turn JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual

CONDITION POSSIBLE CAUSES CORRECTION
GROWLING,
GRATING OR
SCRAPING NOISES1. Drive Plate Broken. 1. Replace.
2. Torque Converter Bolts Hitting
Dust Shield.2. Dust shield bent. Replace or repair.
3. Planetary Gear Set Broken/
Seized.3. Check for debris in oil pan and repair as
required.
4. Overrunning Clutch Worn/
Broken.4. Inspect and check for debris in oil pan. Repair
as required.
5. Oil Pump Components
Scored/Binding.5. Remove, inspect and repair as required.
6. Output Shaft Bearing or Bushing
Damaged.6. Remove, inspect and repair as required.
7. Clutch Operation Faulty. 7. Perform air pressure check and repair as
required.
8. Front and Rear Bands
Mis-adjusted.8. Adjust bands.
DRAGS OR LOCKS
UP1. Fluid Level Low. 1. Check and adjust level.
2. Clutch Dragging/Failed 2. Air pressure check clutch operation and repair
as required.
3. Front or Rear Band Mis-
adjusted.3. Adjust bands.
4. Case Leaks Internally. 4. Check for leakage between passages in case.
5. Servo Band or Linkage
Malfunction.5. Air pressure check servo operation and repair
as required.
6. Overrunning Clutch Worn. 6. Remove and inspect clutch. Repair as required.
7. Planetary Gears Broken. 7. Remove, inspect and repair as required (look
for debris in oil pan).
8. Converter Clutch Dragging. 8. Check for plugged cooler. Perform flow check.
Inspect pump for excessive side clearance.
Replace pump as required.
NO 4-3 DOWNSHIFT 1. Circuit Wiring and/or Connectors
Shorted.1.
Test wiring and connectors with test lamp and
volt/ohmmeter. Repair wiring as necessary. Replace
connectors and/or harnesses as required.
2. PCM Malfunction. 2. Check PCM operation with DRBTscan tool.
Replace PCM only if faulty.
3. TPS Malfunction 3. Check TPS with DRBTscan tool at PCM.
4. Lockup Solenoid Not Venting. 4. Remove valve body and replace solenoid
assembly if plugged or shorted.
5. Overdrive Solenoid Not Venting. 5. Remove valve body and replace solenoid if
plugged or shorted.
6. Valve Body Valve Sticking. 6. Repair stuck 3-4 shift valve or lockup timing
valve.
NO 4-3 DOWNSHIFT
WHEN CONTROL
SWITCH IS TURNED
OFF1. Control Switch Open/Shorted. 1. Test and replace switch if faulty.
2. Overdrive Solenoid Connector
Shorted.2. Test solenoids and replace if seized or shorted.
3. PCM Malfunction. 3.
Test with DRBTscan tool. Replace PCM if faulty.
4. Valve Body Stuck Valves. 4.Repair stuck 3-4, lockup or lockup timing valve.
21 - 22 AUTOMATIC TRANSMISSION - 42REWJ
AUTOMATIC TRANSMISSION - 42RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
CLUNK NOISE FROM
DRIVELINE ON
CLOSED THROTTLE
4-3 DOWNSHIFT1. Transmission Fluid Low. 1. Add Fluid.
2. Throttle Cable Mis-adjusted. 2. Adjust cable.
3. Overdrive Clutch Select Spacer
Wrong Spacer.3. Replace overdrive piston thrust plate spacer.
3-4 UPSHIFT
OCCURS
IMMEDIATELY AFTER
2-3 SHIFT1. Overdrive Solenoid Connector or
Wiring Shorted.1.
Test connector and wiring for loose connections,
shorts or ground and repair as needed.
2. TPS Malfunction. 2. Test TPS and replace as necessary. Check with
DRBTscan tool.
3. PCM Malfunction. 3. Test PCM with DRBTscan tool and replace
controller if faulty.
4. Overdrive Solenoid Malfunction. 4. Replace solenoid.
5. Valve Body Malfunction. 5. Remove, disassemble, clean and inspect valve
body components. Make sure all valves and plugs
slide freely in bores. Polish valves with crocus
cloth if needed.
WHINE/NOISE
RELATED TO ENGINE
SPEED1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Shift Cable Incorrect Routing. 2. Check shift cable for correct routing. Should not
touch engine or bell housing.
NO 3-4 UPSHIFT 1. O/D Switch In OFF Position. 1. Turn control switch to ON position.
2. Overdrive Circuit Fuse Blown. 2. Replace fuse. Determine why fuse failed and
repair as necessary (i.e., shorts or grounds in
circuit).
3. O/D Switch Wire Shorted/Open
Cut.3. Check wires/connections with 12V test lamp
and voltmeter. Repair damaged or loose
wire/connection as necessary.
4. Distance or Coolant Sensor
Malfunction.4. Check with DRBTscan tool and repair or
replace as necessary.
5. TPS Malfunction. 5. Check with DRBTscan tool and replace if
necessary.
6. Neutral Sense to PCM Wire
Shorted/Cut.6. Test switch/sensor as described in service
section and replace if necessary. Engine no start.
7. PCM Malfunction. 7. Check with DRBTscan tool and replace if
necessary.
8. Overdrive Solenoid Shorted/
Open.8. Replace solenoid if shorted or open and repair
loose or damaged wires (DRBTscan tool).
9. Solenoid Feed Orifice in Valve
Body Blocked.9. Remove, disassemble, and clean valve body
thoroughly. Check feed orifice.
10. Overdrive Clutch Failed. 10. Disassemble overdrive and repair as needed.
11. Hydraulic Pressure Low. 11. Pressure test transmission to determine
cause.
12. Valve Body Valve Stuck. 12. Repair stuck 3-4 shift valve, 3-4 timing valve.
13. O/D Piston Incorrect Spacer. 13. Remove unit, check end play and install
correct spacer.
14. Overdrive Piston Seal Failure. 14. Replace both seals.
15. O/D Check Valve/Orifice Failed. 15. Check for free movement and secure
assembly (in piston retainer). Check ball bleed
orifice.
WJAUTOMATIC TRANSMISSION - 42RE 21 - 23
AUTOMATIC TRANSMISSION - 42RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
OIL LEAKS. 1. Fluid Lines and Fittings
Loose/Leaks/Damaged.1. Tighten fittings. If leaks persist, replace fittings
and lines if necessary.
2. Fill Tube (where tube enters
case) Leaks/Damaged.2. Replace tube seal. Inspect tube for cracks in fill
tube.
3. Pressure Port Plug Loose
Loose/Damaged.3. Tighten to correct torque. Replace plug or
reseal if leak persists.
4. Pan Gasket Leaks. 4. Tighten pan screws (150 in. lbs.). If leaks
persist, replace gasket.
5. Valve Body Manual Lever Shaft
Seal Leaks/Worn.5. Replace shaft seal.
6. Rear Bearing Access Plate
Leaks.6. Replace gasket. Tighten screws.
7. Gasket Damaged or Bolts are
Loose.7. Replace bolts or gasket or tighten both.
8. Adapter/Extension Gasket
Damaged Leaks/Damaged.8. Replace gasket.
9. Park/Neutral Switch, or
Transmission Range Sensor
Leaks/Damaged.9. Replace switch and gasket.
10. Converter Housing Area Leaks. 10. Check for leaks at seal caused by worn seal
or burr on converter hub (cutting seal), worn
bushing, missing oil return, oil in front pump
housing or hole plugged. Check for leaks past
O-ring seal on pump or past pump-to-case bolts;
pump housing porous, oil coming out vent due to
overfill or leak past front band shaft access plug.
11. Pump Seal Leaks/Worn/
Damaged.11. Replace seal.
12. Torque Converter Weld
Leak/Cracked Hub.12. Replace converter.
13. Case Porosity Leaks. 13. Replace case.
NOISY OPERATION
IN FOURTH GEAR
ONLY1. Overdrive Clutch Discs, Plates
or Snap Rings Damaged.1. Remove unit and rebuild clutch pack.
2. Overdrive Piston or Planetary
Thrust Bearing Damaged.2. Remove and disassemble unit. Replace either
thrust bearing if damaged.
3. Output Shaft Bearings
Scored/Damaged.3. Remove and disassemble unit. Replace either
bearing if damaged.
4. Planetary Gears Worn/Chipped. 4. Remove and overhaul overdrive unit.
5. Overdrive Unit Overrunning
Clutch Rollers Worn/Scored.5. Remove and overhaul overdrive unit.
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-CoilsŸ, or equivalent. This repair con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-CoilŸ tap, or
equivalent, and installing a Heli-CoilŸ insert, orequivalent, into the hole. This brings the hole back to
its original thread size.
Heli-CoilŸ, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
21 - 26 AUTOMATIC TRANSMISSION - 42REWJ
AUTOMATIC TRANSMISSION - 42RE (Continued)

(10) Remove valve body assembly. Push valve body
harness connector out of case. Then work park rod
and valve body out of case (Fig. 24).
(11) Remove accumulator piston and inner and
outer springs (Fig. 25).
(12) Remove pump oil seal with suitable pry tool
or slide-hammer mounted screw.
(13) Loosen front band adjusting screw locknut 4-5
turns. Then tighten band adjusting screw until bandis tight around front clutch retainer. This prevents
front/rear clutches from coming out with pump and
possibly damaging clutch or pump components.
(14) Remove oil pump bolts.
(15) Thread bolts of Slide Hammer Tools C-3752
into threaded holes in pump body flange (Fig. 26).
(16) Bump slide hammer weights outward to
remove pump and reaction shaft support assembly
from case (Fig. 26).
(17) Loosen front band adjusting screw until band
is completely loose.
Fig. 22 Oil Filter Removal
1 - OIL FILTER
2 - VALVE BODY
3 - FILTER SCREWS (2)
Fig. 23 Valve Body Bolt Locations
1 - VALVE BODY BOLTS
2 - VALVE BODY BOLTS
Fig. 24 Valve Body Removal
1 - GOVERNOR PRESSURE SENSOR
2 - VALVE BODY
3 - PARK ROD
4 - ACCUMULATOR PISTON
5 - GOVERNOR PRESSURE SOLENOID
Fig. 25 Accumulator Piston And Springs
1 - ACCUMULATOR PISTON
2 - OUTER SPRING
3 - INNER SPRING
21 - 30 AUTOMATIC TRANSMISSION - 42REWJ
AUTOMATIC TRANSMISSION - 42RE (Continued)

(29) Loosen rear band adjusting screw 4-5 turns.
(30) Remove low-reverse drum snap-ring (Fig. 35).(31) Remove low-reverse drum and reverse band.
(32) Remove overrunning clutch roller and spring
assembly as a unit (Fig. 36).
(33) Compress front servo rod guide about 1/8 inch
with Valve Spring Compressor C-3422-B (Fig. 37).
(34) 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.
(35) Remove compressor tools and remove front
servo rod guide, spring and servo piston.
Fig. 34 Removing Planetary Geartrain And
Intermediate Shaft Assembly
1 - PLANETARY GEARTRAIN AND INTERMEDIATE SHAFT
ASSEMBLY
Fig. 35 Removing Low-Reverse Drum Snap-Ring
1 - LOW-REVERSE DRUM
2 - HUB OF OVERDRIVE PISTON RETAINER
3 - LOW-REVERSE DRUM SNAP-RING
Fig. 36 Overrunning Clutch Assembly Removal
1 - OVERRUNNING CLUTCH CAM
2 - REAR BAND REACTION PIN
3 - OVERRUNNING CLUTCH ASSEMBLY
Fig. 37 Compressing Front Servo Rod Guide
1 - SPRING COMPRESSOR TOOL C-3422-B
2 - ROD GUIDE SNAP-RING
WJAUTOMATIC TRANSMISSION - 42RE 21 - 33
AUTOMATIC TRANSMISSION - 42RE (Continued)

(36) Compress rear servo spring retainer about
1/16 inch with Valve Spring Compressor C-3422-B
(Fig. 38).
(37) Remove rear servo spring retainer snap-ring.
Then remove compressor tools and remove rear servo
spring and piston.
(38) Inspect transmission components.
NOTE: To Service the overrunning clutch cam or
overdrive piston retainer, refer to the Overrunning
Clutch Cam service procedure in this section.
CLEANING
Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent.
Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
that all fluid passages are clear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.Lubricate transmission parts with MopartATF +4,
type 9602, transmission fluid during overhaul and
assembly. Use petroleum jelly, MopartDoor Ease, or
Ru-GlydeŸ to prelubricate seals, O-rings, and thrust
washers. Petroleum jelly can also be used to hold
parts in place during reassembly.
INSPECTION
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.
Inspect the transmission bushings during overhaul.
Bushing condition is important as worn, scored bush-
ings contribute to low pressures, clutch slip and
accelerated wear of other components. However, do
not replace bushings as a matter of course. Replace
bushings only when they are actually worn, or
scored.
Use recommended tools to replace bushings. The
tools are sized and designed to remove, install, and
seat bushings correctly. The bushing replacement
tools are included in Bushing Tool Set C-3887-B.
Pre-sized service bushings are available for
replacement purposes. Only the sun gear bushings
are not serviced.
The use of crocus cloth is permissible where neces-
sary, providing it is used carefully. When used on
shafts, or valves, use extreme care to avoid rounding
off sharp edges. Sharp edges are vital as they pre-
vent foreign matter from getting between the valve
and valve bore.
Do not reuse oil seals, gaskets, seal rings, or
O-rings during overhaul. Replace these parts as a
matter of course. Also do not reuse snap rings or
E-clips that are bent or distorted. Replace these parts
as well.
ASSEMBLY
Do not allow dirt, grease, or foreign material to
enter the case or transmission components during
assembly. Keep the transmission case and compo-
nents clean. Also make sure the tools and workbench
area used for assembly operations are equally clean.
Shop towels used for wiping off tools and hands
must be made fromlint freematerial. Lint will stick
to transmission parts and could interfere with valve
operation, or even restrict fluid passages.
Lubricate the transmission components with
Moparttransmission fluid during reassembly. Use
MopartDoor Ease, or Ru-GlydeŸ on seals and
O-rings to ease installation.
Fig. 38 Compressing Rear Servo Spring
1 - FRONT SERVO SNAP-RING
2 - REAR SERVO SNAP-RING
3 - SPECIAL TOOL
21 - 34 AUTOMATIC TRANSMISSION - 42REWJ
AUTOMATIC TRANSMISSION - 42RE (Continued)

Petroleum jelly can also be used to hold thrust
washers, thrust plates and gaskets in position during
assembly. However,do notuse chassis grease, bear-
ing grease, white grease, or similar lubricants on any
transmission part. These types of lubricants can
eventually block or restrict fluid passages and inter-
fere with valve operation. Use petroleum jelly only.
Do not force parts into place. The transmission
components and subassemblies are easily installed by
hand when properly aligned.
If a part seems extremely difficult to install, it is
either misaligned or incorrectly assembled. Also ver-
ify that thrust washers, thrust plates and seal rings
are correctly positioned before assembly. These parts
can interfere with proper assembly if mis-positioned.
The planetary geartrain, front/rear clutch assem-
blies and oil pump are all much easier to install
when the transmission case is upright.
(1) Install rear servo piston, spring and retainer
(Fig. 39). Install spring on top of servo piston and
install retainer on top of spring.
(2) Install front servo piston assembly, servo
spring and rod guide (Fig. 40).
(3) Compress front/rear servo springs with Valve
Spring Compressor C-3422-B and install each servo
snap-ring (Fig. 41).
(4) Lubricate clutch cam rollers with transmission
fluid.
(5) Install rear band in case (Fig. 42). Be sure twin
lugs on band are seated against reaction pin.
(6) Install low-reverse drum and check overrun-
ning clutch operation as follows:(a) Lubricate overrunning clutch race (on drum
hub) with transmission fluid.
(b) Guide drum through rear band.
(c) Tilt drum slightly and start race (on drum
hub) into overrunning clutch rollers.
(d) Press drum rearward and turn it in clock-
wise direction until drum seats in overrunning
clutch (Fig. 43).
Fig. 39 Rear Servo Components
1 - SERVO PISTON
2 - PISTON SPRING
3 - SNAP-RING
4 - RETAINER
5 - PISTON SEAL
Fig. 40 Front Servo Components
1 - PISTON SEAL RINGS
2 - SERVO PISTON
3 - SNAP-RING
4 - ROD GUIDE
5 - SPRING
6 - ROD
Fig. 41 Compressing Front/Rear Servo Springs
1 - SPRING COMPRESSOR TOOL C-3422-B
2 - ROD GUIDE SNAP-RING
WJAUTOMATIC TRANSMISSION - 42RE 21 - 35
AUTOMATIC TRANSMISSION - 42RE (Continued)

(e) Turn drum back and forth. Drum should
rotate freely in clockwise direction and lock in
counterclockwise direction (as viewed from front of
case).(7) Install snap-ring that secures low-reverse drum
to hub of overdrive piston retainer (Fig. 44).
(8) Install rear band lever and pivot pin (Fig. 45).
Align lever with pin bores in case and push pivot pin
into place.
(9) Install planetary geartrain assembly (Fig. 46).
Fig. 42 Rear Band Installation
1 - REAR BAND
Fig. 43 Installing Low-Reverse Drum
1 - REAR BAND
2 - LOW-REVERSE DRUM
Fig. 44 Installing Low-Reverse Drum Retaining
Snap-Ring
1 - LOW-REVERSE DRUM
2 - HUB OF OVERDRIVE PISTON RETAINER
3 - LOW-REVERSE DRUM SNAP-RING
Fig. 45 Rear Band Lever And Pivot Pin Installation
1 - REAR BAND LEVER
2 - LEVER PIVOT PIN
21 - 36 AUTOMATIC TRANSMISSION - 42REWJ
AUTOMATIC TRANSMISSION - 42RE (Continued)

(15) Align drive teeth on rear clutch discs with
small screwdriver (Fig. 52). This makes installation
on front planetary easier.
(16) Raise 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.
(17) Slide front band into case.
(18) Install front and rear clutch units as assembly
(Fig. 53). Align rear clutch with front annulus gear
and install assembly in driving shell. Be sure output
shaft thrust washer and thrust plate are not dis-
placed during installation.
(19) 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 installa-
tion.
(20) Assemble front band strut.
(21) Install front band adjuster, strut and adjust-
ing screw (Fig. 54).
(22) Tighten band adjusting screw until band just
grips clutch retainer. Verify that front/rear clutches
are still seated before continuing.
Fig. 50 Assembling Front And Rear Clutch Units
1 - TURN FRONT CLUTCH BACK & FORTH UNTIL SEATED
2 - REAR CLUTCH ASSEMBLY
Fig. 51 Installing Intermediate Shaft Thrust Washer
1 - INTERMEDIATE SHAFT THRUST WASHER
2 - INPUT SHAFT
3 - REAR CLUTCH RETAINER HUB
Fig. 52 Aligning Rear Clutch Disc Lugs
1 - REAR CLUTCH DISCS
2 - USE SMALL SCREWDRIVER TO ALIGN CLUTCH DISC
TEETH
21 - 38 AUTOMATIC TRANSMISSION - 42REWJ
AUTOMATIC TRANSMISSION - 42RE (Continued)

SPECIFICATIONS
TRANSMISSION
GENERAL
Component Metric Inch
Planetary end play 0.127-1.22
mm0.005-0.048
in.
Input shaft end play 0.56-2.31
mm0.022-0.091
in.
Clutch pack clearance/
Front.1.70-
3.40mm0.067-0.134
in.
Clutch pack clearance/
Rear.0.559-0.914
mm0.022-0.036
in.
Front clutch 4 discs
Rear clutch 4 discs
Overdrive clutch 3 discs
Component Metric Inch
Direct clutch 6 discs
42RE Band adjustment
from 72 in. lbs.
Front band Back off 3 turns
Rear band Back off 4 turns
Recommended fluid MoparTATF +4, type 9602
GEAR RATIOS
1ST GEAR 2.74:1
2ND GEAR 1.54:1
3RD GEAR 1.0:1
4TH GEAR 0.69:1
REVERSE 2.21:1
THRUST WASHER/SPACER/SNAP-RING DIMENSIONS
Component Metric Inch
Front clutch thrust washer (reaction shaft
support hub)1.55 mm 0.061 in.
Rear clutch thrust washer (clutch retainer) 1.55 mm 0.061 in.
Intermediate shaft thrust plate (shaft hub pilot) Select fit to set end play
Output shaft thrust washer (rear clutch hub) 1.5-1.6 mm 0.060-0.063 in.
Rear clutch pack snap-ring 1.5 mm 0.060 in.
1.95 mm 0.076 in.
2.45 mm 0.098 in.
Planetary geartrain snap-ring (at front of output shaft) Select fit (three thicknesses avalible)
Overdrive piston thrust plate Thrust plate and
spacer are select fit.
Refer to size charts
and selection
procedures in
Overdrive Unit D&A
procedures Intermiediate shaft spacer
WJAUTOMATIC TRANSMISSION - 42RE 21 - 55
AUTOMATIC TRANSMISSION - 42RE (Continued)