psi range and is used at the accumulator governor front servo and overdrive pressure ports Test Gauge C 3293 has a 300 psi range and is used at the rear servo port where pressures range from 250 to 290 psi In cases where two test gauges are required the 300 psi gauge can be used at any of the other test ports HYDRAULIC PRESSURE TEST PROCEDURE Connect a tachometer to the engine Position the tachometer so it can be observed from under the vehicle Raise the vehicle on hoist that will allow the wheels to rotate freely OVERDRIVE CLUTCH TEST PORT 6 GOVERNOR TEST PORT ACCUMULATOR TEST PORT FRONT gt SERVO TEST PORT TEST PORT J9321 405 Fig 3 Pressure Test Port Locations Test One Transmission In 1 Range This test checks pump output pressure regula tion and condition of the rear clutch and servo circuit Test Gauges C 3292 and C 3293 are re quired for this test Gauge C 3292 has a 100 psi range Gauge C 3293 has a 300 psi range 1 Connect 100 psi Gauge C 3292 to accumulator port 2 Connect 300 psi Gauge C 3293 to rear servo port Fig 3 3 Disconnect throttle and gearshift cables from transmission levers 4 Start and run engine at 1000 rpm 5 Move
51. rotate freely 1 Connect 100 psi Test Gauge C 3292 to governor pressure port Fig 3 2 Move transmission shift lever to D range 3 Start and run engine at curb idle speed and note pressure At idle and with vehicle stopped pressure should be zero to 1 1 2 psi maximum If pressure exceeds this figure a fault exists in the governor pressure control system 4 Slowly increase engine speed and observe speed ometer and pressure test gauge Governor pressure should increase in proportion to vehicle speed Or approximately 1 psi for every 1 mph 5 Pressure rise should be smooth and drop back to 0 to 1 1 2 psi when wheels stop rotating 6 Compare results of pressure tests with analysis chart Fig 4 Test Six Transmission In Overdrive Fourth Gear This test checks line pressure at the overdrive clutch in fourth gear range Use 300 psi Test Gauge C 3292 for this test 1 Raise vehicle and connect test gauge to overdrive clutch pressure port Fig 4 2 Lower vehicle to enough to allow entry into drivers seat Leave vehicle wheels approximately one foot off shop floor 3 Secure test gauge where it can be viewed from drivers seat 4 Verify that overdrive control switch is in ON position 5 Start engine and shift into D range 6 Increase engine rpm gradually until 3 4 shift occurs and note gauge pressure 7 Pressure should be 469 496 kPa 68 72 psi with closed throttle and increase to 620 827 kPa 90 120
52. shift lever on manual lever shaft all the way forward into 1 range 6 Move transmission throttle lever from full for ward to full rearward position and note pressures on both gauges 7 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 lever is moved rearward 8 Rear servo pressure should be same as line pressure within 3 psi 20 68 kPa 2 Test Two Transmission In 2 Range This test checks pump output line pressure and pressure regulation Use 100 psi Test Gauge C 3292 for this test 1 Connect test gauge to accumulator pressure port Fig 3 2 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 at both gauges 5 Line pressure should be 54 60 psi 372 414 kPa with throttle lever forward and gradually increase to 90 96 psi 621 662 kPa as lever is moved rearward Test Three Transmission In D Range This test checks pressure regulation and con dition of the clutch circuits Use both pressure Test Gauges C 3292 and C 3293 for this test 1 Connect test gauges to accumulator and front servo ports Fig 3 Use either test gauge at the two ports 2 Start and run engine at 1600 rpm for this test 3 Move shift lever two det
53. spring Note position of retainer on spring for assembly reference 5 Remove clutch piston from clutch retainer Re move piston by rotating it up and out of retainer 6 Remove seals from clutch piston and dutch re tainer hub Discard both seals as they are not reusable FRONT CLUTCH INSPECTION Clean the front clutch components in solvent and dry them with compressed air only Do not use rags SNAP RING WAVED SPRING RETAINER SNAP RING PRESSURE PLATE CLUTCH J9321 222 CLUTCH PLATES Fig 52 Front Clutch Components 2 or shop towels to dry any of the dutch parts Lint from such materials will adhere to the component surfaces and could restrict or block fluid passages after assem bly Replace the clutch discs if warped 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 or damaged in any way Replace the clutch spring and spring retainer if either is distorted warped or broken Check the lug grooves in the clutch 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 54 The ball must move freely and not stick Inspect the clutch retainer bushings carefully Fig 55 The retainer bushings are not service able It will be
54. will flow back into the transmission and con verter The result could be a repeat failure and shop comeback 21 112 OVERDRIVE UNIT OVERHAUL 42RE Z OVERDRIVE UNIT OVERHAUL 42RE INDEX page page Overdrive Component Cleaning and Inspection 118 Overdrive Unit Disassembly 112 Overdrive Unit Assembly and Adjustment 120 OVERDRIVE UNIT DISASSEMBLY OVERDRIVE REMOVAL 1 Remove transmission speed sensor and O ring seal from overdrive case Fig 1 SOCKET AND WRENCH 11mm SOCKET OVERDRIVE BOLTS 7 SPEED SENSOR Bolts OVERDRIVE UNIT Fig 1 Transmission Speed Sensor Removal Installation 2 Place transmission in upright position Fig 2 las i 3 Remove bolts attaching overdrive unit to trans mission case Fig 2 An 11 mm socket is required Note position of wire harness dips for installation reference 4 Lift overdrive unit up and off transmission case and intermediate shaft Fig 3 5 Remove overdrive piston thrust bearing Fig 4 OVERDRIVE PISTON REMOVAL 1 Remove overdrive piston thrust plate Fig 5 Retain thrust plate It is a select fit part and may 3 Remove overdrive piston from retainer Fig 7 possibly be reused 2 Remove intermediate shaft spacer Fig 69 Re OVERDRIVE CLUTCH PACK REMOVAL tain spacer It is a select fit part and may possibly be 1
55. 2 AUTOMATIC TRANSMISSION 42RE 21 1 AUTOMATIC TRANSMISSION 42RE CONTENTS page page 42RE TRANSMISSION DIAGNOSIS 7 SPECIFICATIONS RES 129 GENERAL INFORMATION 1 TRANSMISSION OVERHAUL 42RE 64 IN VEHICLE SERVICE 42RE 43 TRANSMISSION OVERDRIVE REMOVAL OVERDRIVE UNIT OVERHAUL 42RE 112 AND INSTALLATION 42RE 55 GENERAL INFORMATION INDEX page page Converter Clutch Engagement 5 Recommended Fluid 3 Electronic Governor Components 3 Service Manual Updates 6 Front Band Adjustment 3 Torque Converter 3 E da cnn 3 Transmission Description 1 Governor Pressure Curves 5 Transmission Identification 3 Overdrive Off Switch Transmission Shifting 5 Quick Fill Valve 5 TRANSMISSION DESCRIPTION The Chrysler 42RE is a 4 speed automatic transmis sion Mechanical and hydraulic components in the 42RE are similar to those in Chrysler 42RH transmis sions The major difference between them involves the method of producing governor pressure for shift speed control The 42RE uses electronic components to de velop governor pressure A mechanical governor is used to generate governor pressure in the 42RH First through third gear ranges in
56. 3 125 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 9121 342 Fig 70 Overdrive Piston Thrust Plate Selection OVERDRIVE UNIT OVERHAUL 42RE 21 129 SPECIFICATIONS 42RE GENERAL SPECIFICATIONS 0 089 0 190 mm 0 0035 0 0075 in 0 127 1 22 mm 0 005 0 048 in 0 56 2 31 mm 0 022 0 091 in 1 70 3 40 mm 0 067 0 134 in 0 81 1 40 mm 0 032 0 055 in TRANSMISSION MODEL Oil Pump Clearances all Planetary End Play Input Shaft End Play Clutch Pack Clearance Front Clutch 4 Disc Rear Clutch 4 Disc Clutch Disc Usage Front Clutch Rear Clutch Overdrive Clutch Direct Clutch Band Adjustments backed off form 72 in lbs Front Band Rear Band 3 5 8 Turns 4 Turns MOPAR ATF Plus Type 7176 Automatic ouem Flui J9321 449 Recommended and preferred Fluid 42RE THRUST WASHER SPACER SNAP RING DIMENSIONS Front Clutch Thrust Washer 0 061 in on reaction shaft support hub Rear Clutch Thrust Washer 0 061 in on clutch retainer Intermediate Shaft Thrust Plate 0 060 0 063 in on shaft pilot hub Intermediate Shaft Thrust Washer in rear clutch hub Select fit to set overall end play 0 060 in 0 076 in 0 098 in Rear Clutch Pack Snap Ring Select fit 3 thicknesses available Overdri
57. 33 AldW3ssv ONIN dvNS L3vHS LNdLNO SNINNNY u31nO WNC HOLNTD HOLNTD 1933lQ WNUG 21 12 ONINIVI3U LSNYHL 1 15 ONINNNAYIAO ONINN QHHJAO AYVLINV 1d LSNYHL ANVI3NV d Xiawassv 3lv ld 445 ANY 3v39 NNS 5 HOLNTD LOFA HOLNTD 1238 ONINIVI33 H21n015 HOLNTD 12333 ONIX dVNS ovd 1 12 12344 ONIY dVNS 21015 3ABIQHJAO HOLNTD 3ATIOH3AO DNINIVLAY J3ABIQH3AO LSNYHL NOLSId 31V ld LSNYHL NOLSId 0000000 21 120 OVERDRIVE UNIT OVERHAUL 42RE GEAR CASE ACCESS PLATE Rig se GASKET CASE GASKET PARK PAWL PAWL SHAFT E unit m REACTION PLUG AND SNAP RING J9321 367 PARK LOCK ROD Fig 34 Overdrive Gear Case And Park Lock Compo nents Examine the overdrive and direct dutch discs plates Fig 32 Replace the discs if the facing is worn severely scored or burned and flaking off Replace the clutch plates if worn heavily scored or cracked Check the lugs on the clutch plates for wear The plates should slide freely in
58. 45 mph If the control switch is in the OFF position the dutch will engage after the shift to third gear at approxi mately 56 kmyh 35 mph at light throttle OVERDRIVE OFF SWITCH The overdrive Off switch is located in the instrument panel The switch is a momentary contact device that signals the TCM to toggle current status of the over drive function At key on overdrive operation is al lowed 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 normal position for the control switch is the ON position The switch must be in this position to ener gize the solenoid and allow a fourth gear upshift The control switch has an indicator light The light illuminates when the overdrive switch is turned to the OFF position or when illuminated by the transmission control module The control switch indicator light is also used to signal fault flash codes for diagnostic purposes QUICK FILL VALVE The 3 4 shuttle valve is replaced by a 3 4 quick fill valve in the 42RE valve body The valve maintains a prefill pressure of approximately 5 psi in the overdrive clutch Prefill pressure is maintained in all drive D ranges The purpose of the valve is faster engagement of the overdrive clutch during 3 4 upshifts In operation the valve temporar
59. 5 10 75 in 4 lug converter es 31 Nem 270 in lbs Overdrive Piston Retainer 17 Nem 150 in lbs Crossmember Bolts Nuts 68 50 ft lbs Pressure Test Port 0 14 Nem 10 ft lbs Driveplaie Bolts is ptis 75 Nem 55 ft 165 Propeller Shaft Clamp Bolts 19 170 in lbs s Lever Pivot Shaft hea Reaction Shaft Support Bolts 20 Nem 15 ft lbs RU Rear Band Adjusting Screw Locknut Al Nem 30 ft lbs Front Band Adjusting Screw Locknut 34 Nem 25 165 Solenoid Wiring Connector Screw 4 Nem 35 in Ibs Park Neutral Position Switch 34 Nem 25 ft lbs 22 Solenoid to Transfer Plate Screw 4 35 in lbs Oil Filter Screws 4 35 in lbs Speedometer Adapter Bolt 11 Nem 8 ft lbs Oil Pan 17 Nem 13 ft 165 Valve Body Governor Body Screws 4 Nem 35 in 165 Oll Pump rb cies 20 Nem 15 Ibs 010 Valve Body to Case Bolts 12 100 in lbs In 5 Transmission speed sensor 27 20 ft lbs J9321 451
60. 5 torque TRANSMISSION OVERHAUL 42RE 21 99 5 Install remaining separator plate attaching screws Tighten screws to 4 Nem 35 in Ibs torque Assembling Upper And Lower Housings 1 Position upper housing so internal passages and check ball seats are facing upward Then install check balls in housing Fig 119 Seven check balls are used The single large check ball is approximately 8 7 mm 11 32 in diameter The remaining 6 check balls are approximately 6 3 mm 1 4 in in diameter 2 Position assembled transfer plate and upper housing separator plate on upper housing Fig 130 Besure filter screen is seated in proper housing recess TRANSFER PLATE SEPARATOR FILTER SCREEN 9321 439 Fig 130 Installing Transfer Plate On Upper Housing 3 Position lower housing separator plate on trans fer plate Fig 131 BE SURE TO ALIGN TRANSFER LOWER HOUSING OVERDRIVE SEPARATOR PLATE 29321 441 Fig 131 Lower Housing Separator Plate Installation 4 Install lower housing on assembled transfer plate and upper housing Fig 132 5 Install and start valve body screws by hand 21 100 TRANSMISSION OVERHAUL 42RE Then tighten screws evenly to 4 Nem 35 in 105 torque Start at center and work out to sides when tightening screws Fig 132 VALVE BODY SCREWS 13 LOWER HOUSING TRANSFER PLATE J9321 442 Fig 132 Installing Lower Housing On Transfer Plate And Upper Housing
61. 6 Sun Gear Installation 17 Align splines in hubs of planetary gear and overrunning clutch with Alignment tool 6227 2 Fig 47 Insert tool through sun gear and into splines of both hubs Be sure alignment tool is fully seated before proceeding SPECIAL TOOL 6227 2 SUN GEAR x ASSEMBLED DRUM AND ANNULUS GEAR PRESS PLATES NS 9321 395 Fig 47 Alignment Tool Installation 18 Install direct dutch spring Fig 48 Be sure spring is properly seated on spring plate 19 Assemble and install direct clutch pack on hub as follows a Assemble dutch pack components Fig 49 b Install direct clutch reaction plate on dutch hub first Note that one side of reaction plate is counterbored Be surethis side faces rearward Splines at rear of hub are raised slightly Coun terbore in plate fits over raised splines Plate should be flush with this end of hub Fig 50 OVERDRIVE UNIT OVERHAUL 42RE 21 123 SPECIAL TOOL 6227 2 223 DIRECT CLUTCH SPRING CLUTCH PRESS PLATES 9321 3 Fig 48 Direct Clutch Spring Installation c Install first clutch disc followed by a steel plate until 6 discs and 5 plates have been installed d Install pressure plate This is last clutch pack item to be installed Be sure plate is installed with shoulder side facing upward Fig 51 20 Install clutch hub and clutch pack on direct clutch spring Fig 52 Be sure hub is started on sun gear splines
62. 65334 334 2 IONTIOS JAANO gr dWNd 54 7 34055 344 3g 33BI3ANOO isd 06 0 593 4 ce cz isd 29 66 JANSSIAd 5 MOT 21 41 42RE TRANSMISSION DIAGNOSIS 086 1266 isd 6 0 3155334 13 5 dWfld 45 340155339 39M 2 54 9 JUNSSIYd YONYIAOD CA isd 6 62 54 29 66 34155334 935012 QNO23S TWNNYW YOLDITIS SOTO IS ONISHI INNEN AUT WO BAH on HOLD DAN oo poto e 3ATVA 5 055808 65558884 Wea E 49 P 4 3AIVA TH DINO E rv ny YOLVINWNDDV 2 HDINTD INO HOIfTD 3ABKRIAO YOLVINWNDDY
63. 9321 467 Fig 99 Boost Valve Cover Location COVER BOOST SCREWS VAIVE SPRING COVER AND 5 VALVE PLUG BOOST VALVE SPRING VALVE 19321 468 Fig 100 Boost Valve Components 14 Remove E clip and washer that retains throttle lever shaft in manual lever Fig 102 TRANSMISSION OVERHAUL 42RE 21 89 SPECIAL TOOL 6583 POSITIONED ON DETENT J9321 423 Fig 101 Securing Detent Ball And Spring _ THROTTLE MANUAL SHAFT E CLIP AND __ WASHER eE J9321 424 Fig 102 Throttle Lever E Clip And Washer Removal 15 Remove manual lever and throttle lever Fig 103 Rotate and lift manual lever off valve body and throttle lever shaft Then slide throttle lever out of valve body ROD THROTTLE LEVER MANUAL nm J9321 425 Fig 103 Manual And Throttle Lever Removal 21 90 TRANSMISSION OVERHAUL 42RE 16 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 104 DETENT BALL DETENT SPRING DETENT HOUSING PENCIL MAGNET 29321 426 Fig 104 Detent Ball And Spring Removal 17 Remove park rod E clip and separate rod from manual lever Fig 105 MANUAL LEVER PARK ROD 19121 81 Fig 105 Park Rod Removal 18 Remove screws attaching pressure adjusting screw bracket to valve body and transfer plate Fig
64. AO MOLVIDWIDOV ONIS INOW 338 IOS NONIJAOD 15414 NI SZ 1c f TILIOSHL QNO23S uu cts d 42RE TRANSMISSION DIAGNOSIS 21 36 isd 6 0 3155434 4 JARIQSJAO 5 dWNd isd 33166494 3971 2 isd Q Z 33155354 14165 2 1 SEAS PK Rg isd 76 0 JUNSSAYd 6 0 JafiSS33d YONYIAOD isd 76 25 3959334 RP i jun HREIBEIANOD rm gt 1 HOLD 7 OL 3AIVA DINO YOLVINWNDOV E U SE 1485 2 1 11 __ 2 N cmm ONIS INOS HOLMIO OAMAS 5 NI 9I TOVHGAH 21 37 42RE TRANSMISSION DIAGNOSIS 9LE LEP SF LON HOLMIO 23203ANOO CUHL ah ae TO JANG
65. AUL 42RE 21 93 E CLIP SECONDAR SHUTTLE VALVE Fig 120 Shuttle Valve E Clip And Secondary Spring Location 2 Remove E clip that secure shuttle valve second ary spring on valve stem Fig 120 3 Remove governor plug and shuttle valve covers Fig 121 4 Remove throttle plug primary spring shuttle valve secondary spring and spring guides Fig 121 5 Remove boost valve retainer spring and valve if not previously removed SPRING GUIDES SHUTTLE e VALVE SECONDARY SPRING SHUTTLE VALVE P dd COVER UPPER pale HOUSING THROTTLE KC PLUG SHUTTLE NS VALVE SHUTTLE VALVE PRIMARY 5 SPRING GOVERNOR PLUG e SIS COVER J9321 156 Fig 121 Shuttle And Boost Valve Components 21 94 TRANSMISSION OVERHAUL 42RE OO _ Z UPPER HOUSING REGULATOR VALVE SWITCH VALVE REGULATOR VALVE SPRING SHUTTLE VALVE PRIMARY SPRING 2 3 GOVERNOR PLUG THROTTLE PLUG THROTILE M GOVERNOR 7 VALVE DETENT PLUG AND COVER SPRING J9321 155 Fig 122 Control Valve Locations In Upper Housing 6 Turn upper housing over and remove switch valve 8 Remove throttle plug and 1 2 and 2 3 governor regulator valve and spring and manual valve Fig 122 plugs Fig 122 Also remove shuttle valve primary 7 Remove kickdown detent kickdown valve and spring if not removed in prior step throttle valve and spring Fig 122
66. E ACCUMULATOR SPRING AND HOUSING PLUG 9321 434 Fig 110 3 4 Accumulator Housing Valve Springs And Plug Removal 23 Remove pressure regulator valve spring from lower housing Fig 111 24 Remove boost valve connecting tube Fig 112 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 pry tools to loosen or remove connecting tube Loosen and remove the tube by hand only 25 Turn valve body over so lower housing is facing upward Fig 113 In this position the two check balls TRANSMISSION OVERHAUL 42RE 21 91 LOWER HOUSING pm VALVE AND SPRING FA 3 4 SHIFT VALVE CLUTCH REGULATOR AND VALVE VALVE SPRING PLUG SPRING J9321 146 Fig 111 Lower Housing Valve Spring Locations LOWER HOUSING BOOST DISENGAGE UPPER THIS END OF HOUSING TUBE FIRST J9321 147 Fig 112 Boost Valve Tube Removal in upper housing will remain in place and not fall out when lower housing and separator plate are removed 26 Remove screws attaching valve body lower housing to upper housing and transfer plate Fig 113 Note position of boost valve tube brace for as sembly reference 27 Remove lower housing and overdrive separator plate from transfer plate Fig 114 28 Remove transfer plate from upper housing Fig 115 29 Turn transfer plate over so upper housing sepa rator plate is facing upward Fig 116 30
67. Fig 60 Ridged side of plate faces downward toward piston and flat side toward clutch pack 11 Install first clutch disc in retainer on top of bottom pressure plate Then install a clutch plate REAR CLUTCH RETAINER 29121 152 Fig 65 Pressing Input Shaft Into Rear Clutch Re tainer REAR CLUTCH RETAINER PISTON SPRING PISTON J9121 153 Fig 66 Piston And Wave Spring Position followed by a clutch disc until entire clutch pack is installed 4 clutch discs and 3 metal plates are re quired 12 Install top pressure plate Fig 60 13 Install selective snap ring Fig 60 Be sure snap ring is fully seated in retainer groove 14 Measure clutch pack clearance Fig 67 Clear ance should be 0 64 to 1 14 mm 0 025 to 0 045 in If clearance is incorrect adjust clearance with select fit snap ring 15 Coat rear clutch thrust washer with petroleum jelly and install washer over input shaft and into clutch retainer Fig 68 Use enough petroleum jelly to hold washer in place SELECTIVE SNAP RING FEELER GAUGE RH295 Fig 67 Checking Rear Clutch Pack Clearance 16 Set rear clutch aside for installation during final assembly TRANSMISSION OVERHAUL 42RE 21 81 REAR CLUTCH RETAINER REAR CLUTCH THRUST WASHER FIBER X 1 XX oe 43121 154 Fig 68 Installing Rear Clutch Thrust Washer PLANETARY GEAR TRAIN AND INTER
68. Fig 61 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 62 OVERDRIVE CLUTCH INSTALLATION 1 Install overdrive clutch reaction ring first Reac tion ring is flat with notched ends Fig 63 TAB ENDS OF LOCATING GEARTRAIN ASSEMBLY 19321 360 Fig 60 Overdrive Gear Case Installation EXPAND BEARING LOCATING RING WITH SNAP RING PLIERS PUSH OUTPUT SHAFT FORWARD TO FREE J9321 359 Fig 61 Seating Locating Ring In Rear Bearing 2 Install wave spring on top of reaction ring Fig 64 Reaction ring and wave ring both fit in same ring groove Use screwdriver to seat each ring se curely in groove TORX SCREWDRIVER 125 ACCESS COVER SCREWS 29321 357 Fig 62 Installing Locating Ring Access Cover And Gasket J9321 356 Fig 63 Overdrive Clutch Reaction Ring Installation 3 Assemble overdrive clutch pack Fig 65 4 Install overdrive clutch reaction plate first Note that reaction plate is thinner than pressure plate 5 Install first clutch disc followed by first clutch plate Then install remaining clutch discs and plates in same order OVERDRIVE UNIT OVERHAUL 42RE 21 127 WAVE 2 90321355 Fig 64 Overdrive Clutch Wave Spring Installation 6 Verify clutch pack 4 clutch discs 3 steel pl
69. ING THE DIRECT CLUTCH SPRING IT IS EXTREMELY IMPORTANT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE IS APPROXIMATELY 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 19 2 Position Compressor Tool 6227 1 on clutch hub Fig 19 Support output shaft flange with steel press plates as shown and center assembly under press ram 3 Use Special Tool C 3995 A or similar size tool at top of Tool 6227 1 to help distribute load and provide needed extra press length Fig 19 4 Apply press pressure slowly Compress hub and spring far enough to expose clutch hub retaining ring and relieve spring pressure on clutch pack snap ring Fig 19 SPECIAL TOOL 3995 OR SIMILAR TOOL PRESS RAM SPECIAL TOOL 6227 1 PRESS CLUTCH HUB BED PLATES 2 2 39321 398 Fig 19 Geartrain Mounted In Shop Press 21 116 OVERDRIVE UNIT OVERHAUL 42RE 5 Remove direct clutch pack snap ring Fig 20 6 Remove direct clutch hub retaining ring Fig 21 SPECIAL TOOL CLUTCH Seu HUB DIRECT CLUTCH PACK SNAP RING SPECIAL TOOL J9321 363 Fig 21 Direct Clutch Hub Retaining Ring Removal 7 Release press load slowly and
70. ION Do not overfill the transmission Overfill ing may cause leakage out the pump vent which can be mistaken for a pump seal leak In addition over filling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear train This will reduce the life of the fluid significantly 7 Check fluid condition Fluid should be dark to light red in color and free of partides and sludge a If fluid is discolored or smells burned but transmission operation was OK flush cooler and lines and change fluid and filter Then road test again to confirm proper operation b If fluid is black dark brown turned to sludge contains extensive amount of metal or friction mate rial particles transmission will probably need over haul especially if shift problems were evident during road test EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump totake 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 aerating the fluid and causing the same conditions that occur with a low level In either case air bubbles cause fluid overheating oxidation and varnish buildup which interferes with valve clutch and servo operation Foaming also causes fluid expansion which can sult in fluid overflow from the transmission vent or fill tube Fluid overflow can easily be mista
71. Installing Overdrive Piston Thrust Plate 10 Verify that splines in overdrive planetary gear and overrunning clutch hub are aligned with Tool 6227 2 Fig 8 Overdrive unit cannot be fully installed if splines have rotated out of alignment If misaligned has occurred overdrive will have to be disassembled in order to realign splines 11 Install overdrive unit as follows 21 62 TRANSMISSION OVERDRIVE REMOVAL AND INSTALLATION 42RE _ Z TORQUE 2 3 om Ibs eee 10 12 Nem 90 110 lbs SENSOR SPEEDOMETER PINION ADAPTER CLAMP SL VEHICLE JA SPEED er SENSOR lt gt 19321 385 Fig 13 Speedometer Components a Raise overdrive unit and carefully slide it straight onto intermediate shaft Avoid tilting overdrive unit during installation as planetary gear and overrunning clutch splines could ro tate out of alignment If misalignment occurs overdrive will have to be disassembled in order to realign splines 6 Align and carefully insert park rod into park pawl Rod will make click noise as it enters pawl Move rod rearward slightly 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 this cavity If the rod enters the cavity during installation it will become bent when the
72. KICKDOWN OR NORMAL DOWNSHIFT Incorrect throttle cable adjustment Incorrect gear shift linkage adjustment Front band out of adjustment Hydraulic pressure too high or too low due to valve body malfunction or incorrect hydraulic control pressure adjustment Front servo band or linkage malfunction Clutch or servo malfunction Governor fault TPS fault STUCK IN LOW GEAR WILL NOT UPSHIFT Gearshift linkage or throttle cable out of adjustment 2 Front band out of adjustment Governor component fault loose output shaft support worn pump leaking seal rings or valve body problem stuck 1 2 shift valve or governor plug Clutch or servo malfunction NO LOW GEAR MOVES IN 2ND OR 3RD GEAR ONLY Governor circuit fault Valve body malfunction Front servo piston cocked in bore 4 Front band linkage malfunction Incorrect throttle or gearshift linkage adjustment Adjust cable Adjust linkage Adjust band Perform hydraulic pressure tests to determine cause and repair as required Correct valve body pressure adjustments as required Air pressure test operation and repair as necessary Air pressure test operation and repair as necessary Check with DRB II scan tool or flash codes and repair as needed Check for TPS fault at transmission control module with DRB scan tool or flash codes Adjust and repair linkage or cable if wor
73. L TOOL 6311 SPECIAL TOOL 6312 9221 47 Fig 67 Shaft End Play Measurement 3 Determine correct thickness overdrive piston thrust plate as follows a Position Gauge Tool 6311 across face of over drive case Then position Dial Caliper C 4962 over gauge tool Fig 69 0 Measure distance to clutch hub thrust bearing seat at four points 90 apart Then average measure ments by adding them and dividing by 4 c Select and install required thrust plate from information in thrust plate chart Fig 70 End Play Measurement Inches Spacer Thickness Inches 336 7505 7506 7675 676 7855 7856 8011 158 159 175 176 193 194 211 212 J9121 341 Fig 68 Intermediate Shaft End Play Spacer Selec tion 4 Leave Alignment Tool 6227 2 in place Tool will keep planetary and clutch hub splines in alignment until overdrive unit is ready for installation on trans mission 5 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 SPECIAL 215 TOOL 4962 __ DIRECT CLUTCH HUB THRUST BEARING SEAT SPECIAL TOOL 6311 J9221 48 Fig 69 Overdrive Piston Thrust Plate Measurement Spacer Thickness Inches End Play Measurement Inches 1 7500 1 7649 108 110 1 7650 1 7799 12
74. LATOR PISTON J9321 384 Fig 11 Valve Body Removal ACCUMULATOR OUTER PISTON SPRING lt gt INNER SPRING Fig 12 Accumulator Piston And Springs J9121 208 1 4 DRIVE EXTENSION PLUG J9321 462 Fig 13 Removing Installing Front Band Lever Shaft Access Plug 21 Thread bolts of Slide Hammer Tools C 3752 into threaded holes in pump body flange Fig 14 22 Bump slide hammer weights outward to remove pump and reaction shaft support assembly from case Fig 14 23 Loosen front band adjusting screw until band is completely loose OIL PUMP AND REACTION SHAFT SUPPORT ASSEMBLY YOR SLIDE HAMMER TOOLS C 3752 Fig 14 Removing Oil Pump And Reaction Shaft Support Assembly 24 Squeeze front band together and remove band strut Fig 15 BAND LTS BAND STRUT FRONT gt BAND Fig 15 Removing Installing Front Band Strut 25 Remove front band lever shaft with pencil mag net Pin is accessible from converter housing side of case Fig 16 PENCIL NOS FRONT MAGNET N BAND LEVER SHAFT J9321 463 Fig 16 Removing Front Band Lever Shaft 26 Remove front band lever Fig 17 TRANSMISSION OVERHAUL 42RE 21 67 Fig 17 Removing Installing Front Band Lever 27 Slide front band rearward and onto driving shell Band will not be removed until after front rear dutch removal 28 Remove front and rear dutch units as assembly Grasp input shaft
75. MEDIATE SHAFT OVERHAUL GEARTRAIN DISASSEMBLY FIG 69 1 Remove snap ring tabbed thrust washer and thrust plate from front of output shaft 2 Remove front annulus gear and support assem bly 3 Remove front planetary front thrust washer 4 Remove front planetary gear SELECT FRONT SUPPORT FRONT FRONT SUN SUN DRIVING SHELL DRIVING FIT ANNULUS SNAP ANNULUS PLANETARY GEAR GEAR FRONT THRUST SHELL PLANETARY RING GEAR THRUST SPACER PLATE SNAP RING WASHERS RING THRUST PLATE ANNULUS PLANETARY OVERDRIVE THRUST GEAR SUPPORT REAR GEAR PISTON WASHER PLANETARY SUPPORT SNAP RING LOW REVERSE OVERRUNNING RETAINER GEAR DRIVING SHELL REAR THRUST PLATE SUN GEAR LOCK RING THRUST WASHERS GEAR E INTERMEDIATE INTERMEDIATE SHAFT THRUST SHAFT PLATE REAR PLANETARY ANNULUS ANNULUS GEAR DRUM CLUTCH cy OVERRUNNING CLUTCH SUPPORT CAM CLUTCH CAM BOLTS 9221 18 Fig 69 Transmission Planetary Gear Train 21 82 TRANSMISSION OVERHAUL 42RE 5 Remove front planetary rear thrust washer 6 Remove sun gear and driving shell 7 Remove snap ring that retains sun gear in driv ing shell and remove sun gear and thrust plates Note thrust plate position for assembly reference 8 Remove tabbed thrust washer from rear plan etary gear 9 Remove rear planetary gear from rear annulus gear and remove annulus gear from intermediate shaft 10 Remove snap r
76. OID HARNESS CASE CONNECTOR GOVERNOR BODY GOVERNOR 3 4 PRESSURE ACCUMULATOR SENSOR HOUSING Fig 95 Removing Installing Solenoid Harness Case Connector Shoulder Bolt epe OVERDRIVE CONVERTER 34 CLP 49321 421 SOLENOID gt ACCUMULATOR WIRE HARNESS PLATE Fig 93 Governor Pressure Sensor Removal GOVERNOR O RINGS PRESSURE SOLENOID Fig 96 Unhooking Solenoid Harness From Accumu SOLENOID lator Cover Plate BORE AND GOVERNOR SEAT 9321 422 OVERDRIVE CON VERTER BODY CLUTCH SOLENOID ASSEMBLY HARNESS Fig 94 Governor Pressure Solenoid Removal 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 96 9 Turn valve body over and remove screws that attach overdrive converter solenoid assembly to valve body Fig 97 10 Remove solenoid and harness assembly from valve body Fig 98 11 Remove boost valve cover Fig 99 12 Remove boost valve retainer valve spring and boost valve Fig 100 13 Secure detent ball and spring with Retainer Fig 97 Removing Overdrive Converter Solenoid As Tool 6583 Fig 101 sembly Screws J9321 428 GOVERNOR SOLENOID GOVERNOR SENSOR CONVERTER CLUTCH OVERDRIVE SOLENOID SOLENOID SOLENOID SCREWS 9321 429 Fig 98 Overdrive Converter Clutch Solenoid Assem bly Removal J
77. ON DIAGNOSIS NO DRIVE RANGE REVERSE OK 1 Gearshift linkage either loose damaged or out of 1 Repair or replace linkage components adjustment 2 Low fluid level 3 Valve body malfunction manual valve or shaft damaged or 1 2 shift valve stuck 2 Correct fluid level and check for leaks 3 Remove and disassemble valve body replace as assembly if any valves or bores are damaged 4 Remove and disassemble transmission and rear clutch repair replace worn damaged parts as needed 4 Rear clutch failure 5 Remove and disassemble transmission replace 5 Transmission overrunning clutch failure overrunning clutch 6 Remove and disassemble transmission replace 6 Input shaft seal rings worn or damaged seal rings and any other worn or damaged parts 1 Add fluid and check for leaks if drive is restored 2 Inspect adjust and reassemble linkage as needed replace worn damaged parts NO DRIVE OR REVERSE VEHICLE WILL NOT MOVE 1 Low fluid level 2 Gearshift linkage loose damaged or misassembled 3 Perform preliminary inspection procedure for vehicle that will not move refer to procedure in diagnosis section 3 Failure of driveline component such as U joint axle shaft transfer case component etc 4 Perform pressure test to confirm low pressure 4 Low fluid pressure due to worn or damaged oil replace pump body and o
78. ONIS INOX OMNIS GION3IOS 8 GNODAS NI 42RE TRANSMISSION DIAGNOSIS 21 42 8 1 6 LON HOLNTD HDHANOO VI HLF NI XIAN JOLAIS 1 DELI 54 6 0 33165334 434 NOLAN HMO f OL i H HHU NOIDNS m M3DHANOD dWNd tn GIONTIOS HOLNTD EX E 27 isd 33165344 3871 2 0 33155339 YONYIAOD isd 0 62 Becr 48 14 m VA LIS 2 1 Y a 0 o DES D P x 3 te 33155434 JILLOMHI 84 25 33166334 YOLVINWNDDY OAMSS INOW ONIS LAIHSNMOGd 2 31 LLOWH L 11114 ONIYNG DIINVYGAH CIONSIOS YONZAOD 2 IN VEHICLE SERVICE 42RE 21 43 IN VEHICLE SERVICE 42RE INDEX page page Aluminum Thread Repair 54 Rear Band Adjustment 46 Fluid and Filter Change 43 Recommended Fluid 43 Front Band Ad
79. RNOR VALVE PLUGGED COOLER LINES OR FITTINGS VALVE BODY MALFUNCTION STUCK SWITCH VALVE STUCK CONVERTER CLUTCH VALVE STUCK CONVERTER CLUTCH SOLENOID SOLENOID WIRING DISCONNECTED FAULTY TORQUE CONVERTER FAILED CONVERTER CLUTCH LEAKING TURBINE HUB SEAL ALIGN EXHAUST SYSTEM TUNE ENGINE FAULTY INPUT SHAFT OR SEAL RING THROTTLE CABLE MISADJUSTED gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt lt 2 e Zs lt oci gt 9 A Sw 2 5 aom gols 52 2 8 O z4le 9 az 2 Wr wi 215012 86 4 5 epi 0 22 98 59 2 52 105 lt 2 Za x6 2 0 20 25 5 5 gt 9 2 28 gt 22 lt xc ouai 22 2 gt lt Se So 22 20 39856 565 20 22 22 2212 2 19321 206 42RE TRANSMISSION DIAGNOSIS 32 21 1 1 6 320090232033 AISO NI S3ATI 30153135 T 1 o 3 oe 2 1 P 7 NN e
80. RT BOLT 6 INNER GEAR SEAL RINGS THRUST WASHER J9321 207 Fig 40 Oil Pump And Reaction Shaft Support Components OIL PUMP AND REACTION SHAFT SUPPORT CLEANING AND INSPECTION Clean pump and reaction shaft support components with solvent and dry them with compressed air Inspect the pump housing and support components Replace the housing 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 thrust washer for wear or dam age Replace the washer if necessary Note that the inner gear used in 1993 42RE oil pumps has a new design drive lug The new design incorpo rates drive flats instead of the square lug used previously The 1993 torque converter hub has also been redesigned to accept the new drive If pump gear replacement is necessary be very sure to order and install the new style gears Inspect the pump and reaction shaft support bush ings Minor bushing wear is acceptable Replace the bushings only if scored or severely worn Install the gears in the pump housing and measure end clearance with a feeler gauge and straightedge Fig 41 Clearance should be 0 010 0 06 mm 0 0004 0 0025 in Measure clearance between the outer gear and the pump body Fig 42 Clearance should be 0 08 0 19 mm 0 0035 0 0075 in STRAIGHT EDGE FEELER GAUGE Fig 41 Measuring Pump Gear End Cleara
81. Remove overdrive dutch pack wire retaining ring reused Fig 8 2 Remove overdrive clutch pack Fig 9 Fig Overdrive Unit Removal Installation THRUST BEARING OVERDRIVE PISTON THRUST J9321 351 Fig 4 Overdrive Piston Thrust Bearing Removal Installation Pd OVERDRIVE 2 OVERDRI PISTON SPACER SELECT FIT 1212974 Fig 5 Overdrive Piston Thrust Plate Removal Installation INTERMEDIATE SHAFT INTERMEDIATE SHAFT SPACER SELECT FIT x 9121 298 Fig 6 Intermediate Shaft Spacer Location 21 113 OVERDRIVE UNIT OVERHAUL 42RE OVERDRIVE PISTON PISTON RETAINER J9121 299 Fig 7 Overdrive Piston Removal OVERDRIVE CLUTCH PACK RETAINING 29321 352 Fig 8 Removing Overdrive Clutch Pack Retaining Ring OVERDRIVE CLUTCH PACK f 3 19321 353 Fig 9 Overdrive Clutch Pack Removal 21 114 OVERDRIVE UNIT OVERHAUL 42RE 3 Note position of clutch pack components for as sembly reference Fig 10 Thick reaction plate goes to front as shown PRESSURE PLATE TO FRONT OVERDRIVE CLUTCH CLUTCH DISC 3 CLUTCH PLATE 2 REACTION PLATE REAR 19321 354 Fig 10 Overdrive Clutch Component Position OVERDRIVE GEARTRAIN REMOVAL 1 Remove overdrive clutch wave spring Fig 11 9321 355 Fig 11 Overdrive Clutch Wave Spring Removal Installation 2
82. SSION ASSEMBLY PROCEDURE 1 Install rear servo piston spring and retainer Fig 139 Install spring on top of servo piston and install retainer on top of spring SERVO PISTON PISTON SPRING RETAINER 19121 343 Fig 139 Rear Servo Components 2 Install front servo piston assembly servo spring and rod guide Fig 140 3 Compress front rear servo springs with Valve Spring Compressor C 3422 B and install each servo snap ring Fig 141 4 Examine bolt holes in overrunning clutch cam Note that one hole is not threaded Fig 142 This hole must align with blank area in clutch cam bolt circle Fig 143 Mark hole location on clutch cam and blank area in case with grease pencil paint stripe or scribe mark for assembly reference 5 Mark location of non threaded hole dutch cam and blank area in bolt circle with grease pencil 6 Align and install overrunning clutch and cam in case Fig 144 Be sure cam is correctly installed Bolt holes in cam slightly countersunk on TRANSMISSION OVERHAUL 42RE 21 103 PISTON SERVO PISTON SNAP RING SEAL ROD SPRING GUIDE J9121 344 Fig 140 Front Servo Components b SPRING COMPRESSOR TOOL J9121 136 Fig 141 Compressing Front Rear Servo Springs side Be sure this side of cam faces rearward toward piston retainer 7 Verify that non threaded hole in clutch cam is properly aligned Check alignment by threading a bolt into each b
83. Use liberal quantity of petroleum jelly to hold thrust plate in position on piston SPECIAL 42 Install overdrive piston thrust bearing in direct TOOL 6227 2 dutch hub Fig 167 Use liberal quantity of petroleum jelly to hold thrust bearing in place Note that one side of bearing has dark coated surface This surface faces overdrive piston Also be sure raised shoulder on inside diameter of bearing faces forward as well 43 Apply small amount of petroleum jelly to pilot hub of intermediate shaft 44 Verify alignment of splines in overdrive unit planetary gear and overrunning clutch Be sure Align ment Tool 6227 2 is still fully seated Fig 168 If planetary gear and overrunning clutch splines become misaligned overdrive unit cannot be Fig 168 Checking Alignment Of Overdrive Planetary fully installed on intermediate shaft Overdrive Gear And Overrunning Clutch Splines unit may have to be disassembled in order to realign splines 45 Carefully withdraw alignment tool from over drive unit 9221 36 46 Lubricate intermediate shaft splines and bush ing surfaces with transmission fluid or petroleum jelly 21 110 TRANSMISSION OVERHAUL 42RE 47 Install overdrive unit Note that intermediate shaft is snug fit in overdrive planetary gear and overrunning clutch If overdrive unit will not seat fully use overdrive attaching bolts to draw gear case down and seat it against transmission 48 Apply 1 2 drops of Mopar thread adh
84. ack with safety chains 2 Check torque converter hub and hub drive notches for sharp edges burrs scratches or nicks Polish hub and notches with crocus doth or 400 grit paper if necessary Hub must be smooth to avoid damaging pump seal 3 Lubricate converter hub and pump seal lip with Mopar high temperature wheel bearing grease 4 Verify that converter is fully seated Use straight edge and steel ruler to check seating Fig 4 Surface of 21 57 converter lugs should be 12 7 mm 1 2 in to rear of straight edge when converter is fully seated STRAIGHTEDGE Fig 4 Checking Torque Converter Seating 5 Temporarily secure converter with C clamp at tached to housing or with metal strap attached across converter housing 6 Check condition of converter driveplate Replace driveplate if cracked distorted or damaged 7 Verify that transmission dowel pins are seated in engine block and protrude far enough to held transmis sion in alignment 8 Coat torque converter pilot hub of crankshaft with light coat of Mopar high temperature wheel bearing grease 9 Move transmission under vehicle and position it at rear of engine Remove C clamp or strap used to secure converter in housing 10 Align transmission with engine dowels and align converter with driveplate Offset holes in drive plate are next to 1 8 inch hole in inner circle of plate Fig 5 11 Move transmission forward until seated on en gine block dowel
85. ake booster hide inter TE panel and slide module out of dash 1993 Grand Cherokee Grand Wagoneer Publication No 81 370 3147A TSB 21 17 93 May 28 1993 TCM RETAINING PLATE Q ar CLA ETT COLUMN N BRACKET N TCM HARNESS DRIVER TCM RELEASE HARNESS SIDE OF TAB CONNECTOR INSTRUMENT PANEL J9421 166 Fig 15 TCM Location And Mounting 42RE Work modul wnwar ntil module harn nn ri ible 4 Lift rel t n harn nn r Fig 15 Pull conn r out of module and remove module from vehicle TCM Installation 1 refully align and plug harn nn r int module Verify that conn r is full t proceeding 2 Work module upward into position on dash Then lide module st into mounting holes in h Se ee deo is TI tial Condition 42RE TRANSMISSION DIAGNOSIS TRANSMISSION DIAGNOSIS Possible Cause 21 17 Correction HARSH ENGAGEMENT FROM NEUTRAL TO DRIVE OR NEUTRAL TO REVERSE Note The shift from neutral to reverse is normally quite firm Hydraulic pressure at the rear servo can approach 300 psi in reverse gear Do not confuse a firm engagement with a truly harsh engagement DELAYED ENGAGEMENT FROM NEUTRAL TO DRIVE OR REVERSE Engine idle speed too high 2 Driver riding accelerator pedal during shift Throttle cable misadjusted or binding reverse only Band adjustment needed loose mounting bolts Worn or damaged U j
86. and cushion springs if collapsed distorted or broken Re place the plug or piston if cracked bent or worn Discard the servo snap ring and spring retainer if distorted or warped If doubt exists about the condition of any servo component replace it Do not reuse suspect parts SPRING RETAINER SERVO SPRING PISTON SERVO SNAP CUSHION SPRING RING PISTON SEAL PISTON PLUG SS SNAP RING SERVO PISTON J9121 173 Fig 88 Rear Servo Components ASSEMBLING REAR SERVO PISTON 1 Assemble piston plug cushion spring and piston Fig 88 2 Compress cushion spring in vise and install pis ton plug snap ring Fig 87 3 Install new seal on piston Be sure seal lip is toward servo bore Fig 89 4 Lubricate piston seal with petroleum jelly Lubri cate other servo parts with transmission fluid BE SURE SEAL LIP IS TOWARD SERVO BORE REAR SERVO PISTON J9121 175 Fig 89 Installing Rear Servo Piston Seal VALVE BODY SERVICE AND ADJUSTMENT VALVE BODY MAIN COMPONENT DISASSEM BLY CAUTION Do not clamp any valve body component in a vise This practice can damage the component resulting in unsatisfactory operation after assembly and installation Do not use pliers to remove any of the valves plugs or springs and do not force any of the components out or into place The valves and valve body housings will be damaged if force is used Tag or mark the valve body springs for reference as th
87. and Cherokee Grand Wagoneer service manual The correct floorshift cable mechanism and adjustment procedures are provided in the transmis sion In Vehide Service section 2 42RE TRANSMISSION DIAGNOSIS 21 7 42RE TRANSMISSION DIAGNOSIS INDEX page page Air Testing Transmission Clutch and Band Diagnostic Trouble Flash Codes 8 Operation ses peer eda 12 Hydraulic Pressure Test 10 Analyzing the Road Test 9 Overdrive Electrical Controls 8 Checking Fluid Level and Condition 7 Preliminary Diagnosis 7 Converter Housing Fluid Leak Diagnosis 13 Road Testing 9 Converter Stall Test 11 Stall Test Analysis 12 Diagnosis and Hydraulic Flow Charts 16 Transmission Throttle Valve Cable and Shift Cable Ad Diagnosis Procedures 7 J stment dee DIAGNOSIS PROCEDURES Begin diagnosis by checking the easily accessible items such as fluid level fluid condition and throttle cable shift linkage adjustments A road test will deter mine if further diagnosis is necessary Procedures outlined in this section should be per formed in the following sequence to realize the most accurate results 1 Preliminary diagnosis 2 Fluid Level and condition 3 Leak tests if fluid level is low 4 Linkage Adjustment 5 Overd
88. and E dip TRANSMISSION OVERHAUL 42RE 21 98 sjayoeig puy sonjer iddn 821 3AIVA ONILSQfIv ONINdS 34155344 6 15008 JUNSSANd H2LIAAS JNU TIV8 144130 YOLVINDIY u3A31 77 4 3AIVA 3lvid e 15008 JAVA YIISNVUL JAVA YONYIAOD NAOQDDI 16008 ONINdS ONINdS ANY 3AIVA JAYA 31LLOSI HL 15008 YANIVLAY ONINdS O JAVA 2 SS 11 14 u3N344lLS 9 O Old YONYIAOD JAVA 19185 INVA ce q1LLOHS JAYA 5 WNANVW 27 X NOLIVMNVd3S A eur J 34155384 YONYIAOD 3ATVA FILLOYHL ONINdS YOLVINDIY SS 2 O o G 3A331S 34155384 O YOLVINO Counts 3AIVA Ine 3AIVA 22 YOLVINOIY 2 D FATWA 31LLDHS AOS 3ATVA 29 445 2 14IHS Zl 30109 9 ONIYdS AYVGNOD3S 3ATVA YAAOD JAVA JAVA 31LLOHS l4IHS 141 5 2 VALVE BODY REASSEMBLY 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
89. and adjusting screw Fig 161 TRANSMISSION OVERHAUL 42RE 21 107 CLUTCH SMALL SCREWDRIVER TO ALIGN CLUTCH DISC TEETH J9121 192 Fig 158 Aligning Rear Clutch Disc Lugs FRONT CLUTCH INPUT SHAFT J9121 124 Fig 159 Installing Front Rear Clutch Assemblies 30 Push front band lever shaft completely into place Then tighten band adjusting screw until band just grips dutch retainer Verify that front rear clutches still seated before continuing 31 Coat band reaction pin access plug with sealer and install plug in converter housing 32 Check seal rings on reaction shaft support hub Verify that seal rings are hooked together and that front clutch thrust washer is properly positioned Fig 162 Use extra petroleum jelly to hold thrust washer in place if necessary CAUTION The thrust washer bore ID is chamfered on one side Make sure this side of the washer is facing toward the front of the transmission 33 Thread two Pilot Stud Tools C 3288 B into 21 108 TRANSMISSION OVERHAUL 42RE Z FRONT OIL PUMP GASKET C 3288 B Fig 160 Installing Front Band And Reaction Pin J9121 195 BAND BAND LEVER STRUT FRONT Fig 163 Installing Pilot Studs And Oil Pump Gasket 35 Lubricate oil pump body seal with Ru Glyde petroleum jelly Lubricate pump shaft seal lip with petroleum jelly 36 Install
90. and fluid passages Wipe the governor pressure sensor and solenoid valve with dry lint free shop towels only The O rings on the sensor and solenoid valve are the only service able components Figs 126 and 127 Be sure the vent ports in the solenoid valve are open and not blocked by dirt or debris Replace the valve and or sensor only when DRB II 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 calibration and result in solenoid failure In addition the filter on the solenoid valve is NOT serviceable Do not iry to remove the filter as this will damage the valve hous ing CAUTION DO NOT TURN THIS SCREW FOR ANY REASON DOING SO WILL RUIN SOLENOID VALVE CALIBRATION CAUSING FAILURE SOLENOID VALVE O RINGS SERVICEABLE SOLENOID VALVE FILTER NOT SERVICEABLE VENT PORTS 19321 455 Fig 126 Governor Pressure Solenoid Valve O Ring And Vent Location 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 Z RETAINING CLIP GOVERNOR PRESSURE SENSOR
91. are properly routed Figs 95 and 96 Solenoid wires must be clear of manual lever and park rod Valve Body Final Assembly And Adjustment 1 Insert manual lever detent spring in upper hous ing RIGHT SIDE SCREW CONVERTER CLUTCH VALVE SPRING 3 4 SHIFT VALVE SPRING 3 4 ACCUMULATOR 9321 160 Fig 134 Installing Converter Clutch And 3 4 Shift Valve Springs CONVERTER CLUTCH ACCUMULATOR VALVE PLUG BOSS J9321 161 Fig 135 Seating 3 4 Accumulator On Lower Hous ing 2 Position line pressure adjusting screw in adjust ing screw bracket 3 Install spring on end of line pressure regulator valve 4 Install switch valve spring on tang at end of adjusting screw bracket 5 Position adjusting screw bracket on valve body Align valve springs and press bracket into place In stall 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 Nem 35 in 105 torque 6 Install throttle lever in upper housing Then install manual lever over throttle lever and start manual lever into housing 7 Position detent ball on end of spring Then hold detent ball and spring in detent housing with Retainer Tool 6583 Fig 101 TRANSMISSION OVERHAUL 42RE 21 101 8 Align manual lever with detent ball and manual valve Hold throttle lever upward Then press down manual lever until fully seated Remove
92. ates 1 reaction plate and 1 pressure plate are required 7 Install clutch pack pressure plate Note that pressure plate is thickest plate dutch pack 8 Install clutch pack wire type retaining ring Fig 66 SHAFT END PLAY ADJ USTMENT 1 Place overdrive unit in vertical position and mount unit in vise or in workbench with appropriate size mounting hole cut into it Be sure unit is facing upward for access to direct clutch hub 2 Determine correct thickness shaft spacer as follows a Insert Special Tool 6312 through sun gear planetary gear and into pilot bushing in output shaft Be sure tool bottoms against planetary shoulder intermediate REACTION OVERDRIVE PRESSURE PLATE CLUTCH DISCS 3 PLATE 9321 369 CLUTCH PLATES 2 Fig 65 Overdrive Clutch Components 21 128 OVERDRIVE UNIT OVERHAUL 42RE OVERDRIVE CLUTCH PACK RETAINING RING 19321352 Fig 66 Installing Overdrive Clutch Pack Retaining Ring b Position Gauge Tool 6311 across face of over drive case Fig 67 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 measured Fig 67 d Select proper thickness end play spacer from spacer chart based on distance measured Fig 68 e Remove Gauge Alignment Tool 6312 SPECIAL SPECIA
93. before proceeding WARNING THE NEXT STEP IN GEARTRAIN ASSEM BLY INVOLVES COMPRESSING THE DIRECT CLUTCH HUB AND SPRING IT IS EXTREMELY IM PORTANT THAT PROPER EQUIPMENT BE USED TO COMPRESS THE SPRING AS SPRING FORCE IS AP PROXIMATELY 830 POUNDS USE COMPRESSOR TOOL C 6227 1 AND A HYDRAULIC TYPE SHOP PRESS WITH A MINIMUM RAM TRAVEL OF 6 INCHES THE PRESS MUST ALSO HAVE A BED THAT CAN BE ADJUSTED UP OR DOWN AS REQUIRED RELEASE CLUTCH SPRING TENSION SLOWLY AND COM PLETELY TO AVOID PERSONAL INJURY 21 Carefully remove Alignment Tool 6227 2 from clutch and hub splines Withdraw tool slowly to avoid spline misalignment Tool must be removed at this point to provide room for compressor tool movement 22 Position Compressor Tool 6227 1 on clutch hub Fig 53 OVERDRIVE UNIT OVERHAUL 42RE 21 124 REACTION DIRECT PLATE CLUTCH DISCS 6 PRESSURE PLATE 29321 368 CLUTCH PLATES 5 49 Direct Clutch Pack Components Fig REACTION DIRECT PLATE CLUTCH COUNTERBORE PRESSURE PLATE Fig 50 Correct Position Of Direct Clutch Reaction Plate 23 Position Special Tool C 3995 A or similar type tool on top of Tool 6227 1 Fig 19 DIRECT iS CLUTCH REACTION 1 ir 4 43074 PLATE ZA nr 2 77 FLUSH WITH CST A END OF HUB SURE SHOULDERM SIDE OF PLATE FACES UPWARD J9121 330 Fig 51 Correct Position Of Direct Clutch Pressure CLUTCH HUB 24 Compress clutch
94. ch material or metal particles an overhaul may be necessary Drain fluid to correct level if overfilled If fluid is highly aerated full of bubbles and foamy oil pump gasket or seal may have failed or pump body is porous or cracked Remove valve body and air test clutch band and servo operation disassemble and repair transmission as needed Adjust band Inspect replace as required Check with DRB II scan tool or flash codes and repair as necessary NO REVERSE D RANGES OK Gearshift linkage is either out of adjustment or damaged Rear band is out of adjustment Valve body malfunction stuck damaged manual valve regulator valve or check ball Rear servo or front clutch malfunction Overdrive unit direct clutch malfunction Repair replace linkage parts as needed Adjust band Remove and service valve body replace valve body if any valves or valve bores are worm or damaged Remove and disassemble transmission replace worn damaged servo and clutch parts as necessary Remove and disassemble overdrive unit Repair direct clutch as needed HAS FIRST REVERSE ONLY NO 1 2 OR 2 3 UPSHIFT 1 Governor component fault 2 Front servo problem 1 Test electrical components with DRB scan tool or flash codes and repair as needed 2 Pressure check and repair as needed J9321 335 Z _ ee TRANSMISSION DIAGNOSIS 21 19 TRANSMISSI
95. condenser if equipped 2 Remove screws and U nuts securing cooler to radiator and support 3 Tag cooler hoses for installation reference 4 Position drain pan under cooler hoses 5 Loosen cooler connecting hose clamps and discon nect hoses 6 Remove auxiliary cooler 7 Connect cooler hoses Z 8 Position cooler on radiator and install cooler attaching U nuts and screws 9 Tighten cooler hose clamps securely 10 Install grille and air conditioning condenser 11 Check and adjust transmission fluid level 12 If air conditioning condenser lines were discon nected during service evacuate and recharge system ALUMINUM THREAD REPAIR Damaged or worn threads in the aluminum trans mission case and in the valve body can be repaired with Heli Coil or similar quality thread inserts Essentially repair consists of drilling out the worn or damaged threads tapping the hole with a special tap and install ing the thread insert into the tapped hole This proce dure returns the hole threads to original size Heli Coil or equivalent tools and inserts are readily available from most automotive parts suppliers Stain less steel inserts are recommended Z TRANSMISSION OVERDRIVE REMOVAL AND INSTALLATION 42RE 21 55 TRANSMISSION OVERDRIVE REMOVAL AND INSTALLATION 42RE INDEX page page General Information 55 Torque Converter and Drive Plate Service 57 Oil Pump Seal Replacement
96. condition of each clutch part after cleaning Replace the rollers and the retainer and spring assem bly if the rollers springs or spring retainer are worn or damaged Replace the clutch cam if worn cracked or damaged Inspect the overrunning dutch race and low reverse drum Replace the drum and race as an assembly if either part is worn scored or damaged Examine the overdrive piston retainer carefully for wear cracks scoring or other damage Be sure the TRANSMISSION OVERHAUL 42RE 21 71 CAM BOLTS OVERRUNNING CLUTCH AND LOW REVERSE DRUM 29121 224 Fig 32 Removing Overrunning Clutch From Low Reverse Drum retainer hub is a snug fit in the case low reverse drum Replace the retainer if worn or damaged OVERRUNNING CLUTCH ASSEMBLY 1 Install clutch rollers in spring retainer Fig 33 Be sure springs are seated squarely against rollers RETAINER SPRINGS ROLLERS J9121 225 Fig 33 Installing Overrunning Clutch Rollers In Re tainer 2 Install roller and spring assembly in clutch cam Fig 34 3 Lubricate overrunning clutch rollers springs cam and race with transmission fluid Verify compo nent installation before proceeding Bolt holes in clutch cam are countersunk on one side Be sure this side of cam will face rearward as shown Fig 34 4 Inspect bolt holes in overrunning clutch cam Note that one hole is not threaded Identify location of non threaded hole with paint mark for
97. control module or governor pressure sensor Governor pressure low at all mph figures Lubrication line pressure Clogged fluid cooler or lines seal low at all throttle positions rings leaking output shaft plugged debris worn bushings in pump or clutch retainer J9321 404 WARNING NEVER ALLOW ANYONE TO STAND DI RECTLY IN LINE WITH THE VEHICLE FRONT OR REAR DURING A STALL TEST ALWAYS BLOCK THE WHEELS AND APPLY THE SERVICE AND PARKING BRAKES DURING THE TEST STALL TEST PROCEDURE 1 Connect tachometer to engine Position tachom eter so it can be viewed from driver seat 2 Check transmission fluid level Add fluid if nec essary 3 Start and run engine until transmission fluid reaches normal operating temperature 4 Block front wheels 5 Fully apply service and parking brakes 6 Open throttle completely for no more than five seconds and record maximum engine rpm registered on tachometer CAUTION Stall testing causes a rapid increase in transmission fluid temperature Do not hold the throttle open any longer than five seconds If more than one stall test is required run the engine at 1000 rpm with the transmission in Neutral for at least 20 seconds to cool the fluid Z 7 If engine speed exceeds maximum shown in stall speed chart release accelerator immediately This in dicates that transmission clutch slippage is occurring 8 Shift transmission into Neutral Operate engine for 20 s
98. d TRANSMISSION COOLER TESTING AND FLUSHING If a transmission malfunction contaminates the fluid the cooler and lines must be reverse flushed thoroughly Flushing will prevent sludge and particles from flowing back into the transmission after repair The flushing procedure applies to standard and auxiliary coolers alike Pressure equipment is preferred for reverse flushing However reverse flushing can be performed with hand operated equipment as follows COOLER REVERSE FLUSHING PROCEDURE 1 Identify and disconnect cooler pressure and re turn lines at transmission Rear lineis return line from cooler Front lineis pressure line to cooler Fig 26 2 Position drain pan under cooler pressure line to catch material flushed through cooler and lines 3 Reverse flush cooler using hand operated suction gun filled with mineral spirits Insert gun nozzle or RETURN LINE PRESSURE OUTLET LINE CLAMP RADIATOR SUPPORT RETURN WITHOUT AUXILIARY COOLER B 13 19 Nem 115 165 IN IBS PRESSURE OUTLET us LINE IN VEHICLE SERVICE 42RE 21 53 hose into cooler return line Then force mineral spirits into line and through cooler 4 Continue reverse flushing until fluid exiting cooler pressure line is dear and free from debris Replace cooler if fluid cannot be pumped through it 5 Clear flushing materials from cooler and lines with short pulses of compressed air Insert air gun nozzle into cooler
99. d as a More than half of vehicle operation occurs in heavy city traffic during hot weather above 90 F b Vehicle is used for taxi police limousine or similar commercial operation c Vehicle is used for trailer towing or heavy load hauling When the factory fluid is drained refill the transmis sion with Mopar ATF Plus type 7176 fluid Mopar Dexron should only be used when ATF Plus is not available FLUID FILTER REPLACEMENT PROCEDURE 1 Raise vehicle 2 Remove oil pan and drain fluid 3 Clean oil pan and pan magnet Then clean re maining gasket material from gasket surface of trans mission case 4 Remove fluid filter screws and remove filter 5 Position new filter on valve body and install filter screws Tighten screws to 4 35 in 105 torque 6 Position new gasket on oil pan and install pan on transmission Tighten pan bolts to 150 in Ibs 17 Nem torque 7 Lower vehicle and refill transmission with M ATF Plus type 7176 fluid TRANSMISSION THROTTLE VALVE CABLE ADJUST MENT The transmission throttle valve 15 operated by a cam on the throttle lever The throttle lever is operated by an adjustable cable Fig 2 The cable attached toan arm mounted on the throttle lever shaft A lock button at the engine end of the cable is provided for cable adjustment A correctly adjusted throttle valve cable will cause the throttle lever on the transmission to move simul taneou
100. d before repair First it must be verified that a leak condition actually exists And second the true source of the leak must be determined 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 refill after repair Converter housing leaks have several potential sources Through careful observation aleak 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 6 42RE TRANSMISSION DIAGNOSIS 21 13 Pump vent or pump attaching bolt leaks are gener ally deposited on the inside of the converter housing and not on the converter itself Fig 6 Pump seal or gasket leaks usually travel down the inside of the converter housing Front band lever pin plug leaks are generally depos ited on the housing and not on the converter PUMP SEAL PUMP PUMP VENT BOLT PUMP GASKET REAR MAIN SEAL LEAK CONVERTER HOUSING CONVERTER 19021 35 Fig 6 Converter Housing Leak Paths LEAK DIAGNOSIS PROCEDURE 1 Raise rear of vehicle allow accumulated fluid to drain out of converter housing 2 Check and adjust transmission fluid level 3 Raise vehicle Remove converter housing dust cover and wipe as much fluid as poss
101. d install it in trans mission case Position pump so bolts are facing out and are accessible b Secure pump assembly in case with 2 or 3 bolts or with pilot studs c Tighten support to pump bolts to 20 Nem 15 ft 105 d Remove pump assembly from transmission case 21 76 TRANSMISSION OVERHAUL 42RE 12 Install new oil seal in pump with Special Tool C 4193 and Tool Handle C 4171 Fig 51 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 with petroleum jelly Lubricate pump seal with Ru Glyde or petroleum jelly SPECIAL TOOL 4193 WM J9321 183 Fig 51 Pump Oil Seal Installation FRONT CLUTCH OVERHAUL FRONT CLUTCH DISASSEMBLY 1 Remove waved snap ring and remove pressure plate clutch plates and dutch discs Fig 52 2 Compress dutch piston spring with Compressor Tool C 3575 A Fig 53 Be sure legs of tool are seated squarely on spring retainer before compressing spring 3 Remove retainer snap ring and remove compres sor tool RETAINER HUB AL us CLUTCH PISTON PISTON SPRING PISTON SEAL FRONT CLUTCH RETAINER SPRING RETAINER 2 aa FRONT 2 2 COMPRESSOR CLUTCH 22 TOOL 3575 SPRING 2 2 RETAINER SNAP RING SPRING RETAINER N 39121 147 Fig 53 Compressing Front Clutch Piston Spring 4 Remove spring retainer and clutch
102. d lines must be flushed if repair was to correct a problem that gener ated sludge metal particles or clutch friction mate rial The torque converter should also be replaced when contaminated by a malfunction The transmis sion fluid and converter will be contaminated again if residue debris is not flushed from the cooler and lines beforehand 1 Mount transmission on jack Secure transmis sion to jack with safety chains 2 Check torque converter hub and hub drive notches for sharp edges burrs scratches or nicks Polish hub and notches with crocus cloth or 400 grit paper if necessary Hub must be smooth to avoid damaging pump seal 3 Lubricate converter hub and pump seal lip with Mopar high temperature wheel bearing grease 4 Verify that converter is fully seated Use straight edge and steel ruler to check seating Fig 4 Surface of converter lugs should be 12 7 mm 1 2 in to rear of straight edge when converter is fully seated 5 Temporarily secure converter with C clamp at tached to housing or with metal strap attached across converter housing 6 Check condition of converter driveplate Replace driveplate if cracked distorted or damaged 7 Verify that transmission dowel pins are seated in engine block and protrude far enough to held transmis sion in alignment 8 Coat torque converter pilot hub of crankshaft with light coat of Mopar high temperature wheel bearing grease 9 Move transmission under vehic
103. d pivot and reaction pins Fig 26 Use parallel jaw snap ring pliers to remove pins Insert and spread plier jaws in pin bore to grip pin Then twist and pull pins to remove them 38 Remove rear band lever 39 Remove low reverse drum and rear band as assembly Turn drum clockwise and pull outward to remove it from overrunning clutch Fig 27 40 Remove bolts attaching overrunning clutch cam to case Fig 28 41 Remove overrunning clutch cam and roller clutch assembly as a unit Fig 29 Turn cam back and forth and tilt it inward to remove it from case PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT ASSEMBLY 19121 217 Fig 23 Removing Planetary Geartrain And diate Shaft Assembly LOW REVERSE OVERDRIVE a PISTON RETAINER 1 DRUM SNAP RING J9121 351 Fig 24 Removing Low Reverse Drum Snap Ring 42 Compress front servo rod guide about 1 8 inch with Valve Spring Compressor C 3422 B Fig 30 A C damp and Special Tool C 4470 can also be used to compress rod guide 43 Remove front servo rod guide snap ring Exer cise caution when removing snap ring Servo bore can be scratched or nicked if care is not exercised 44 Remove compressor tools and remove front servo rod guide spring and servo piston inch with Valve Spring Compressor TRANSMISSION OVERHAUL 42RE 21 69 CLA Sass SS PSION C7 SS RETAINER RETAINER BOLTS
104. d repair as required Air pressure check operation of clutches and repair as required Adjust bands Air pressure check servo operation and repair as required Air pressure check clutch operation and repair as required Remove inspect and repair as required look for debris in oil pan Remove and inspect clutch repair as required Check for debris in oil pan and repair as required Inspect and check for debris in oil pan repair as required Remove inspect and repair as required Remove inspect and repair as required Perform air pressure check and repair as required Adjust bands BUZZING NOISE Low fluid level Air being drawn into pump suction passages Overrunning clutch damaged Valve body misassembled bolts loose weak spring or mispositioned valve or check ball Add fluid and check for leaks Check pump for porous casting scores on mating surfaces and excess rotor clearance repair as required Replace clutch Remove disassemble inspect valve body reassemble correctly if necessary replace assembly if valves or springs are damaged J9321 338 OIL COMES OUT FILLER TUBE OIL LEAKS ITEMS LISTED REPRESENT POSSIBLE LEAK POINTS AND SHOULD ALL BE CHECKED TRANSMISSION DIAGNOSIS Possible Cause 42RE TRANSMISSION DIAGNOSIS 21 23 Correction Transmission overfilled Breather vent in oil pump blocked Fluid coole
105. detent ball retainer tool after lever is seated 9 Then Install manual lever seal washer and E clip 10 Lubricate solenoid case connector O rings and shaft of manual lever with light coat of petroleum jelly 11 Verify that throttle lever is aligned with end of kickdown valve stem and that manual lever arm is engaged in manual valve Fig 136 12 Install boost valve valve spring retainer and cover plate Tighten cover plate screws to 4 Nem 35 in lbs torque 13 Obtain new fluid filter for valve body but do not install filter at this time 14 If line pressure and or throttle pressure adjust ment screw settings were not disturbed continue with overhaul or reassembly However if adjustment screw settings were moved or changed readjust as described in Valve Body Control Pressure Adjustment procedure KICKDOWN VALVE Fig 136 Manual And Throttle Lever Alignment GOVERNOR BODY SENSOR AND SOLENOID INSTALLATION CAUTION Do not turn the small screw at the end of the governor pressure solenoid valve for any reason Fig 126 Turning the screw in either direction will ruin solenoid calibration and result in solenoid fail ure In addition the filter on the solenoid valve is NOT serviceable Do not try to remove the filter as this will damage the solenoid valve housing 1 Turn valve body assembly over so accumulator side of transfer plate is facing down 2 Install new O rings on governor pressure sole
106. e a If overdrive unit does not require service imme diately insert Alignment Tool 6227 2 in splines of planetary gear and overrunning clutch Fig 9 If misalignment occurs overdrive unit may have to be disassembled in order to realign splines OVERDRIVE UNIT ATTACHING BOLTS 7 19021 83 Fig 8 Removing Installing Overdrive Unit Attaching Bolts b If overdrive unit requires service refer to Over drive Unit Overhaul procedures 19 Remove and retain bearing and select fit spacer These parts may remain on overdrive piston rear of transmission case sliding hub or intermediate shaft during removal Z _ TRANSMISSION OVERDRIVE REMOVAL AND INSTALLATION 42RE 20 Place several clean shop towels on a bench Then position unit on towels to absorb spilled fluid 21 Position overdrive unit over drain pan and tilt unit to drain residual fluid from case Examine fluid clutch material or metal fragments If fluid contains these items overhaul will be necessary SPECIAL TOOL J9321 133 Fig 9 Overdrive Spline Alignment Tool Installation OVERDRIVE UNIT INSTALLATION 4 WHEEL DRIVE 1 BesureAlignment Tool 6227 2 is still fully seated in splines of overdrive planetary gear and overrunning clutch If misalignment occurs overdrive will have to be disassembled in order to realign splines 2 If original case gasket is in good condition pro ceed to step 6 If overdrive piston retai
107. econds Stop engine shift transmission into Park and release brakes 9 Stall speeds should be in 1800 2100 rpm range STALL TEST ANALYSIS STALL SPEED TOO HIGH If the stall speed exceeds specifications by more than 200 rpm transmission clutch slippage is indicated STALL SPEED TOO LOW Low stall speeds with a properly tuned engine indi cate a torque converter overrunning clutch problem The condition should be confirmed by road testing prior to converter replacement The converter overrunning clutch is slipping when Stall speeds are 250 to 350 below specified mini mum and the vehicle operates properly at highway speeds but has poor low speed acceleration STALL SPEED NORMAL If stall speeds are normal but abnormal throttle opening is required to maintain highway speeds the converter overrunning clutch is seized and the torque converter must be replaced CONVERTER NOISE DURING TEST A whining noise caused by fluid flow is normal during a stall test However loud metallic noises indicate a damaged converter To confirm that noise is originating from the converter operate the vehide at light throttlein Drive and Neutral on a hoist and listen for noise coming from the converter housing AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION Air pressure testing can be used to check transmis sion front rear clutch and band operation with the transmission either in the vehicle or on the work bench as a final check after
108. ehicle and move remaining pipes aside for working clearance 16 Disconnect and remove crankshaft position sen sor Retain sensor attaching bolts CAUTION The crankshaft position sensor can be damaged if the transmission is removed or installed with the sensor still bolted to the engine block To avoid damage remove the sensor before removing the transmission 17 Disconnect transmission shift linkage at shift lever on transmission 18 Remove transmission shift linkage torque shaft assembly from retainers on transmission and frame rail Move linkage aside for working clearance 19 Remove brackets that attach transmission to engine block if equipped 20 Remove dust shield cover from front side of transmission converter housing 21 Remove starter motor bolts Pull starter rear ward until clear of housing and position it out of way on nearby component Starter does not have to be re moved from vehicle nor does cable have to be discon nected 22 Remove bolts attaching torque converter to drive plate 23 Disconnect cooler lines at quick disconnect fit tings in transmission Refer to In Vehicle Service sec tion for procedures TRANSMISSION OVERDRIVE REMOVAL AND INSTALLATION 42 Z 24 Disconnect solenoid and park neutral position switch wires at transmission 25 Remove transmission fill tube and dipstick 26 Lower transmission for access to converter housing uppe
109. emoval 4 TRANSMISSION OVERDRIVE REMOVAL AND INSTALLATION 42RE Seal Installation Use Installer Tool C 3860 A Fig 3 To use the tool place the seal in the pump opening with the seal lip facing inward Then tap the seal into place with the installer tool Tool Handle C 4171 may be used with the installer tool if desired AD 1 PUMP SWS SN SEAL Y 23 LA 2 Se d ALD e JEN JA J SPECIAL C 4193 OR 5 3860 ix J9321 447 Fig 3 Oil Pump Seal Installation TORQUE CONVERTER AND DRIVE PLATE SERVICE After the transmission has been removed the drive plate and torque converter can replaced or removed for service access Thetorque converter is not a serviceable part If the converter is contaminated by a transmission malfunc tion or damaged in any way it must be replaced as an assembly Do not attempt to flush a converter contaminated by metal or clutch facing particles Flushing will not remove these contaminants TRANSMISSION INSTALLATION 2 WHEEL DRIVE CAUTION The transmission cooler and lines must be flushed if repair was to correct a problem that gener ated sludge metal particles or clutch friction mate rial The torque converter should also be replaced when contaminated by a malfunction The transmis sion fluid and converter will be contaminated again if residue debris is not flushed from the cooler and lines beforehand 1 Mount transmission on jack Secure transmis sion to j
110. ents rearward from full forward position This is D range 4 Read pressures on both gauges as transmission throttle lever is moved from full forward to full rear ward position 5 Line pressure should be 54 60 psi 372 414 kPa with throttle lever forward and gradually increase as lever is moved rearward 6 Front servo is pressurized only in D range and should be same as line pressure within 3 psi 21 kPa up to downshift point Test Four Transmission In Reverse This test checks pump output pressure regula tion and the front clutch and rear servo circuits Use 300 psi Test Gauge C 3293 for this test 1 Connect 300 psi gauge to rear servo port Fig 3 2 Start and run engine at 1600 rpm for test 3 Move transmission shift lever four detents rear ward from the full forward position This is Reverse range 4 Move throttle lever all way forward then all way rearward and note gauge readings 5 Pressure should be 145 175 psi 1000 1207 kPa with lever forward and increase to 230 280 psi 1586 1931 kPa as lever is moved rearward Test Five Governor Pressure This test checks governor operation by measur ing 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 42RE TRANSMISSION DIAGNOSIS 21 11 will not downshift The test should be performed on a hoist that will allow the rear wheels to
111. eplace seals and clean valves as necessary be sure all valves slide freely in bores Check operation with DRB scan tool replace module only if faulty Check operation with DRB II scan tool Replace TPS only if faulty 1 Overdrive solenoid wiring or connectors faulty Overdrive or lockup solenoid not venting Transmission control module Overdrive off switch in dash open shorted or wiring is open or shorted Check solenoid wiring and connections for shorts grounds repair as necessary Test solenoids and replace if seized or shorted Test with DRB scan tool replace controller if faulty Test switch function with DRB scan tool nected to TCM Replace switch or repair wiring as necessary J9321 343 Condition 42RE TRANSMISSION DIAGNOSIS OVERDRIVE DIAGNOSIS Possible Cause 21 29 Correction HARSH 1 2 2 3 OR 3 2 SHIFTS MAY STALL WHEN GEAR SHIFT LEVER 15 PLACED IN D POSITION ONLY 1 Converter clutch solenoid failure TORQUE CONVERTER CLUTCH ENGAGES IN SECOND AND OR THIRD GEAR NOISY OPERATION IN FOURTH GEAR ONLY 1 Converter clutch solenoid or wiring problem Lb Remove valve body and replace solenoid Test solenoid and wiring for continuity shorts or grounds replace solenoid and relay if faulty repair wiring and connectors as necessary Overdrive clutch discs plates or snap rings
112. es Fig 11 7 Install overdrive piston in retainer if removed Lubricate piston seals with Ru Glyde Door Eze or petroleum jelly to ease installation Be sure piston locating lugs are aligned in piston retainer 8 Install thrust bearing in overdrive clutch hub Use liberal quantity of petroleum jelly to hold bearing in position 21 63 CAUTION Be sure the shoulder on the inside diam eter of the bearing is facing forward 9 Install thrust plate in overdrive piston hub Fig 12 Use liberal amount of petroleum jelly to hold thrust plate in position 10 Verify that splines in overdrive planetary gear and overrunning clutch hub are aligned with Tool 6227 2 Fig 8 Overdrive unit cannot be fully installed if splines have rotated out of alignment If misaligned has occurred overdrive will have to be disassembled in order to realign splines 11 Install overdrive unit as follows a Raise overdrive unit and carefully slide it straight onto intermediate shaft Avoid tilting overdrive unit during installation as planetary gear and overrun ning clutch splines could rotate out of alignment If misalignment occurs overdrive will have to be dis assembled in order to realign splines 6 Align and carefully insert park rod into park pawl Rod will make click noise as it enters pawl Move rod slightly to check engagement CAUTION It is possible for the park rod to displace into a cavity just above the pawl sprag during ins
113. esive or Loctite 242 to overdrive unit attaching bolts Then install and tighten bolts to 34 25 ft Ibs torque Be sure wire harness clips are placed on appropri ate overdrive bolts beforehand 49 Measure and if necessary correct input shaft end play as follows Fig 169 a Besureoverdriveunit is installed on transmis sion End play cannot be properly checked with overdrive unit off transmission b Attach dial indicator to converter housing c Position indicator plunger against input shaft and zero indicator d Move input shaft in and out and record read ing End play should be 0 56 2 31 mm 0 022 0 091 in Proceed to step e if end play is not within specified limits e Intermediate shaft thrust washer in hub of rear dutch retainer controls end play Washer is a select fit part and can be changed to adjust end play If end play turns out to be incorrect remove oil pump and clutches Then install thinner thicker thrust washer as necessary TRANSMISSION Fig 169 Measuring Input Shaft End Play 50 Install accumulator piston and inner and outer springs Fig 11 51 Verify that park neutral position switch has not been installed in case Valve body can not be installed if switch is in position 52 Verify that valve body solenoid harness is se cured in 3 4 accumulator housing cover plate 53 Install valve body as follows a Align and carefully insert park rod into pawl Rod will
114. essure solenoid valve Fig 4 21 4 AUTOMATIC TRANSMISSION 42RE SOLENOID FILTER GOVERNOR PRESSURE SOLENOID J9321 408A Fig 3 Governor Pressure Solenoid Valve The sensor output signal provides the necessary feedback to the transmission control module This feedback is needed to adequately control governor pressure O RING RETAINING CLIP GOVERNOR PRESSURE SENSOR J9321 409 Fig 4 Governor Pressure Sensor Governor Body And Transfer Plate A new transfer plate is used with the 42RE valve body The transfer plate is designed to a supply transmission line pressure to the governor pressure solenoid valve and b 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 5 GOVERNOR BODY J9321 410 Fig 5 Governor Body Transmission Fluid Temperature Thermister Transmission fluid temperature readings are sup plied to the transmission control module by the ther mister Fig 6 The temperature readings are used to control engagement of the fourth gear overdrive clutch Z the converter clutch and governor pressure Normal resistance value for the thermister at room tempera ture is approximately 1000 ohms The transmission control module TCM prevents engagement of the converter clutch and overdrive clutch when fluid temperature 15 below approximately 1 C If fluid
115. ey are removed Do not allow them to become intermixed 1 Disconnect wires from governor pressure sensor and solenoid Fig 90 GOVERNOR PRESSURE GOVERNOR PRESSURE SOLENOID VALVE AND WIRES 29321 457 Fig 90 Governor Pressure Solenoid And Sensor Wire Locations 2 Remove screws attaching governor body and tainer plate to transfer plate Fig 91 3 Remove retainer plate governor body and gasket from transfer plate Fig 92 4 Disconnect wires from governor pressure sensor if not done previously Fig 93 TRANSMISSION OVERHAUL 42RE 21 87 RETAINER 125 PLATE TORX BIT GOVERNOR BODY TRANSFER PLATE SCREW 2 19321 459 Fig 91 Governor Body And Retainer Plate Attaching Screw Removal installation TRANSFER PLATE SCREWS RETAINER PLATE J9321 460 Fig 92 Governor Body Retainer Plate And Gasket Removal 5 Remove governor pressure sensor from governor body Sensor is retained in body with M shaped spring clip Fig 93 Remove clip with small pointed tool and slide sensor out of body 6 Remove governor pressure solenoid by pulling it straight out of bore governor body Fig 94 Remove and discard solenoid O rings if worn cut or torn 7 Remove small shoulder bolt that secures solenoid harness case connector to 3 4 accumulator housing Fig 95 Retain shoulder bolt Either tape it 21 88 TRANSMISSION OVERHAUL 42RE CLZ SOLEN
116. ference 16 Remove valve body assembly Push valve body harness connector out of case Then work park rod and valve body out of case Fig 11 Exercise care TRANSMISSION OVERHAUL 42RE 21 65 OIL FILTER FILTER SCREWS 3 J9321 383 Fig 6 Oil Filter Removal Installation OVERDRIVE CLUTCH PISTON PISTON ZAYY INTERMEDIATE RETAINER SHAFT SELECTIVE SPACER Ca Fig 7 Overdrive Piston Removal 9121 210 SPECIAL TOOL J9321 181 4 3981 Fig 8 Oil Pump Seal Removal 21 66 TRANSMISSION OVERHAUL 42RE NEUTRAL SWITCH SOLENOID 19121 114 Fig 9 Park Neutral Position Switch Removal Installation VALVE 2 BODY 1897 1742 P 7 Fig 10 Valve Body Bolt Locations during removal as governor pressure solenoid and transducer can both be damaged by rough handling 17 Remove accumulator piston and inner and outer springs Fig 11 18 Remove front band lever shaft access plug Fig 13 Plug is accessible through converter housing Use 1 4 inch drive extension to remove plug as shown 19 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 20 Remove oil pump bolts 2 PRESSURE T SENSOR GOVERNOR PRESSURE SOLENOID ACCUMU
117. front end of transmission upward as far as possible and support case with wood blocks Front rear clutch and oil pump assemblies are easier to install if transmission is as close to upright position as possible INTERMEDIATE SHAFT THRUST PLATE 19121 215 INTERMEDIATE SHAFT HUB Fig 153 Installing Intermediate Shaft Thrust Plate INPUT SHAFT TEFLON SEAL RING METAL SEAL RING REAR CLUTCH RETAINER Fig 154 Input Shaft Seal Ring Location REAR CLUTCH RETAINER REAR CLUTCH THRUST WASHER FIBER Fig 155 Installing Rear Clutch Thrust Washer REAR CLUTCH ASSEMBLY Fig 156 Assembling Front And Rear Clutch Units INTERMEDIATE SHAFT THRUST WASHER REAR CLUTCH RETAINER HUB INPUT SHAFT 29121 214 Fig 157 Installing Intermediate Shaft Thrust Washer 25 Install front and rear clutch units as assembly Fig 159 Align rear clutch with front annulus gear and install assembly in driving shell Be sure output shaft thrust washer and thrust plate are not displaced during installation 26 Carefully work assembled clutches back and forth to engage and seat rear clutch discs on front annulus gear Also be sure front clutch drive lugs are fully engaged in slots of driving shell after installation 27 Slide front band over front clutch retainer Fig 160 28 Insert front band lever pivot shaft part way into case Fig 160 29 Install front band lever strut
118. hub and spring just enough to place tension on hub and hold it in place 9121 329 25 Slide direct clutch pack upwards on hub Fig 53 Then set dutch pack on edge of dutch hub and compressor tool as shown 26 Slowly compress clutch hub and spring Fig 53 Compress spring and hub only enough to expose ring grooves for dutch pack snap ring and clutch hub retaining ring CLUTCH HUB DIRECT CLUTCH PACK CLUTCH DRUM J9321 397 Fig 52 Installing Direct Clutch Pack And Clutch Hub 27 Realign clutch pack on hub and seat clutch discs and plates in clutch drum Fig 53 DIRECT CLUTCH PLATES DISCS CLUTCH DRUM Fig 53 Seating Clutch Pack In Drum 28 Install direct clutch pack snap ring Fig 54 Be very sure snap ring is fully seated in clutch drum ring groove 29 Install clutch hub retaining ring Fig 55 Be very sure retaining ring is fully seated in sun gear ring groove 30 Slowly release press ram remove compressor tools and remove geartrain assembly GEAR CASE ASSEMBLY AND INSTALLATION 1 Position park pawl and spring in case and install park pawl shaft Fig 34 Verify that end of spring with 90 bend is hooked to pawl and straight end of springis seated against case 2 Install pawl shaft retaining bolt Tighten bolt to 27 Nem 20 ft Ibs torque 3 Install park lock reaction plug Note that plug has locating pin at rear Fig 56 Be sure pin is seated in hole in case before
119. ible from con verter housing 4 Fabricate test probe Fig 7 Attach probe to converter housing with a dust shield bolt 5 Have a helper run engine at 2500 rpm with transmission in Neutral for two minutes then stop engine 6 Inspect test probe and converter housing If a leak is evident note color of fluid Transmission fluid is red Engine oil ranges in color from brown to green or to black when oil is dirty 7 If probe upper surface 15 wet with fluid converter and seal are not at fault A path of fluid across probe upper surface indicates a converter or seal leak Fluid leaking under the probe is coming from pump housing area Fig 8 8 Fluid leaking under the probe could be from pump seal and or bushing pump vent kickdown lever shaft access plug pump bolts or porous spots in pump body or transmission case Fig 8 9 If porous spots in the transmission case or pump body are the suspected leak source pressurize trans mission as described in Leak Testing With Air Pres sure 21 14 42RE TRANSMISSION DIAGNOSIS 5 1 2 BOTTOM OF TORQUE CONVERTER HOUSING DUST SHIELD MATERIAL 5 1 2 X 1 1 2 X 1 32 BOLT SHEET METAL RN778 Fig 7 Converter Housing Leak Test Probe Fig 8 Pump Area Inspection Points TORQUE CONVERTER LEAK POINTS Possible sources of converter leaks are a leaks at the weld joint around the outside diameter weld and b leaks at the converter hub weld Fig 9
120. ily bypasses the clutch piston feed orifice at the start of a 3 4 upshift This exposes a larger passage into the piston retainer resulting in a much faster clutch fill and apply se quence 21 6 AUTOMATIC TRANSMISSION 42RE The valve does not bypass the regular clutch feed orifice throughout the 3 4 upshift Instead once a predetermined pressure develops within the clutch the valve closes the bypass Clutch fill is then com pleted through the regular feed orifice SERVICE MANUAL UPDATES NEW THROTTLE VALVE CABLE A different throttle valve cable is used on 2 models with the 42RE transmission and 4 0L engine Thecable is similar to the one used on V8 models with the 46RH transmission NEW THROTTLE VALVE CABLE ADJ USTMENT PROCEDURE A new throttle valve cable adjustment procedure has been developed for the 42RE and 46RH throttle valve cable Z The adjustment procedure is new for the 1993 model year and applies to 42RE and 46RH transmissions equally Make note on page 21 92 Group 21 of your 1993 Grand Cherokee Service M anual and refer to the procedure in this manual when adjustment is neces sary The new adjustment procedure is described in the In Vehicle Service section TRANSMISSION SHIFT MECHANISM A floor shift linkage mechanism is used on all 2 models with the 42RE and 46RH automatic transmis sion A column type gearshift linkage was not released Make a note of this information on page 21 191 of your 1993 Gr
121. imilar heavy load hauling check fluid level and condition at least once a week Fluid level is checked with the engine running at curb idle speed the transmission in Neutral and the transmission fluid at normal operating temperature hot The 42RE transmission dipstick is on the driver side of the engine compartment at the rear of the engine The dipstick handle has the universal symbol for a gear imprinted on it for identification FLUID LEVEL CHECK PROCEDURE 1 Transmission fluid must be at normal operating temperature for accurate fluid level check Drive ve hide if necessary to bring fluid temperature up to normal hot operating temperature of 82 C 180 F 2 Position vehicle on level surface This is ex tremely important for accurate fluid level check 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 and check fluid level as follows a Dipstick has three fluid level indicating marks which are a MIN dot mark an OK mark and a MAX fill arrow mark b Correct level is to MAX arrow nark on dipstick This is correct maximum hot fluid level Acceptable level is between OK mark and max arrow mark on dipstick c If level is at or below MIN level dot on dipstick add only enough fluid to restore correct leve
122. ing con tact surface of spring plate with generous amount of petroleum jelly This will help hold bearing in place during installation 14 Install planetary thrust bearing on sun gear 21 122 OVERDRIVE UNIT OVERHAUL 42RE BE SURE THRUST BEARING IS SEATED SQUARELY AGAINST CLUTCH HUB J9121 323 Fig 41 Installing Overrunning Clutch Thrust Bear ing CLUTCH OVERRUNNING DRUM CLUTCH ASSEMBLY EXPANDING TYPE SNAP RING OVERRUNNING CLUTCH ASSEMBLY SEATED IN OUTPUT SHAFT CLUTCH DRUM ANNULUS Ne 7 GEAR J9121 314 Fig 42 Installing Overrunning Clutch Fig 45 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 15 Install assembled sun gear spring plate and thrust bearing Fig 46 Be sure sun gear and thrust bearing are fully seated before proceeding Z PLANETARY GEAR ANNULUS GEAR 19121 324 Fig 43 Installing Planetary Gear SUN GEAR SPRING PLATE SPRING PLATE SNAP RING 19121 325 Fig 44 Sun Gear And Spring Plate Assembly SPRING PLANETARY THRUST BEARING 29121 326 Fig 45 Installing Planetary Thrust Bearing 16 Mount assembled output shaft annulus gear and clutch drum in shop press Direct clutch spring hub and clutch pack are easier to install with assembly mounted in press SUN GEAR AND SPRING PLATE ASSEMBLY 19121 327 Fig 4
123. ings securing annulus gears to supports Then separate each gear from support PLANETARY GEARTRAIN INSPECTION 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 damaged 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 part that is worn or damaged Do not attempt to reuse these parts Inspect the intermediate shaft carefully Pay particu lar attention tothe machined bushing bearing surfaces on the shaft Replace the intermediate shaft if any machined sur faces are scored pitted or damaged in any way Also replace the shaft if the splines are damaged or exhibits cracks at any location Be sure the select spacer groove on the shaft is in good condition Trial fit the spacer if necessary PLANETARY GEARTRAIN ASSEMBLY 1 Lubricate intermediate shaft and planetary com ponents with transmission fluid Use petroleum jelly to lubricate and hold thrust washers and plates in posi tion 2 Assemble rear annulus gear and support if dis assembled Be sure support snap ring is seated and that shoulder side of support faces
124. installing snap ring OVERDRIVE UNIT OVERHAUL 42RE 21 125 DIRECT SPECIAL root is RING J9321 400 Fig 54 Installing Direct Clutch Pack Snap Ring SPECIAL TOOL 6227 1 CLUTCH HUB RETAINING RING 29321 401 Fig 55 Installing Clutch Hub Retaining Ring 4 Install reaction plug snap ring Fig 57 Com press snap ring only enough for installation do not distort it REACTION PLUG SNAP RING DO NOT OVERCOMPRESS TO INSTALL 20 TUS PARK LOCK REACTION LOCATING SIN PLUG J9121 338 Fig 56 Reaction Plug Locating Pin And Snap Ring 5 Install new seal in gear case Fig 58 4 x 4 gear case use Tool Handle C 4171 and Installer 5062 OVERDRIVE UNIT OVERHAUL 42RE REACTION PLUG SNAP RING 21 126 SNAP RING 8921 240 PLIERS Fig 57 Reaction Plug And Snap Ring Installation or similar size tool to seat seal in case On 4 x 2 gear case use same tool handle and suitable size installer to seat seal in case 4x4 REAR SEAL GEAR INSTALL WITH CASE SPECIAL TOOLS 5062 AND C 4171 J9321 402 Fig 58 Rear Seal Installation In 4 x 4 Gear Case 6 Verify that tab ends of rear bearing locating ring extend into access hole in gear case Fig 59 7 Support geartrain on Tool 6227 1 Fig 60 Be sure tool is securely seated in clutch hub 8 Install overdrive gear case on geartrain Fig 60 9 Expand front bearing locating ring with snap ring pliers
125. ion converter housing Two small vise grip pliers van be used to hold and align cover during installation 17 Install and connect starter motor 18 Connect transmission shift and throttle valve cables to valve body manual shaft and transmission brackets 19 Fasten wire harnesses in dips on transmission case 20 Connect wires to solenoids park neutral posi tion switch transmission speed sensor and vehide Speed sensor 21 Install transmission fill tube and O ring 22 Install rear crossmember and attach rear insu lator to transmission and crossmember 23 Connect cooler lines to transmission case fit tings Pull lines outward to verify that they are se curely seated and retained by wire retainer clips 24 Align and install propeller shaft Clean and lubricate slip yoke before installation 25 Install exhaust system components 26 Lower vehide TRANSFER CASE bra M VENT FILTER TRANSMISSION FILL TUBE FILL TUBE TORQUE O RING gt 5 A Ad J9321 346 Fig 6 Transmission And Fill Tube Mounting Z _ TRANSMISSION OVERDRIVE REMOVAL AND INSTALLATION 42RE 27 Connect battery negative cable 28 Fill or top off transmission fluid level with Mopar ATF Plus type 7176 29 Check transmission control cable adjustments Readjust cables if necessary TRANSMISSION INSTALLATION 4 WHEEL DRIVE CAUTION The transmission cooler an
126. ip snaps into place behind cooler line flange 6 Note position of plastic insert When cooler line is fully seated insert will no longer extend beyond end of fitting 7 Verify that both sides of wire retainer clip are seated behind flange on cooler line Fig 24 8 Pull outward on cooler lines to verify that they are properly secured 21 52 IN VEHICLE SERVICE 42RE RETAINER CLIP STARTED IN ONE SIDE OF FITTING 29321 264 Fig 22 Starting New Retainer Clip On Type Fitting RETAINER CLIP SEATED IN FITTING 19321 265 Fig 23 Seating New Retainer Clip In Type Fitting CAUTION The retainer clips must secure the cooler lines in the fittings If the clips are deformed or distorted normal fluid pressure could unseat the cooler lines resulting in fluid loss and transmission damage Be very sure the clips are in good condition and firmly seated behind the cooler line flanges Fig 24 9 Reinstall splash shield under radiator if re moved DISCONNECTING COOLER LINES TYPE FIT TING 1 Remove splash shield for access if cooler lines will be disconnected at radiator cooler 2 If fitting and cooler line are encrusted with dirt mud or grease clean out fitting and line with Mopar spray type brake cleaner Plastic release tool will not fit into retainer clip if fitting is full of foreign material 3 Slide small plastic release tool into fitting 4 Push and turn tool to spread retainer c
127. ission fluid or petroleum jelly CAUTION The thrust washer is a one way fit The washer inside diameter is chamfered on one side Be sure the washer is installed with the chamfered side facing forward 7 If reaction shaft seal rings are being replaced install new seal rings on support hub Fig 49 Lubri cate seal rings with transmission fluid or petroleum TRANSMISSION OVERHAUL 42RE 21 75 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 installation 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 SUPPORT HUB J9321 218 Fig 49 Hub Seal Ring Position 8 Install reaction shaft support on pump housing Fig 50 9 Align reaction support on pump housing Use alignment marks made at disassembly Or rotate sup port until bolt holes in support and pump housing are all aligned holes are offset for one way fit REACTION SHAFT SUPPORT Fig 50 Assembling Reaction Shaft Support And Pump Housing 10 Install all bolts that attach support to pump housing Then tighten bolts finger tight 11 Tighten support to pump bolts to required torque as follows a Reverse pump assembly an
128. ive Unit Overhaul procedures 14 Remove and retain bearing and select fit spacer These parts may remain on overdrive piston rear of transmission case sliding hub or intermediate shaft during removal 15 Place several dean shop towels on a bench Then position unit on towels to absorb spilled fluid 16 Position overdrive unit over drain pan and tilt unit to drain residual fluid from case Examinefluid for dutch material or metal fragments If fluid contains these items overhaul will be necessary OVERDRIVE UNIT INSTALLATION 2 WHEEL DRIVE 1 BesureAlignment Tool 6227 2 is still fully seated in splines of overdrive planetary gear and overrunning clutch If misalignment occurs overdrive will have to be disassembled in order to realign splines 2 If original case gasket is in good condition pro ceed to step 6 If overdrive piston retainer was not removed during service and original case gasket is not reusable prepare new gasket as described in steps 3 through 5 3 Cut out old case gasket around piston retainer with razor knife 4 Use old gasket as template and trim new gasket to fit Fig 10 5 Position new gasket over piston retainer and on transmission case Use petroleum jelly to hold gasket in place if necessary Do not use any type of sealer to secure gasket Use petroleum jelly only 6 Install selective spacer on intermediate shaft if removed Spacer goes in groove just rearward of shaft rear splin
129. justment 46 Servicing Transmission Cooler Line Fittings 50 Gearshift Cable Adjustment 45 Speedometer Service 47 Oil Pump Seal 43 Transmission Cooler Testing and Flushing 53 Park Interlock Cable Adjustment 45 Transmission Fluid Level Check 43 Park Lock Service 43 Transmission Throttle Valve Cable Adjustment 44 Park Neutral Position Switch 48 Valve Body Service 48 PARK LOCK SERVICE The park lock components are located within the overdrive unit and cannot be serviced in the vehicle The overdrive unit must be removed and disassembled for access to the park lock components Refer to the sections dealing with transmission overdrive removal installation and over haul sections for overdrive unit repair procedures OIL PUMP SEAL The transmission and torque converter must be removed for access to the oil pump seal Oil pump seal replacement procedures are described in the Transmis sion Removal I nstallation section RECOMMENDED FLUID Recommended fluid for the 42RE is Mopar ATF Plus type 7176 Mopar Dexron 11 fluid should only be used when AFT plus is not available TRANSMISSION FLUID LEVEL CHECK Transmission fluid level should be checked a mini mum of four times per year under normal operation If the vehicle is used for trailer towing or s
130. ken for a leak if inspection is not careful OVERDRIVE ELECTRICAL CONTROLS The electrical controls governing the shift into fourth gear consist of the overdrive off switch in the instru ment panel and the overdrive solenoid on the valve body The overdrive off switch valve body solenoid case connectors and related wiring can all be tested with a 12 volt test lamp or volt ohmmeter Check continuity of each component when diagnosis indicates this is necessary Switch and solenoid continuity should be checked whenever the transmission fails to shift into fourth gear range DIAGNOSTIC TROUBLE FLASH CODES Diagnostic trouble flash codes are provided for diag nosis purposes The lamp in the overdrive off switch is used to signal the various flash codes 2 The flash codes and type of fault indicated outlined in the Flash Code Chart Fig 1 To view flash codes proceed as follows a Turn ignition key on and off three times Then leave overdrive off switch in normal overdrive on position b Immediately begin counting number of flashes displayed by overdrive off switch indicator lamp c Flash codes will correspond to powertrain con trol module in duration and spacing d A code 55 identifies end of flash code transmis sion E FAULT DESCRIPTION 1 Engine RPM input Output shaft sensor input Vehicle speed input Governor pressure sensor input Throttle position sensor i
131. l Mopar ATF Plus type 7176 is the preferred fluid Mopar Dexron should only be used when ATF Plus is not available 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 8 If transmission is overfilled fluid can be removed with 1 8 to 3 16 in diameter tubing and suction gun Tubing will have to be adapted to nozzle of gun and be long enough to extend down fill tube and into trans mission oil pan FLUID AND FILTER CHANGE NORMAL CHANGE INTERVAL Thefluid and filter should be changed and the bands adjusted at recommended maintenance intervals or whenever the transmission has been disassembled for any reason 21 44 IN VEHICLE SERVICE 42RE DIPSTICK MIN MAX MINIMUM LEVEL DOT MARK ADD FLUID MAXIMUM CORRECT FLUID LEVEL ACCEPTABLE FLUID LEVEL 29321 96 Fig 1 Typical Dipstick Fluid Level Marks Refer to the Driveline section in Group O Lubrica tion and Maintenance for recommended change inter vals Refer to the fluid filter replacement and band adjustment procedures in this section SEVERE USAGE CHANGE INTERVAL Under severe usage the fluid and filter should be changed and the bands adjusted at 12 000 mile 19 000 Km intervals Severe usage is define
132. lamp circuit SWITCH TEST 1 Verify that gearshift linkage is correctly adjusted before testing Switch will not operate properly if linkage adjustment is incorrect 2 To test switch remove wiring connector Then test continuity between center terminal and transmis sion case Continuity should exist only when transmis sion is in Park or Neutral 3 Shift transmission into reverse and test continu ity at switch outer terminals a Continuity should exist only when transmis sion is in Reverse 2 6 Continuity should not exist between outer ter minals and case PARK NEUTRAL POSITION SWITCH REPLACE MENT 1 Raise vehicle and position drain pan under switch 2 Disconnect switch wires and remove switch from case 3 Move shift lever to Park and Neutral positions Verify that switch operating lever fingers are centered in switch opening in case Fig 12 4 Install new seal on switch and install switch in case Tighten switch to 34 Nem 25 ft Ibs torque 5 Connect switch wires lower vehicle and top off transmission fluid level CONTACT E 00 2 RH266 SWITCH Fig 12 Park Neutral Position Switch Contacts VALVE BODY SERVICE GENERAL SERVICE INFORMATION The valve body can be removed for service without having to remove the entire transmission assembly The valve body can be disassembled for cleaning and inspection of the individual components Refer to the procedures in the Transmission Unit Suba
133. lay check 24 Check planetary geartrain end play with feeler gauge Fig 85 Gauge goes between shoulder on inter mediate shaft and end of rear annulus support 25 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 haveto be replaced Snap ring is available in three different thicknesses for adjust ment purposes TRANSMISSION OVERHAUL 42RE 21 85 9121 171 Fig 85 Checking Planetary Geartrain End Play FRONT SERVO AND BAND OVERHAUL FRONT SERVO DISASSEMBLY FIG 86 1 Remove small snap ring from servo piston 2 Remove piston rod springs and guide 3 Remove and discard servo piston rings and O ring FRONT BAND AND SERVO INSPECTION Clean the servo components with solvent and dry them with compressed air 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 Replace the front band if distorted the lining is burned or flaking off or excessively worn Check the servo piston bore for wear Replace the piston and rod as an assembly if either part is worn or damaged Replace any servo component if doubt exists about its condition Do not reuse suspect parts ASSEMBLING FRONT SERVO PISTON 1 Lubricate seal rings and O rings with petroleum jelly Lubricate other servo parts with transmissio
134. ld be replaced as an assembly when diagnosis indicates a malfunction has occurred or when a major malfunction allows debris to enter the converter GEAR RATIOS Forward Gear ratios for the 42RE transmission are First gear 2 74 1 Second gear 1 54 1 Third gear 1 00 1 Fourth gear 0 69 1 RECOMMENDED FLUID The only fluid recommended for the 42RE transmis sion is Mopar ATF Plus type 7176 Do not use Dexron except in emergency or if ATF Plus is not available TRANSMISSION IDENTIFICATION The transmission part identification numbers and codes are stamped on the left side of the case just above the oil pan gasket surface Fig 2 The first letter number group is the assembly part number The next number group the transmission build date Thelast number group is the transmission serial number Refer tothis information when ordering replacement parts FRONT BAND ADJUSTMENT Thefront band adjustment for 42RE transmissions is considerably different from prior 4 speed models On 42RE transmissions the front band is backed off 3 5 8 turns after tightening the adjusting screw to spedified torque Refer to the front band adjustment procedure in the In vehide Service section when band adjustment is necessary AUTOMATIC TRANSMISSION 42RE 21 3 BUILD SERIAL NUMBER DATE NUMBER 29121 202 Fig 2 Transmission Identification Number And Code Location ELECTRONIC GOVERNOR COMPONENTS Governor
135. ld bushingin viseor with pliers and back remover tool out of bushing 5 Assemble Bushing Installer Tools C 4171 and SP 5325 Fig 46 6 Slide new bushing onto Installer Tool SP 5325 7 Position reaction shaft support upright on a dean 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 SPECIAL TOOL 4171 SPECIAL TOOL 5 1191 SPECIAL TOOL SP 3633 SPECIAL TOOL SP 5324 SPECIAL TOOL BUSHING REMOVAL BUSHING INSTALLATION J9221 243 Fig 46 Replacing Reaction Shaft Support Bushing ASSEMBLING OIL PUMP AND REACTION SHAFT SUPPORT 1 Lubricate gear bore in pump housing with trans mission fluid 2 Lubricate pump gears with transmission fluid 3 Support pump housing on wood blocks Fig 47 2 4 Install outer gear in pump housing Fig 47 Gear can be installed either way it is not a one way fit PUMP L HOUSING BLOCKS J9321 219 Fig 47 Supporting Pump And Installing Outer Gear 5 Install pump inner gear Fig 48 CAUTION The pump inner gear is a one way fit The bore on one side of the gear inside diameter is chamfered Be sure the chamfered side faces forward to front of pump J9321 465 Fig 48 Pump Inner Gear Installation 6 Install new thrust washer on hub of reaction shaft support Lubricate washer with transm
136. le and position it at rear of engine Remove C clamp or strap used to secure converter in housing 10 Align transmission with engine dowels and align converter with driveplate Offset holes in drive plate are next to 1 8 inch hole in inner circle of plate Fig 4 11 Move transmission forward until seated on en gine block dowels Then install oneor twotransmission attaching bolts to hold transmission in place Fig 6 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 modulated clutch surfaces in the converter If new bolts are required use the bolts specified in the parts catalogue only 21 59 12 Verify converter bolt length Bolt measurement is from bottom underside of bolt head to end of bolt threads e On 9 5 3 lug converter bolts should be 11 7 mm 0 46 in long On 10 75 in 4 lug converter bolts should be 11 2 mm 0 44 in long 13 Install torque converter bolts Tighten bolts as follows On models with 9 5 in 3 lug converter tighten bolts to 54 Nem 40 ft 165 e On models with 10 75 in 4 lug converter tighten bolts to 31 Nem 270 in 105 14 Install and tighten remaining transmission at taching bolts Fig 6 15 Install dust cover on transmission converter housing Two small vise grip pliers van be used to hold and align cover during installation 16 Install starter motor
137. level and check for leaks Adjust linkage and repair linkage if worn or damaged Adjust band Replace fluid and filter If oil pan and old fluid were full of clutch disc material and or metal particles overhaul will be necessary Remove transmission and replace oil pump Remove transmission remove oil pump and replace seal rings Check electrical functions with DRB scan tool or flash codes and repair as necessary Perform pressure test remove transmission and repair as needed Remove and disassemble transmission and repair as necessary repair required J9321 334 21 18 Condition 42RE TRANSMISSION DIAGNOSIS TRANSMISSION DIAGNOSIS Possible Cause Correction SHIFTS DELAYED OR ERRATIC SHIFTS ALSO HARSH AT TIMES Low fluid level Throttle cable out of adjustment Throttle cable binding Gearshift linkage out of adjustment Fluid filter partially clogged Air in fluid due to overfill condition or air leakage into pump suction passages Clutch or servo problem Front band out of adjustment may cause harsh 1 2 shift Accumulator springs seals worn or damaged Governor pressure control system fault Correct fluid level and check for leaks Adjust cable as described in service section Adjust cable replace if worn or damaged Adjust linkage as described in service section Replace filter If filter and fluid contained clut
138. lip and disconnect cooler line and or fitting Fig 25 TRANSMISSION FITTING COOLER HOSE FITTING J9321 257 Fig 24 Correct Seating Of Cooler Lines In Type Fitting FITTING RELEASE TOOL COOLER LINE FLANGE J9321 453 Fig 25 Disconnecting Type Fitting 5 Cover open ends of cooler lines and fittings to prevent dirt entry 6 Inspect condition of fitting Replace transmission fitting as an assembly if fitting body or retainer dip 15 damaged Replace cooler line as assembly if fitting swedged into cooler line hose is damaged RECONNECTING COOLER LINES TYPE FIT TING 1 If transmission or radiator fittings require re placement apply Mopar Lock N Seal or Loctite 242 to fitting threads before installation 2 Wipe off cooler line and fitting with dean dry cloth 3 Insert cooler line into fitting Then push line inward until retainer clip secures line A snap or click sound will be heard and felt through the line when the retainer clip seats behind the cooler line flange 4 Pull outward on cooler lines to verify that they are properly secured 2 CAUTION The retainer clips must secure the cooler lines in the fittings If the clips are deformed or distorted normal fluid pressure could unseat the cooler lines resulting in fluid loss and transmission damage Be very sure the cooler lines are firmly secured as described in step 4 above 5 Install splash shield if remove
139. lled Small raised tabs should be facing upward Semi circular lugs on underside of retainer are for positioning retainer in spring 21 78 TRANSMISSION OVERHAUL 42RE SMALL TABS ON RETAINER FACE UPWARD 19321 224 Fig 58 Correct Spring Retainer Installed Position 7 Compress piston spring and retainer with Com pressor Tool C 3575 A Fig 53 Then install new snap ring to secure spring retainer and spring 8 Install clutch plates and discs Fig 52 Install steel plate then disc until all plates and discs are installed 9 Install pressure plate and waved snap ring Fig 52 10 Check clutch plate clearance Fig 59 Clear ance should be 1 70 to 3 40 mm 0 067 to 0 134 in If clearance is incorrect clutch discs plates pressure plates and snap ring may have to be changed FEELER GAUGE WAVED SNAP RING EN EE eS FEELER GAUGE RH288 Fig 59 Measuring Front Clutch Pack Clearance REAR CLUTCH OVERHAUL REAR CLUTCH DISASSEMBLY 1 Remove plastic thrust washer from forward side of clutch retainer 2 Remove selective clutch pack snap ring Fig 60 2 3 Remove top pressure plate clutch discs steel plates bottom pressure plate and wave spring Fig 60 4 Remove clutch piston Grasp piston and rotate piston up and out of retainer 5 Remove and discard piston seals 6 Remove input shaft snap ring Fig 61 7 Press input shaft out of retainer
140. make dick noise as it enters pawl Move rod slightly to check engagement 2 CAUTION is possible for the park rod to displace into a cavity just above the pawl sprag during instal lation Make sure the rod is actually engaged in the pawl and has not displaced into the cavity If the rod enters the cavity during installation it will become bent when the overdrive bolts are tightened If this occurs the rod will have to be removed and replaced b Align and seat valve body on case Be sure manual lever shaft and overdrive connector 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 diagonal pattern to 12 Nem 105 in Ibs torque Do not overtighten valve body bolts This could result in distortion and cross leakage after installa tion 54 Install new filter on valve body Tighten filter screws to 4 Nem 35 Ibs 55 Adjust front and rear bands as follows a Loosen band adjusting screw locknuts b Tighten each band adjusting screw to 5 Nem 72 in 165 with torque wrench c Back off front band adjusting screw 3 5 8 turns d Back off rear band screw 4 turns e Tighten each adjusting screw locknut Hold adjusting screws with wrench to prevent turning when tightening locknut 56 Install seal on park neutral position switch Fig 170 Then install and tighten switch to 34 Nem 25
141. mis sion is noisy stop engine Remove oil pan and check for debris If pan is clear remove transmission and check for damaged drive plate converter oil pump or input shaft If propeller shafts do turn and transmission is not noisy perform hydraulic pressure test to de termine if problem is a hydraulic or mechanical CHECKING FLUID LEVEL AND CONDITION 1 Place vehicle on level surface This is important for an accurate reading 2 Do not check level until fluid is at normal hot operating temperature of approximately 180 F This is necessary to avoid false readings which could produce under or over fill condition 3 Start and run engine at curb idle speed and apply parking brakes 4 Shift transmission through all gear ranges and back to Neutral 5 Clean top of filler tube and dipstick to keep dirt out of tube 6 Remove dipstick and check fluid level as follows a Dipstick has three fluid level indicating marks which area MIN dot mark an OK mark and a MAX fill arrow mark b Correct level is to Full or MAX arrow mark on dipstick This is correct maximum hot fluid level Acceptable level is between OK mark and max arrow mark on dipstick 21 8 42RE TRANSMISSION DIAGNOSIS If level is at or below MIN level dot on dipstick add only enough fluid to restore correct level Mopar ATF Plus type 7176 is the preferred fluid Mopar Dexron can be used if ATF Plus is not readily available CAUT
142. n or damaged 2 Adjust band Check operating pressures and test governor component with DRB scan tool or flash codes Repair as needed Air pressure check operation of clutches and bands repair faulty component Test governor components with 11 scan tool Remove clean and inspect Look for sticking 1 2 valve 2 3 valve governor plug or broken springs Inspect servo and repair as required 4 Inspect linkage and look for bind in linkage Adjust linkage J9321 337 21 22 Condition 42RE TRANSMISSION DIAGNOSIS TRANSMISSION DIAGNOSIS Possible Cause Correction CREEPS IN NEUTRAL DRAGS OR LOCKS UP GROWLING GRATING OR SCRAPING NOISES 1 Gearshift linkage out of adjustment Valve body malfunction warped body cross leakage loose screws Clutch dragging Front or rear band of adjustment Servo band or linkage malfunction i e binding linkage warped band servo piston stuck Dragging clutch does not release fully Broken or seized planetary gears Overrunning clutch worn broken or seized Planetary gear set broken or seized Overrunning clutch worn seized or broken Oil pump components scored binding or broken Output shaft bearing or bushing damaged Faulty clutch operation Front and rear bands out of adjustment Adjust linkage Perform hydraulic pressure test to determine cause an
143. n fluid 2 Install new O ring on servo piston rod 3 Install new seal on piston rod guide and install new seal rings on piston 4 Assemble rod piston servo springs and snap ring Fig 86 21 86 TRANSMISSION OVERHAUL 42RE SERVO PISTON PISTON ROD SNAP RING PISTON SPRING SERVO SNAP GUIDE RING SEAL J9121 172 Fig 86 Front Servo Components REAR SERVO AND BAND OVERHAUL REAR SERVO PISTON DISASSEMBLY 1 Remove seal from servo piston Note which way seal lip faces for assembly reference 2 Compress cushion spring in vise only enough to allow piston plug snap ring removal Fig 87 Use wood block between vise jaws and end of piston plug to keep plug aligned and in position 3 Remove snap ring from end of piston plug Fig 87 4 Open vise and remove wood block piston plug cushion spring and servo piston SMALL WOOD BLOCK VISE PLIERS J9121 174 Fig 87 Removing Installing Servo Piston Plug Snap Ring REAR SERVO INSPECTION Clean the servo components Fig 88 with solvent and dry them with compressed air Check rear band condition Replace the band if distorted the lining is burned or flaking off or the lining is excessively worn Check the band pivot and reaction pins Minor pin scoring can be deaned up with crocus cloth However replace the pins if worn se verely scored or cracked Replace the pin O rings Inspect the servo components Replace the servo
144. n one but not both positions If the engine starts in any position other than Park or Neutral or if the engine will not start at all the park neutral position switch may be faulty Gearshift Adjustment Procedure 1 Shift transmission into Park 2 Raise vehide 3 Release cable adjuster damp at transmission end of cable to unlock cable Fig 5 4 Unsnap cable from cable bracket Fig 5 5 Check transmission shift lever position by mov ing it all the way rearward into Park detent 6 Verify positive engagement of park lock by at tempting to rotate propeller shaft Shaft will not rotate when park lock is engaged 7 Snap cable into cable bracket on transmission 8 Lock shift cable by pressing cable adjuster clamp down until it snaps into place 9 Check engine starting Engine should start only in Park and Neutral 10 Lower vehicle THROTTLE VALVE CABLE 10 SHIFT CABLE SN BRACKET CUN SHIFT TRANSMISSION CABLE SHIFT LEVER J9321 417 Fig 5 Shift Cable Attachment At Transmission PARK INTERLOCK CABLE ADJUSTMENT 1 Shift transmission into Park 2 Turn ignition switch to Accessory position 21 46 IN VEHICLE SERVICE 42RE CAUTION Be sure the ignition switch is in the Acces sory position for cable adjustment The cable and lever mechanism will not adjust correctly if the switch lock cylinder is in Park position 3 Remove shift lever bezel and console screw
145. nce Measure gear tooth clearance with a feeler gauge Align one tooth of the outer gear in inner gear and measure clearance Fig 43 Clearance should be 0 08 0 19 mm 0 0035 0 0075 REPLACING OIL PUMP BUSHING 1 Remove pump bushing with Tool Handle C 4171 and Bushing Remover SP 3551 Fig 44 2 Install new pump bushing with Tool Handle C 4171 and Bushing Installer SP 5117 Fig 44 Bush ing should be flush with pump housing bore 3 Stake new pump bushing in two places with blunt punch Fig 45 Remove burrs from stake points with knife blade afterward 21 74 TRANSMISSION OVERHAUL 42RE Fig 42 Measuring Pump Housing To Inner Gear Clearances SPECIAL TOOL C171 SPECIAL TOOL PUMP HOUSING SP 3551 BUSHING SPECIAL TOOL 4171 SPECIAL TOOL SP 5117 BUSHING INSTALLATION J9221 242 Fig 44 Removing Oil Pump Bushing REPLACING REACTION SHAFT SUPPORT BUSHING 1 Assemble Bushing Remover Tools SP 1191 3633 and 5324 Fig 46 Do not clamp any part of reaction shaft or support in vise 2 Hold Cup Tool SP 3633 firmly against reaction shaft and thread remover SP 5324 into bushing as far Fig 45 Staking Oil Pump Bushing as possible by hand Then thread remover tool 3 4 additional turns into bushing with a wrench 3 Turn remover tool hex nut down against remover cup to pull bushing from shaft Clean all chips from shaft after bushing removal 4 Lightly grip o
146. ner was not removed during service and original case gasket is not reusable prepare new gasket as described in steps 3 through 5 3 Cut out old case gasket around piston retainer with razor knife 4 Use old gasket as template and trim new gasket to fit Fig 10 GASKET SHARP KNIFE 8921 269 Fig 10 Trimming Replacement Overdrive Case Gasket 5 Position new gasket over piston retainer and on transmission case Use petroleum jelly to hold gasket 21 61 in place if necessary Do not use any type of sealer to secure gasket Use petroleum jelly only 6 Install selective spacer on intermediate shaft if removed Spacer goes in groove just rearward of shaft rear splines Fig 11 N SPACER GROOVE SELECTIVE SPACER INTERMEDIATE SHAFT 9021 96 Fig 11 Intermediate Shaft Selective Spacer Location 7 Install overdrive piston in retainer if removed Lubricate piston seals with Ru Glyde Door Eze or petroleum jelly to ease installation Be sure piston locating lugs are aligned in piston retainer 8 Install thrust bearing in overdrive clutch hub Use liberal quantity of petroleum jelly to hold bearing in position CAUTION Be sure the shoulder on the inside diam eter of the bearing is facing forward 9 Install thrust plate in overdrive piston hub Fig 12 Use liberal amount of petroleum jelly to hold thrust plate in position OVERDRIVE OVERDRIVE PISTON THRUST 9121 354 Fig 12
147. nput Transmission fluid temperature input Overdrive override control switch input System voltage Internal fault in module Governor pressure solenoid output Overdrive solenoid output Converter clutch solenoid output Overdrive override control switch lamp output Internal fault in module 26 Governor pressure sensor offset drift End of code transmission J9321 347 Fig 1 DIAGNOSTIC TROUBLE FLASH CODE CHART 42RE TRANSMISSION THROTTLE VALVE CABLE AND SHIFT CABLE ADJUSTMENT Transmission throttle cable adjustment is important to proper operation This adjustment positions the valve body throttle valve which controls shift speed quality and part throttle downshift sensitivity If cable setting is too short early shifts and slippage between shifts may occur If the setting is too long shifts may be delayed and part throttle down 2 shifts may be very sensitive Refer to the In Vehicle Service section for adjustment procedure Shift cable adjustment is important because it posi tions the valve body manual valve Incorrect adjust ment will cause creep in Neutral premature clutch wear delayed engagement in all gear ranges or a no start in Park or Neutral Proper operation of the park neutral position switch will provide a quick check of linkage adjustment Refer totheln VehideService section for linkage adjustment procedure ROAD TESTING Before r
148. nsmission speed sensor at rear of overdrive unit 8 Remove exhaust system Y pipe for working clear ance 9 Undip wire harnesses from transmission clips 10 Disconnect throttle valve and gearshift cables from levers on valve body manual shaft Move cables aside and secure them to underbody 11 Remove dust cover from transmission converter housing 12 Disconnect and remove starter motor 13 Remove bolts attaching converter to driveplate 14 Disconnect cooler lines at transmission fittings Refer to Service section for procedures 15 Support transmission with transmission jack 16 Remove bolts nuts attaching rear insulator to rear crossmember Then remove rear crossmember 17 Lower transmission for access to converter housing upper bolts and crankshaft position sensor 18 Remove crankshaft position sensor Retain sen sor attaching screws CAUTION The crankshaft position sensor can be damaged if the transmission is removed or installed with the sensor still bolted to the engine block To avoid damage remove the sensor before removing the transmission 19 Remove transmission fill tube and tube O ring seal 20 Remove bolts attaching transmission to engine block 21 Slide transmission away from engine and in stall C clamp on converter housing to hold converter in place 22 Lower transmission and move from under ve hide 23 If transmission is to be serviced remove it f
149. o leaks clogged filter or cooler ines Accumulator piston cracked spring broken or seal worn Clutch or servo malfunction leaking seals or worn plates Overrunning clutch worn not holding slips in 1 only Low fluid level Aerated fluid see Slips in forward Drive Ranges Gearshift linkage out of adjustment 4 Rear band out of adjustment Hydraulic pressure too low due to worn pump worn seal rings clutch or servo seal leakage Worn front clutch leaking rear servo or worn rear band Band linkage binding Overdrive unit direct clutch slipping 1 Add fluid and check for leaks Check for bad pump gasket or seals dirt between pump halves and loose pump bolts or defective O ring at filler tube Adjust as needed Perform hydraulic and air pressure tests to determine cause Inspect and repair as necessary Air pressure check clutch servo operation and repair as required Replace clutch CQ Add fluid and check for leaks See Slips in Forward Drive Ranges Adjust linkage Adjust band Perform hydraulic pressure tests to determine cause Air pressure check clutch servo operation and repair as required 7 Inspect and repair as required Remove and disassemble overdrive unit Repair clutch as needed J9321 336 Condition 42RE TRANSMISSION DIAGNOSIS TRANSMISSION DIAGNOSIS Possible Cause 21 21 Correction NO
150. oad testing be sure the fluid level and all cable adjustments have been checked and adjusted if necessary Observe engine performance during the road test A poorly tuned engine will not allow an accurate analysis 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 band or overrunning clutch problems If the condition is advanced an overhaul may be necessary to restore normal operation A slipping clutch or band can often be determined by comparing which internal units are applied in the various gear ranges The Clutch and Band Application chart Fig 2 provides a basis for analyzing road test results Reverse Drive Range First Second Third Fourth TRANSMISSION CLUTCHES AND BANDS REAR OVERRUN OVERDRIVE BAND CLUTCH CLUTCH 42RE TRANSMISSION DIAGNOSIS 21 9 ANALYZING THE ROAD TEST Refer to the Clutch and Band Application chart Fig 2 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
151. oints Loose axle pinion nut Hydraulic pressure is incorrect Engine transmission mounts worn or damaged Faulty converter lockup clutch if equipped Clutch band or planetary component is damaged Check adjust idle speed Advise owner operator Adjust cable setting Adjust rear band Check engine transmission propeller shaft crossmember and axle bolt torque tighten loose bolts and replace missing bolts Remove propeller shaft and replace U joints Replace nut and check pinion threads before installing new nut replace pinion gear if threads are damaged Check pressures remove overhaul or adjust valve body as needed repair oil pump if necessary Replace as necessary Replace converter and flush cooler and lines before installing new converter Remove disassemble and repair transmission as necessary 1 Engine idle speed too low Low fluid level Gearshift linkage out of adjustment 4 Rear band out of adjustment Valve body filter plugged Oil pump gears worn or damaged or pump body or seal is damaged allowing pump to take in air causing fluid aeration Reaction shaft seal rings worn or broken Governor pressure solenoid valve or electrical circuit fault Low hydraulic pressure Clutch band or servo damaged Torque converter drain down after several days out of service Adjust idle speed 2 Correct
152. olt hole Adjust dutch cam position if necessary 8 Install and tighten overrunning clutch cam bolts to 17 Nem 13 ft Ibs torque Note that clutch cam bolts are shorter than piston retainer bolts 9 Lubricate dutch cam rollers with transmission fluid 10 Install rear band reaction pin Fig 145 Besure pin is fully seated in case 11 Install rear band in case Fig 146 Besuretwin lugs on band are seated against reaction pin 12 Install low reverse drum and check overrun ning dutch operation as follows a Lubricate overrunning dutch race on drum hub with transmission fluid 21 104 TRANSMISSION OVERHAUL 42RE NON THREADED HOLE OVERRUNNING CLUTCH CAM NS OVERRUNNING z CLUTCH CAM SEAT IN CASE ON THREADED HOLE IN CLUTCH CAM ALIGNS HERE BLANK AREA OF SEAT 19121 541 Fig 143 Location Of Blank Area In Clutch Cam Bolt Circle 2 5 IDENTIFYING NON THREADED HOLE IN CAM AND CASE OVERRUNNING ZCLUTCH ASSEMBLY 19121346 Fig 144 Overrunning Clutch Installation 0 Guide drum through rear band c Tilt drum slightly and start race on drum hub into overrunning clutch rollers J9121 348 Fig 146 Rear Band Installation d Press drum rearward and turn it in clockwise direction until drum seats in overrunning clutch Fig 147 Turn drum back and forth Drum should rotate freely in clockwise direction and lock in counterclockwise directi
153. on as viewed from front of case 13 Install new gasket at rear of transmission case Use petroleum jelly to hold gasket in place Be sure to align governor feed holes in gasket with feed passages in case Fig 148 Also install gasket before overdrive piston retainer Center hole in gasket is smaller than retainer and cannot be installed over retainer 14 Position overdrive piston retainer on transmis sion case and align bolt holes in retainer gasket Ss ce LOW REVERSE ES gt O A M O BE SUR GOVERNOR TUBE FEED HOLES IN CASE AND A GASKET ARE ALIGNED J9121 349 Fig 148 Installing Aligning Case Gasket and case Fig 149 Then install and tighten retainer bolts to 17 Nem 13 ft 165 torque 15 Install snap ring that secures low reverse drum to hub of piston retainer Fig 150 16 Install rear band lever and pivot pin Fig 151 Align lever with pin bores in case and push pivot pin into place 17 Install planetary geartrain assembly Fig 152 18 Install thrust plate on intermediate shaft hub Fig 153 Use petroleum jelly to hold thrust plate in place 19 Check seal ring on rear dutch retainer hub Fig 49 and seal rings on input shaft Fig 154 Verify that diagonal cut ends of teflon seal rings are properly TRANSMISSION OVERHAUL 42RE S c gt 5 PISTON 2222 21 105
154. on transmission Tighten pan bolts to 17 Nem 150 in 165 torque 9 Lower vehicle and refill transmission with rec ommended fluid ADJUSTING REAR BAND LEVER LOCKNUT J9321 382 Fig 9 Rear Band Adjusting Screw Location 2 3 Nem 10 12 Nem SPEEDOMETER ADAPTER IN VEHICLE SERVICE 42RE 21 47 SPEEDOMETER SERVICE Rear axle gear ratio and tire size determine speed ometer pinion requirements If the pinion must be replaced refer to the parts catalogue information for the correct part SPEEDOMETER ASSEMBLY REMOVAL 1 Raise vehicle 2 Disconnect wires from vehicle speed sensor 3 Remove adapter damp and screw Fig 10 4 Remove speed sensor and speedometer adapter as assembly 5 Remove speed sensor retaining screw and re move sensor from adapter 6 Remove speedometer pinion from adapter 7 Inspect sensor and adapter O rings Fig 9 Re move and discard O rings if worn or damaged 8 Inspect terminal pins in speed sensor Clean pins with Mopar electrical spray cleaner if dirty or oxidized Replace sensor if faulty or pins are loose severely corroded or damaged SPEEDOMETER INSTALLATION AND INDEX ING 1 Thoroughly dean adapter flange and adapter mounting surface in housing Surfaces must be dean for proper adapter alignment and speedometer opera tion 2 Install new O rings on speed sensor and speed ometer adapter if necessary Fig 10 3 Lubricate
155. ond curve is used when fluid temperature is at or above 0 5 C 31 F during normal city or highway driving A third curve is used during wide open throttle operation The fourth curve is used when driving with the transfer case in low range TRANSMISSION SHIFTING Shift valve operation in 42RE transmissions with the electronic governor mechanism is basically unchanged The 1 2 and 2 3 upshift sequence occurs exactly the same as in non electronic governor transmission The valve body shift valves are still moved by a combination of throttle and governor pressure The only real difference is that governor pressure is gener ated by electrical components instead of a mechanical valve and weight assembly AUTOMATIC TRANSMISSION 42RE 21 5 The conditions under which a shift to fourth will not occur also remain the same These being shift to third not yet completed overdrive switch is in OFF position throttle is at 3 4 to wide open position vehicle speed too low for 3 4 shift to occur transmission fluid temperature is below 1 C 30 F or above 121 C 250 F CONVERTER CLUTCH ENGAGEMENT 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 the normal position the clutch will engage after the shift to fourth gear and above approximately 72 km h
156. onnect battery negative cable 2 Raise vehicle on hoist 3 Remove exhaust Y pipe catalytic converter and tailpipe 4 Mark propeller shaft and U joint for alignment reference Fig 1 5 Disconnect and remove propeller shaft 6 Disconnect vehicle speed sensor and transmis sion speed sensor wires 7 Support transmission with adjustable jack stand and wood block 8 Remove nuts and bolts attaching transmission mount to center crossmember 9 Remove nuts and bolts attaching crossmember to frame rails 10 Rotate crossmember diagonally to clear frame rails and remove crossmember Z ______ TRANSMISSION OVERDRIVE REMOVAL AND INSTALLATION 42RE 11 Support overdrive unit with transmission jack 12 Remove bolts attaching overdrive unit to trans mission Fig 8 CAUTION The overdrive unit must be fully supported during removal This is necessary to prevent damaging the intermediate shaft Do not allow the shaft to support the entire weight of the overdrive unit 13 Carefully slide overdrive unit off intermediate shaft Do not tilt overdrive unit during removal Keep it as level as possible a If overdrive unit does not require service im mediately insert Alignment Tool 6227 2 in splines of planetary gear and overrunning clutch Fig 9 If misalignment occurs over drive unit may have to be disassembled in order to realign splines b If overdrive unit requires service refer to Over dr
157. overhaul Air pressure testing requires that the oil pan and valve body be removed from the transmission The servo and clutch apply passages are shown in Figure 5 FRONT CLUTCH AIR TEST Place one or two fingers on the clutch housing and apply air pressure through front dutch apply passage Fig 5 Piston movement can be felt and a soft thud heard as the clutch applies FRONT SERVO APPLY REAR SERVO APPLY FRONT SERVO RELEASE LINE PRESSURE ACCUMULATOR PRESSURE Alez ON TO TORQUE GOVERNOR JCONVERTOR PRESSURE cy FROM TORQUE CONVERTER lt gt GOVERNOR TO COOLER CRH252 Fig 5 Air Pressure Test Passages 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 thud heard as the clutch applies FRONT SERVO AIR TEST Apply air pressure to the front servo apply passage The servo rod should extend and cause the band to tighten around the drum Spring tension should re lease 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 tension should re lease the servo when air pressure is removed CONVERTER HOUSING FLUID LEAK DIAGNOSIS When diagnosing converter housing fluid leaks two items must be establishe
158. pressure is developed and controlled elec tronically in the 42RE transmission Components used for development and control of governor pressure in dude governor body new design valve body transfer plate governor pressure solenoid valve governor pressure sensor fluid temperature thermister transmission speed sensor throttle position sensor transmission control module TCM Governor Pressure Solenoid Valve The solenoid valve generates the governor pressure needed for upshifts and downshifts It is an electro hydraulic device and is located in the governor body on the valve body transfer plate Fig 3 The inlet side of the solenoid valve is exposed to normal transmission line pressure The outlet side of the valve leads to the valve body governor circuit The solenoid valve regulates line pressure to produce governor pressure The average current supplied to the solenoid controls governor pressure One amp current produces zero kPa psi governor pressure Zero amps sets the maximum governor pressure The transmission control module TCM supplies electrical power to the solenoid valve Operating volt ageis 12 volts DC andis provided through the battery terminal on the module The solenoid is polarity sensitive The TCM ener gizes the solenoid by grounding it through the power ground terminal on the transmission control module Governor Pressure Sensor The governor pressure sensor measures output pres sure of the governor pr
159. psi at 1 2 to 3 4 throttle 5 0H x 3 5W Fig 4 Pressure Test Analysis Chart CONVERTER STALL TEST Stall testing involves determining maximum engine rpm obtainable at full throttle with the rear wheels locked and the transmission in D range This test checks the holding ability of the converter overrunning clutch and both of the transmission clutches When stall testing is completed refer to the Stall Speed Specifications chart and Stall Speed Diagnosis guides 21 12 42 TRANSMISSION DIAGNOSIS INDICATION Pump and regulator valve OK TEST CONDITION Line pressure OK during any one test Leakage in rear clutch area servo clutch seals governor support seal rings Line Pressure OK in R but low in D 2 1 Overdrive clutch piston seal or check ball problem Pressure Low in D Fourth Gear Range Pressure OK in 1 2 but Leakage in front clutch area servo low in D3 and R clutch seals retainer bore pump seal rings Pressure OK in 2 butlow Leakage in rear servo inRand 1 Leakage in servo broken servo Front servo pressure low i ring or cracked servo piston In Clogged filter stuck regulator valve worn or faulty pump plugged fluid cooler Pressure low in all positions Governor pressure solenoid Governor pressure too high valve faulty at idle speed Faulty governor pressure solenoid transmission
160. r bolts 27 Remove bolts attaching transmission converter housing to engine Note that some bolts may be acces sible only from front engine side of housing 28 Move transmission rearward until clear of en gine block dowels On some models part of hem flange joining vehicle cab and dash panel may interfere with transmission removal Peen this part of flange over with a mallet if necessary 29 Secure torque converter in housing with small C clamp 30 Lower transmission and remove it from under vehicle 31 Remove C clamp and remove converter from transmission Place converter on workbench for inspec tion or reassembly Cover converter hub with clean lint free cloth 32 Oil pump converter and driveplate can now be serviced if necessary Refer to information in this section OIL PUMP SEAL REPLACEMENT The pump oil seal can be replaced without removing the pump and reaction shaft support assembly from the transmission case Seal Removal Remove the seal with Special Tool C 3861 Fig 2 To use the remover tool First start the tool into the seal by hand Next thread the tool into the seal as far as it will go Use a wrench on the tool hex to turn the tool Continue tightening until all the tool threads firmly grip the metal part of the seal Then tighten the tool puller screw to withdraw the seal from the pump body x PUMP SEAL e 82RH 42RH OR C 3860 A 36RH 46RH 29321 180 Fig 2 Oil Pump Seal R
161. r gears if necessary pump 5 Transmission internal component damaged 5 Remove and disassemble transmission repair or replace failed components as needed 6 Remove disassemble and inspect valve body replace valve body as assembly if any valve or bore is damaged clean and essen ble correctly if all parts are in good condition 6 Valve body malfunction seized valve damaged manual lever valve body screws loose or overtightened causing distortion and bind J9121 443 21 20 Condition 42RE TRANSMISSION DIAGNOSIS TRANSMISSION DIAGNOSIS Possible Cause Correction MOVES IN 2ND OR 3RD GEAR ABRUPTLY DOWNSHIFTS TO LOW Governor circuit fault Valve body malfunction SLIPS IN LOW GEAR D ONLY BUT NOTIN 1 POSITION Transmission overrunning clutch faulty not holding 1 Test governor components with DRB II scan tool 2 Remove clean and inspect look for stuck 1 2 valve or governor plug 1 Replace overrunning clutch SLIPS FORWARD DRIVE RANGES SLIPS IN REVERSE ONLY Low fluid level Air in fluid fluid is foamy full of bubbles shifts are spongy caused by air getting into pump suction passages Gearshift linkage or throttle cable out of adjustment low hydraulic pressure due to worn pump incorrect control pressure adjustment valve body warpage or malfunction sticking governer leaking seal rings clutch seals a ung serv
162. r or cooler lines plugged Air in fluid aerated Oil filter clogged Rear servo piston or seal failure Valve body switch valve sticking Speedometer adapter Pan gasket Filler tube where tube enters case Fluid lines and fittings Valve body manual lever shaft seal Pressure port plug loose Rear bearing access plate Gasket damaged or bolts are loose Adapter extension gasket damaged Neutral switch Converter housing area Cooler line fittings and hoses Pump seal Torque converter Drive fluid to correct level remove neutral switch and drain through switch hole with suction gun Inspect and clear blockage Flush cooler and lines See Slips In Forward Drive Ranges Replace filter determine the reason for clogged condition and repair Check hydraulic pressure of servo in reverse will register low or fluctuate rapidly Repair replace servo piston and seal Replace case if servo bore is damaged Remove and clean valve Replace both adapter seals Tighten pan screws to 150 inch pounds if leaks persist replace gasket do not overtighten screws Replace O ring seal Tighten fittings if leaks persist replace fittings and lines if necessary Replace shaft seal Tighten to correct torque replace plug if leak persists Replace gasket Replace bolts or gasket or tighten bolts Replace gasket Replace switch and gasket Check for leaks a
163. r washer if worn or damaged Check condition of the seal rings on the input shaft and clutch retainer hub Replace the seal rings only if obviously damaged The input shaft front seal ring is teflon with chamfered ends Therear 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 REAR CLUTCH ASSEMBLY 1 Soak clutch discs in transmission fluid 2 Install new seal rings on clutch retainer hub and input shaft Figs 63 and 64 a Be sure clutch hub retainer seal ring is fully seated in groove Fig 63 Ring must not be twisted or distorted 2 ourur INPUT SHAFT SHAFT SNAP THRUST WASHER METAL CLUTCH PISTON REAR CLUTCH PISTON PISTON SPRING WAVE 1 SPRING REAR CLUTCH SNAP RING PLIERS 9121 149 Fig 61 Removing Installing Input Shaft Snap Ring b Note that input shaft front seal ring is teflon and rear seal ring is metal Fig 64 Be sure cham fered ends of teflon ring are properly joined and that ends of rear ring are securely hooked together c Lubricate retainer and shaft seal rings with light coat of petroleum jelly after installation 3 Lubricate splined end of input shaft and dutch retainer with transmission fluid Then press input shaft into retainer Fig 65 4 Install input shaft retaining ring Fig 61 TRANSMISSION OVERHAUL 42RE 21 79 REAR INPUT I CLUTCH CLUTCH RETAINER
164. return line and continue short air pulses until all fluid is deared from cooler and lines 6 Pump one quart of fresh automatic transmission fluid through cooler and lines before reconnecting lines TESTING COOLER FLUID FLOW Cooler flow is tested by measuring the amount of fluid pumped through the cooler in a specified time by the transmission oil pump 1 Disconnect cooler return rear line at transmis sion and place it in one quart test container 2 Add extra quart of fluid to transmission 3 Use stopwatch to check test time 4 Shift into Neutral 5 Start and run engine at curb idle speed and note cooler flow Approximately 1 quart 0 9 liter of fluid should flow into test container in 20 seconds ITEM _____ TORQUE 2 4 Nem 18 35 IN LBS 18 23 N m 159 203 IN LBS RADIATOR RADIATOR AND CONDENSER ON MODELS WITH AIR CONDITIONING RETURN AUXILIARY COOLER J9321 240 Fig 26 Transmission Cooler Line Identification 21 54 IN VEHICLE SERVICE 42RE 6 If fluid flow is intermittent or flows less than one quart in 20 seconds or fails to allow flow at all cooler is plugged and should be replaced MAIN COOLER REPLACEMENT The main transmission cooler is located in the radia tor lower tank The cooler is not a serviceable compo nent If the cooler is damaged in any way the radiator will have to be replaced AUXILIARY COOLER REPLACEMENT 1 Remove grille and air conditioning
165. rive control switch test 6 Road test 7 Stall test 8 Hydraulic pressure test 9 Air pressure tests 10 Analyze test results and consult diagnosis charts PRELIMINARY DIAGNOSIS Two basic procedures are required One procedure for vehicles that are driveable and an alternate procedure for disabled vehicles will not back up or move for ward VEHICLE IS DRIVEABLE 1 Check for TCM fault codes with DRB 1 scan tool or with fault flash codes at lamp in overdrive Off switch 2 Check fluid level and condition 3 Adjust throttle and gearshift linkage 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 problems were noted during road test 7 Perform air pressure test to check clutch band operation VEHICLE IS DISABLED 1 Check fluid level and condition 2 Check for broken disconnected throttle valve cable or lever 3 Check for cracked leaking cooler lines or loose missing pressure port plugs 4 Raise vehicle start engine shift transmission into gear and note following a If propeller shafts turn but wheels do not problem is with differential or axle shafts b If propeller shafts do not turn and trans
166. rod to displace into a cavity just above the pawl sprag during instal lation Make sure the rod is actually engaged in the pawl and has not displaced into this cavity If the rod enters the cavity during installation it will become bent when the overdrive bolts are tightened The rod will then have to be replaced because it is not repairable 21 50 IN VEHICLE SERVICE 42RE 15 16 SOCKET RH272 Fig 16 Manual Lever Shaft Seal Installation CG RINGS Fig 17 Accumulator Piston Components 9 Install accumulator springs and piston in case Then swing valve body over piston and outer spring to hold it in place 10 Align accumulator piston and outer spring manual lever shaft and electrical connector in case Then seat valve body on case and install one or two bolts to hold valve body in place 11 Tighten valve body bolts alternately and evenly to 11 Nem 100 in 165 torque 12 Install new fluid filter on valve body Tighten filter screws to 4 Nem 35 in 105 torque 13 Install and connect park neutral position switch in case 14 Install throttle and gearshift levers on valve body manual lever shaft 15 Check and adjust front and rear bands if neces sary 16 Connect valve body overdrive and converter clutch solenoid wires to case connector 17 Install oil pan and new gasket Tighten pan bolts to 17 Nem 13 ft Ibs torque 18 Lower vehicle and fill transmission with M opar ATF Plus type
167. rom jack and position it on bench TRANSMISSION REMOVAL 4 WHEEL DRIVE 1 Raise vehicle on hoist 2 Remove skid plate if equipped 3 Mark front and rear propeller shafts and U joints for alignment reference Fig 1 4 Disconnect and remove both propeller shafts 5 Disconnect vehicle speed sensor and transmis sion output shaft speed sensor wires 6 Disconnect electrical wires from clips on trans mission and transfer case 7 Disconnect transfer case shift linkage at transfer case range lever Then remove linkage bracket bolts and remove linkage and bracket from transfer case Move linkage aside for clearance 8 Remove nuts attaching transfer case to overdrive unit gear case 9 Removetransfer case Support transfer case with transmission jack Secure transfer case to jack with safety chains Then move transfer case rearward and off transmission 10 Remove transfer case from transmission jack and place transfer case on bench 11 Support transmission with transmission jack 21 56 INDEX SHAFT TO Fig 1 Marking Propeller Shaft And Yoke For Align ment Reference 12 Remove nuts and bolts attaching transmission mount to crossmember 13 Remove bolts and nuts attaching crossmember to frame rails 14 Rotate crossmember diagonally to clear frame rails and remove crossmember 15 Disconnect exhaust pipes at manifold and at converter and or muffler connections as needed Then remove Y pipe from v
168. rovides throttle position input signals to both the transmission control module and powertrain controller This input signal is used to determine overdrive and converter clutch shift schedule and to select the proper governor curve TRANSMISSION OUTPUT SHAFT SPEED SENSOR SEAL J9321 411 Fig 7 Transmission Speed Sensor Transmission Control Module TCM The TCM controls operation of the converter clutch overdrive dutch and governor pressure solenoid The control module determines transmission shift points based on input signals from the transmission thermistor transmission output shaft speed sensor crankshaft position sensor vehicle speed sensor and throttle position sensor Operating voltage is supplied through the battery terminal on the control module The ignition voltage signal is supplied through a terminal on the ABS control module The DRB scan tool be used to check operation of the control module and transmission electrical com ponents The diagnostic connector for the scan tool is located under the driver side of the instrument panel The connecor has a 6 way terminal and is blue in color GOVERNOR PRESSURE CURVES 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 tempera ture is at or below 1 C 30 F A sec
169. s Raise bezel and console for access to cable 4 Pull cable lock button up to release cable Fig 6 5 Pull cable forward Then release cable and press cable lock button down until it snaps in place 6 Check cable adjustment as follows a Place shift lever in Park b Check shift handle release button and ignition lock cylinder operation Release button should be in released out position and lock cylinder should ro tate freely from Off to Lock c Next place shift lever in D or R position and check lock cylinder operation again Cylinder should not rotate from Off to Lock position d Check shift lever operation Shifting out of Park position should only be possible when ignition lock cylinder is in Off Run or Start positions Shift lever should be locked in when lock cylinder is in Accessory and Lock positions PARK INTERLOCK INTERLOCK CABLE CABLE LOCK BUTTON SHIFT LEVER AND HOUSING ASSEMBLY HOUSING MOUNTING J9321 416 Fig 6 Shift And Park Interlock Cables FRONT BAND ADJUSTMENT The front band adjusting screw is located on the driver side of the transmission case above the manual valve and throttle valve levers ADJ USTMENT PROCEDURE 1 Raise vehicle 2 Loosen band adjusting screw locknut Then back locknut off 4 5 turns Be sure adjusting screw turns freely in case Lubricate screw threads if necessary 5 16 SOCKET 2 3 Tighten band adjusting screw to 8 72 in
170. s Then install one or twotransmission attaching bolts to hold transmission in place Fig 6 CAUTION It is essential that correct length bolis be used to attach the converter to the driveplate Bolts that are too long will damage the modulated clutch surfaces in the converter If new bolts are required use the bolts specified in the parts catalogue only 12 Verify converter bolt length Bolt measurement is from bottom underside of bolt head to end of bolt threads e On 9 5 in 3 lug converter bolts should be 11 7 mm 0 46 in long 21 58 Fig 5 Torque Converter And Driveplate Markings e On 10 75 in 4 lug converter bolts should be 11 2 mm 0 44 in long 13 Install torque converter bolts Tighten bolts as follows CONVERTER ENGINE OIL PAN TRANSMISSION CONVERTER HOUSING DRIVEPLATE 9 2 ls ow ITEM TORQUE A 50 64 N m 37 47 ft lbs 30 35 N m 22 26 ft Ibs 11 20 N m 96 180 in lbs D 47 61 N m 35 40 ft lbs TRANSMISSION OVERDRIVE REM OVAL AND INSTALLATION 42RE VU ERTER une 2 On models with 9 5 in 3 lug converter tighten bolts to 54 Nem 40 ft 105 e On models with 10 75 in 4 lug converter tighten bolts to 31 Nem 270 in Ibs 14 Install and tighten remaining transmission at taching bolts Fig 6 15 Install and connect crankshaft position sensor 16 Install dust cover on transmiss
171. s and tighten plug to 17 150 in Ibs torque 7 Adjust front band 8 Lubricate pump seal and converter hub with transmission fluid or petroleum jelly and install con verter 21 16 42RE TRANSMISSION DIAGNOSIS 9 Install transmission and converter housing dust shield 10 Lower vehicle DIAGNOSIS AND HYDRAULIC FLOW CHARTS The diagnosis charts provide additional reference when diagnosing a transmission fault The charts provide general information on a variety of transmis sion overdrive unit and torque converter clutch fault conditions The hydraulic flow charts outline fluid flow and hydraulic circuitry Circuit flow is outlined for all gear ranges including park and neutral Circuit flow for converter clutch application in fourth gear is also provided SERVICE peer i M f whenever a fault is suspected Replace the module only id is indi fault occurred ICM Location The TCM is located on the driver side of the dash ible f h ifi Strument panel Fig 15 TCM Mountin Ihe module has integral mounting studs for attach ment to th h nel A retainin late and tw locknuts secure the module to the dash Fig 15 Although the module is inside the vehicle the retain 17 side of the dash panel TCM Removal 1 In engine compartment remove module locknuts nd r ve module retaining plate Locknuts an retaining plate are on driv m partment near br
172. s 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 clear 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 compo nents and circulate throughout the transmission after assembly A sufficient quantity of lint can block fluid passages 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 AND OVERDRIVE PISTON RETAINER INSPECTION AND OVERHAUL If the overrunning dutch and cam came out with the low reverse drum remove the cam and clutch from the drum as follows Thread two dutch cam bolts into the cam Then lift the dutch and cam out of the drum with the bolts Fig 32 Rotate the cam back and forth to ease removal if necessary CLEANING AND INSPECTION Clean the clutch rollers springs and retainer clutch cam low reverse drum and overdrive piston retainer in solvent Air dry the rollers after cleaning Inspect
173. seals LOWER HOUSING TRANSMISSION OVERHAUL 42RE 21 95 3 4 ACCUMULATOR HOUSING ACCUMULATOR PISTON O RING SEALS PISTON SPRING COVER PLATE AND SCREWS 29321 456 Fig 125 3 4 Accumulator Housing Components 3 4 ACCUMULATOR PISTON AND SPRING 3 4 ACCUMULATOR HOUSING 3 4 TIMING THROTTLE PLUG 3 4 SHIFT VALVE AND SPRING VALVE AND SPRING SPRING TIMING ER VALVE CONVERTER RETAIN COVER CLUTCH VALVE AND SPRING OVERDRIVE CONVERTER CLUTCH SOLENOID TIMING VALVE AND SPRING CONVERTER CLUTCH SOLENOID SOLENOID GASKET HARNESS ines OVERDRIVE CONNECTOR 9321 438 SEPARATOR PLATE Fig 124 Location Of 3 4 Shift Valves And Springs In Lower Housing 21 96 TRANSMISSION OVERHAUL 42RE VALVE BODY CLEANING AND INSPECTION Clean the valve housings valves plugs springs and separator plates with a standard parts cleaning solu tion 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 the 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 will adhere to the valve body components Lint will interfere with valve operation and may clog fil ters
174. sensor and adapter O rings with trans mission fluid ADAPTER O RING SPEEDOMETER PINION ADAPTER CLAMP SL 2 VEHICLE SPEED Fig 10 Speedometer Components 21 48 IN VEHICLE SERVICE 42RE 4 Install vehicle speed sensor in speedometer adapter Tighten sensor attaching screw to 2 3 Nem 15 27 in 165 torque 5 Install speedometer pinion in adapter 6 Count number of teeth on speedometer pinion Do this before installing assembly in housing Then lubricate pinion teeth with transmission fluid 7 Note index numbers on adapter body Fig 11 These numbers will correspond to number of teeth on pinion 8 Install speedometer assembly in housing 9 Rotate adapter until required range numbers are at o dock position Be sure range index numbers correspond to number of teeth on pinion gear 10 Install speedometer adapter clamp and retain ing screw Tighten clamp screw to 10 12 Nem 90 110 in lbs torque 11 Connect wires to vehicle speed sensor 12 Lower vehicle and top off transmission fluid level if necessary SPEEDOMETER INDEX ADAPTER NUMBER LOCATION 9321 386 Fig 11 Location Of Index Numbers On Speedometer Adapter PARK NEUTRAL POSITION SWITCH The center terminal of the switch is the starter circuit terminal It provides the ground for the starter solenoid circuit through the selector lever in Park and Neutral positions only The outer terminals on the switch are for the backup
175. sly with the throttle body lever from the idle 2 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 AD JUSTMENT 1 Turn ignition key to OFF position 2 Remove air deaner 3 Verify that lever on throttle body is at curb idle position Then verify that transmission throttle lever Fig 3 is also at idle fully forward position 4 Slide cable off attachment stud on throttle body lever Fig 4 5 Compare position of cable end to attachment stud on throttle body lever Fig 4 a Cable end and attachment stud should be aligned or centered on one another to within 1 mm 0 039 in in either direction b If cable end and attachment stud are mis aligned off center cable will have to be adjusted as described in Throttle Valve Cable Adjustment proce dure 6 Reconnect cable end to attachment stud Then with aid of a helper observe movement of transmission throttle lever and lever on throttle body a If both levers move simultaneously from idle to half throttle and back to idle position adjustment is correct 6 If transmission throttle lever moves ahead of or lags behind throttle body lever cable adjustment will be necessary Or if throttle body lever prevents transmission lever from returning to closed position cable adjustment will be necessary
176. solenoid failure Sensor or fluid temperature thermister fault Overdrive piston seal failure 9 Wrong overdrive piston spacer Low hydraulic pressure Transmission fluid overheat over 260 F Turn control switch to ON position Replace switch if shorted or open and repair loose or damaged wires Check wires connections with 12V test lamp and voltmeter repair damaged or loose wires connections as necessary Remove disassemble clean valve body thoroughly Verify solenoid failure with test lamp and replace solenoid Test with DRB scan tool ohmmeter Replace sensor or thermister as needed Replace both seals Remove unit check end play and install correct spacer Pressure test transmission to determine cause See overheat information in transmission diagnosis charts SLIPS IN OVERDRIVE FOURTH GEAR Low fluid level Overdrive piston or seal malfunction Overdrive clutch pack worn 4 3 4 shift valve timing valve or accumulator malfunction Overdrive piston retainer bleed orifice blown ovt Overdrive unit thrust bearing failure 1 Add fluid and check for leaks Remove overdrive unit replace piston seals if worn replace piston if damaged if piston retainer is damaged it will be necessary to remove and disassemble the transmission Remove overdrive unit and rebuild clutch pack 4 Remove and overhaul valve body Replace
177. ssembly Overhaul section The only replaceable valve body components are manual lever manual lever washer seal E clip and shaft seal manual lever detent ball throttle lever fluid filter switch valve and spring pressure adjusting screw bracket governor pressure solenoid governor pressure sensor e converter dutch overdrive solenoid assembly and harness e governor housing gasket e solenoid case connector O rings 2 The remaining valve body components are serviced only as part of a complete valve body assembly VALVE BODY REMOVAL 1 Shift transmission into Neutral 2 Raise vehicle 3 Remove gearshift and throttle levers from shaft of valve body manual lever 4 Disconnect wires at park neutral position switch 5 Disconnect wires at park neutral position switch and solenoid case connector Fig 13 SOLENOID pm CASE CONNECTOR PARK NEUT POSITION SWITCH ps CONNECTOR TERMINAL J9321 387 Fig 13 Transmission Case Electrical Connector Lo cations 6 Position drain pan under transmission oil pan 7 Remove transmission oil pan and gasket 8 Remove fluid filter from valve bogy 9 Remove bolts attaching valve body to transmis sion case 10 Lower valve body enough to remove accumula tor piston and springs 11 Work manual lever shaft and electrical connec tor out of transmission case Then lower valve body rotate it away from case pull park rod out of sprag and remo
178. t Replace any insert that is cut torn or damaged in any way Replace the transmission fitting as an assembly if the fitting body is damaged Replace the cooler line as an assembly if the fitting swedged into the cooler line hose is damaged IN VEHICLE SERVICE 42RE 21 51 RETAINER CLIP Fig 21 Removing Retainer Clip To Release Cooler Line RECONNECTING COOLER LINES TYPE FIT TING 1 If transmission or radiator fittings will be re placed apply Mopar Lock N Seal or Loctite 242 to fitting threads before installation 2 Wipe off fittings and cooler lines with lint free cloth or shop towels 2 Install plastic inserts in fittings Use new inserts if originals were damaged an any way or if doubt exists about insert condition 3 Install new clips on fittings as follows a Start retainer clip in slot on one side of fitting Fig 22 b Swing retainer clip across and over fitting Then carefully seat clip in slot on opposite side of fitting Fig 23 It is not necessary to overspread a new clip in order to install it Clip will easily slip into opposite fitting slot if care is exer cised CAUTION Do not attempt to salvage a retainer clip if it becomes bent or distorted A salvaged clip will not properly secure the cooler line in the fitting 4 Wipe end of each cooler line clean with lint free cloth or shop towel 5 Start cooler line into fitting Then push cooler line inward until wire retainer cl
179. t 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 rign 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 Replace fittings and hoses Replace seal Replace converter J9321 339 21 24 42RE TRANSMISSION DIAGNOSIS Z TRANSMISSION DIAGNOSIS OVERHEAT DURING 1 Vehicle not properly equipped for trailer towing Be sure vehicle is equipped with recommended COMMERCIAL OPERATION commercial use optional components i e HD springs OR WHILE TRAILER TOWING transmission axle larger CID engine auxiliary FLUID DARK AND BURNED cooler correct axle ratio If vehicle is not so WITH SOME SLUDGE equipped it should not be used for severe FORMATION service operation 2 Drain fluid change filter and install auxiliary 2 Vehicle not equipped with auxiliary fluid cooler cooler 3 Cut down on idling time shift into neutral every so often and run engine at 1000 rpm to help circulate fluid through cooler 3 Extensive idling time or operation in heavy traffic in hot weather 4 Be sure vehicle is properly equipped to handle load do not tow Class Ill type loads
180. tal lation Make sure the rod is actually engaged in the pawl and ha not displaced into this case cavity If the rod enters the cavity during installation it will be come bent when the overdrive bolts are tightened If this occurs the rod will have to be replaced because it is not repairable c Work overdrive unit forward on intermediate shaft until seated against transmission case If unit is not fully seated tighten overdrive bolts to draw it up against transmission case 12 Apply Mopar Lock N Seal or Loctite 242 to threads of overdrive attaching bolts 13 Install and tighten overdrive unit attaching bolts to 34 Nem 25 ft Ibs 14 Install transfer case Tighten attaching nuts to 41 Nem 30 ft Ibs torque 15 Connect transmission throttle valve and gear shift cables 16 Install crossmember and rear mount 17 Connect all necessary electrical wires 18 Install and index speedometer adapter and pin ion Fig 13 Refer to In Vehicle Service section for indexing procedure 19 Align and connect propeller shaft Tighten U joint damp bolts to 19 Nem 170 in Ibs torque 20 Install exhaust system components 21 Lower vehide 22 Connect battery negative cable 23 Check and adjust transmission shift and throttle valve cables if necessary 24 Check and adjust transmission fluid level Use Mopar ATF Plus type 7176 fluid 21 64 TRANSMISSION OVERHAUL 42RE TRANSMISSION OVERHAUL 42RE INDEX
181. temperature exceeds 126 C 260 F the transmission control module will cause a 4 3 downshift and engage the converter clutch Engagement is ac cording to the third gear converter clutch engagement schedule The overdrive OFF lamp in the instrument panel also illuminates 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 The thermistor is mounted on the underside of the converter clutch solenoid Fig 6 It is immersed in transmission fluid at all times OVERDRIVE SOLENOID CONVERTER CLUTCH SOLENOID THERMISTOR LOCATED ON UNDERSIDE OF THIS SOLENOID J9321 412 Fig 6 Converter Clutch Solenoid And Thermistor Location Transmission Speed Sensor The speed sensor Fig 7 is located in the overdrive gear case The sensor is positioned over the park gear and monitors transmission output shaft rotating speed The sensor used with the 42RE transmission is the same as is used in Chrysler 41TE and 42LE front drive automatic transmissions 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 transmission control module for processing The vehicle speed sensor also serves as backup to the transmission speed sensor Signals from this sensor are shared with the powertrain control module Throttle Position Sensor TPS The TPS p
182. the 42RE are provided by the clutches bands overrunning clutch and planetary gear sets in the transmission unit Fourth gear range is provided by the overdrive unit which contains an overdrive clutch direct clutch plan etary gear set and overrunning clutch The overdrive clutch is applied in fourth gear only The direct clutch is applied in all ranges except fourth gear The 42RE valve body transfer plate is completely new It is redesigned to accept a new governor body and different hydraulic circuitry The governor pressure solenoid valve and sensor are mounted in this body The new transfer plate channels line pressure to the solenoid valve through the governor body It also chan nels governor pressure from the solenoid valve to the governor circuit It is the solenoid valve that develops necessary governor pressure The 42RE overdrive unit is quite different from previous overdrive units It is shorter in length as a result of eliminating the mechanical governor mecha nism governor tubes and governor support AUTOMATIC TRANSMISSION 42RE 21 2 IPPON x uoissiusuejJ 1 LOr 1ZE6F 5 HDLNID avid 1 3AISQN3AO NOISId AlaWw3ssv dari Aaoa 3AIVA uvio AMNVI3NV Id INOJ HOLNTD
183. the drum Replace the plates or drum if binding occurs Check condition of the annulus gear direct clutch hub clutch drum and clutch spring Fig 32 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 in good condition The clutch plates and discs should slide freely in these components Inspect the thrust bearings and spring plate Fig 33 Replace the plate if worn or scored Replace the bearings if rough noisy brinnelled or worn Inspect the planetary gear assembly and the sun gear and bushings Fig 34 If either the sun gear or the bushings are damaged replace the gear and bush ings as an assembly The gear and bushings are not serviced separately The planetary carrier and pinions must be in good condition Also be sure the pinion pins are secure and in good condition Replace the carrier if worn or dam aged Inspect the overrunning clutch and race The 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 Check the machined surfaces on the output shaft These surfaces should be clean and smooth Very minor 2 nicks or scratches can be polished down with crocus cloth Replace the shaft if worn severely scored or damaged in any way Inspect the output shaft bushings Fig 35 The small bushing is the
184. 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 overrun ning clutch is faulty Similarly if slippage occurs in any two forward gears the rear clutch is slipping Applying the same method of analysis note that the front and rear clutches are applied simultaneously only in D range third and fourth gear If the transmis sion slips in third gear either the front clutch or the rear clutch is slipping If the transmission slips in fourth gear but not in third gear theoverdrive dutch is slipping By selecting 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 clutch is slipping If slippage occurs during the 3 4 shift or only in fourth gear the overdrive dutch is slipping Similarly if the direct dutch were to fail the transmission would lose both reverse gear and overrun nn n J9221 22 Fig 2 Clutch And Band Application Chart 21 10 42RE TRANSMISSION DIAGNOSIS braking in 2 position manual second gear If the transmission slips in any other two forward gears the transmission rear clutch is probably slipping f the transmission will not shift to fourth gear the control switch overdri
185. transmission fluid or petroleum jelly 3 Position tube behind tube brace 4 Start tube in lower housing port first Then swing tube downward and work opposite end of tube into upper housing port 5 Seat both ends of tube once they are in position Note that tube brace may be bent slightly to ease installation and secure tube lower connection TUBE BRACE LOWER 49321 443 Fig 133 Boost Valve Tube Installation 3 4 Accumulator Installation 1 Position converter clutch valve and 3 4 shift valve springs in housing Fig 134 2 Loosely attach accumulator housing with right side screw Fig 134 Install only one screw at this time as accumulator must befree to pivot upward for ease of installation 3 Position plug on end of converter clutch valve spring Then compress and hold springs and plug in place with fingers of one hand 4 Swing accumulator housing upward over valve springs and plug 5 Hold accumulator housing firmly in place and install remaining two attaching screws Be sure springs and dutch valve plug are properly seated Fig 135 6 Attach solenoid case connector to 3 4 accumula tor with shoulder type screw Connector has small locating tang that fits in dimple at top of accumulator housing Fig 95 Seat tangin dimple beforetightening connector screw 7 Install solenoid assembly and gasket Tighten solenoid attaching screws to 8 Nem 72 in 165 torque 8 Verify that solenoid wires
186. uminum stock WELD OR BRAZE 1 8 SEAL THIS END AIR TIGHT POLISH OUTSIDE 1 3 4 OF OPEN END FOR 1 498 THIS DISTANCE ON TUBE BREAK EDGE 1 16 MIN MATERIAL 1 1 2 INCH O D THIN WALLED STEEL TUBING AND 1 8 INCH STEEL DISC RN780 Fig 10 Converter Hub Seal Cup 15 32 INCH DRILL 4 HOLES MATERIAL 1 4 INCH STEEL STOCK 1 1 4 INCH WIDE RN781 Fig 11 Seal Cup Retaining Strap 2 13 32 DRILL 2 HOLES WELD OR BRAZE 3 3 4 RADIUS RN783 MATERIAL 3 16 INCH STEEL STOCK Fig 12 Pump Vent Plug AIR PRESSURE LEAK TEST PROCEDURE 1 Install vent plug converter hub seal cup and cup retaining strap Fig 13 CAUTION Be sure the surfaces of the hub seal cup are smooth and free of nicks scratches or burrs Surface irregularities on the cup will damage the pump seal if not removed Sand and polish the cup with 400 grit sandpaper or crocus cloth to smooth the surface if necessary 2 Close off remaining transmission openings with rubber plugs or stoppers or similar devices Do not close off rear cooler line fitting Hand operated air pump will be attached to this fitting 3 Attach Air Pump 7700 to rear cooler line fitting Connect a length of copper tube to fitting Then attach pump hose to tube with hose clamp Fig 14 4 Apply a thick soapy water solution to suspected leak areas CAUTION The recommended test pressure is 8 psi The maximum allowable test pressure is
187. ve Piston Thrust Plate Thrust plate and spacer are select fit components Refer to size charts and selection procedures in Overdrive Unit Assembly and Adjustment J9321 450 Planetary Geartrain Snap Ring at front end of intermediate shaft Intermediate Shaft Spacer 42RE PRESSURE SPECIFICATIONS 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 Closed Throttle at accumulator 372 414 kPa 54 60 psi Front Servo Third Gear Only No more than 21 kPa 3 psi lower than line pressure Rear S Range No more then 21 kPa 3 psi lower than line pressure ERE TIUS R Range 1103 kPa 160 psi at idle builds to 1862 kPa 270 psi at 1600 rpm DR Pressure should respond smoothly to changes in mph and return to 0 7 kPa 0 1 Governor ES psi when stopped with transmission in D 1 2 Pressure above 7 kPa 112 Closed Throttle psi at standstill will prevent transmission from downshifting J9321 471 21 130 OVERDRIVE UNIT OVERHAUL 42RE 42RE TORQUE SPECIFICATIONS DESCRIPTION TORQUE DESCRIPTION TORQUE Cooler Line Fittings at transmission 18 Nem 13 ft 165 Overdrive to Transmission Converter Bolts Case 34 Nem 25 16
188. ve 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 usually cannot be determined until hydraulic and air pressure tests are performed Practically any condition 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 transmission Perform the hydraulic and air pressure tests to help pinpoint the problem cause 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 Use 100 psi Gauge C 3292 to check pressure at the accumulator front servo and governor Use 300 psi Gauge 3293 to check pressure at the rear servo PRESSURE TEST PORT LOCATIONS There are pressure test ports at the accumulator front servo and rear servo Governor and overdrive dutch pressure test ports are located at the left and right rear sides of the case Fig 3 Line pressure is checked at the accumulator port on theright side of the case The front servo pressure port is at theright sideof the case just behind thefiller tube opening Therear servo and governor pressure ports are at the
189. ve valve body Fig 14 VALVE BODY INSTALLATION 1 Verify that park neutral position switch has NOT been installed in case Valve body cannot be installed if switch is in place 2 Check condition of O ring seals on valve body harness connector Fig 15 Replace seals on connector body if cut or worn 3 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 16 4 Check condition of seals on accumulator piston Fig 17 Install new piston seals if necessary 5 Place valve body manual lever in low 1 position so ball on park lock rod will be easier toinstall in sprag 6 Lubricate shaft of manual lever with petroleum jelly This will ease inserting shaft through seal in case 7 Lubricate seal rings on valve body harness con nector with Ru Glyde or petroleum jelly 8 Position valve body on case and work end of park lock rod into and through pawl sprag Turn propeller IN VEHICLE SERVICE 42RE 21 49 VALVE BODY HARNESS GOVERNOR PRESSURE SOLENOID GOVERNOR PRESSURE SENSOR J9321 388 Fig 14 42RE Valve Body VALVE BODY CONNECTOR HARNESS O RINGS CONNECTOR 29321 389 Fig 15 Valve Body Harness Connector O Ring Seal Locations shaft to align sprag and park lock teeth if necessary Rod will make click noise as it enters pawl to check engagement CAUTION It is possible for the park
190. viceable individually or as an assembly The fittings in the cooler line hoses are serviced only as part of the cooler line Only the retaining clip and insert are serviceable On type fittings the wire retainer clip is not a reusable part It must be replaced if removed from the fitting for any reason In addition the plastic insert should be replaced if cut torn or damaged in any way A damaged insert could prevent the cooler line from seating properly Type fittings are not serviceable The fitting or cooler line must be replaced as an assembly when necessary DISCONNECTING COOLER LINE TYPE I FIT TING 1 11 cooler lines will disconnected at main cooler in radiator remove splash shield under radiator for ac cess to fittings 2 Pry wire retainer dips off fittings with small screwdriver Fig 21 Discard clips as they are NOT reusable after being removed 3 Pull cooler line out of fitting 4 Remove and retain plastic insert from each fit ting TRANSMISSION FITTING COOLER HOSE FITTING J9321 257 Fig 18 Type Quick Disconnect Fitting RETAINING SEAT FITTING CLIP 19321 245 Fig 19 Type Quick Disconnect Fitting Components RELEASE COOLER TOOL LINE SHRINK WRAP MATERIAL FITTING BODY 9321 452 Fig 20 Type Il Quick Disconnect Fitting And Re lease Tool 5 Cover open ends of line and fitting to prevent dirt entry 6 Inspect condition of each plastic inser
191. with a vehicle that is only rated for Class or operation 4 Tow vehicle overloaded exceeding vehicle tow capacity 5 Remove or reposition item causing air flow 5 Air flow to auxiliary cooler blocked by snow plow blockage front mounted spare tire bug screen or similar item 1 Add fluid and check for leaks 2 Flush cooler and lines and replace radiator if transmission fluid has entered coolant 1 Low fluid level 2 Fluid cooler lines blocked or cooler cracked oil in engine coolant OVERHEAT DURING NORMAL OPERATION FLUID DISCOLORED SMELLS BURNED 3 Switch valve sticking 3 Remove disassemble clean valve body 4 Check and correct as required 5 Adjust bands 4 Clutch pack clearance incorrect too tight 5 Bands too tight J9121 450 Condition 42RE TRANSMISSION DIAGNOSIS TRANSMISSION DIAGNOSIS Possible Cause NO START IN PARK OR NEUTRAL Gearshift linkage out of adjustment Park neutral position switch wire broken or open Faulty park neutral position switch Valve body manual lever assembly bent worn broken or not aligned with switch SLUGGISH ACCELERATION AT LOW SPEEDS OR REQUIRES EXCESSIVE THROTTLE OPENING TO MAINTAIN HIGHWAY SPEEDS FLUID CONTAMINATED DISCOLORED FULL OF SLUDGE AND OR METAL AND FRICTION MATERIAL PARTICULAR 1 Poor engine performance Gearshift linkage or throttle cable
192. with shop press and suitable size press tool Fig 62 8 Remove input shaft front rear seal rings REAR CLUTCH INSPECTION Clean the clutch components with solvent and dry them with compressed air Do not use rags or shop towels to dry any of the dutch parts Lint from such materials will adhere to component surfaces and could restrict or block fluid passages after assembly Replace the clutch discs if warped worn scored burned charred the lugs are damaged or if the facing is flaking off Replace the top and bottom pressure plates if scored warped or cracked Besurethedriving lugs on the pressure and clutch 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 clutch 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 ball in the piston The 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 eithe
193. y If contamination is severe cooler flushing converter replacement and another overhaul may be necessary particularly if shift problems were also present If transmission is operating properly drain fluid reverse flush cooler and lines and change fluid and filter However if shift problem has developed converter replacement and transmission overhaul may be required Replace radiator and cooler and flush lines If problem was diagnosed early enough fluid and filter change may only be necessary If contamination period was prolonged overhaul and converter replacement may be required Repair transmission flush cooler and lines Replace converter if necessary Install auxiliary cooler if needed Also install HD cooling system if needed if tow vehicle and unit being towed are both overloaded the only repair is to reduce the load to rated limits However if trailer or boat is too large for two vehicle the only option is for the owner to move up to properly equipped and load rated tow 19321 340 21 26 42RE TRANSMISSION DIAGNOSIS Condition OVERDRIVE DIAGNOSIS Possible Cause Correction NO 3 4 UPSHIFT Fourth gear overdrive switch in dash in OFF position Fourth gear overdrive switch shorted open wires loose Overdrive solenoid or circuit wire loose shorted open Solenoid feed orifice in valve body is blocked or blown out Fourth gear overdrive

automatic transmission—42re

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automatic transmission—42re