start switch JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual

CONDITION POSSIBLE CAUSES CORRECTION
NO START IN PARK
OR NEUTRAL1. Gearshift Linkage/Cable
Mis-adjusted.1. Adjust linkage/cable.
2. Neutral Sense Wire Open/Cut. 2. Check continuity with test lamp. Repair as
required.
3. Park/Neutral Switch, or
Transmission Range Sensor Faulty.3. Refer to service section for test and
replacement procedure.
4. Park/Neutral Switch, or
Transmission Range Sensor
Connection Faulty.4. Connectors spread open. Repair.
5. Valve Body Manual Lever
Assembly Bent/Worn/Broken.5. Inspect lever assembly and replace if damaged.
NO REVERSE (OR
SLIPS IN REVERSE)1. Direct Clutch Pack (front clutch)
Worn.1. Disassemble unit and rebuild clutch pack.
2. Rear Band Mis-adjusted. 2. Adjust band.
3. Front Clutch Malfunctioned/
Burned.3. Air-pressure test clutch operation. Remove and
rebuild if necessary.
4. Overdrive Thrust Bearing
Failure.4. Disassemble geartrain and replace bearings.
5. Direct Clutch Spring Collapsed/
Broken.5. Remove and disassemble unit. Check clutch
position and replace spring.
WJAUTOMATIC TRANSMISSION - 42RE 21 - 25
AUTOMATIC TRANSMISSION - 42RE (Continued)

REMOVAL
The overdrive unit can be removed and serviced
separately. It is not necessary to remove the entire
transmission assembly to perform overdrive unit
repairs.
If only the overdrive unit requires service, refer to
Overdrive Removal for proper procedures.
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo-
nent damage. The converter driveplate, pump bush-
ing, or oil seal can be damaged if the converter is
left attached to the driveplate during removal. Be
sure to remove the transmission and converter as
an assembly.
(1) Disconnect battery negative cable.
(2) Disconnect and lower or remove necessary
exhaust components.
(3) Disconnect fluid cooler lines at transmission.
(4) Remove starter motor. (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
(5) Disconnect and remove crankshaft position sen-
sor. (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION/CRANKSHAFT POSITION SENSOR -
REMOVAL) Retain sensor attaching bolts.
CAUTION: The crankshaft position sensor will be
damaged if the transmission is removed, or
installed, while the sensor is still bolted to the
engine block, or transmission (4.0L only). To avoid
damage, be sure to remove the sensor before
removing the transmission.
(6) Remove the bolts holding the bell housing
brace to the transmission.
(7) Remove nut holding the bell housing brace to
the engine to transmission bending brace.
(8) Remove the bell housing brace from the trans-
mission (Fig. 13).
(9) Remove the bolt holding the torque converter
cover to the transmission.
(10) Remove the torque converter cover from the
transmission.
(11) If transmission is being removed for overhaul,
remove transmission oil pan, drain fluid and reinstall
pan.
(12) Remove fill tube bracket bolts and pull tube
out of transmission. Retain fill tube seal. On4x4
models, it will also be necessary to remove bolt
attaching transfer case vent tube to converter hous-
ing.
(13) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.(14) Mark propeller shaft and axle yokes for
assembly alignment. Then disconnect and remove
propeller shaft. On4x4models, remove both propel-
ler shafts.
(15) Disconnect wires from park/neutral position
switch and transmission solenoid.
(16) Disconnect gearshift cable from transmission
manual valve lever (Fig. 14).
Fig. 13 Bell Housing Brace and Converter Cover
1 - Transmission
2 - Torque Converter Cover
3 - Bellhousing Brace
Fig. 14 Transmission Shift Cable
1 - SHIFT CABLE
2 - MANUAL LEVER
3 - MANUAL LEVER
WJAUTOMATIC TRANSMISSION - 42RE 21 - 27
AUTOMATIC TRANSMISSION - 42RE (Continued)

(32) Install valve body as follows:
(a) Align and carefully insert park rod into pawl.
Rod will make click noise as it enters pawl. Move
rod slightly to check engagement.
(b) Align and seat valve body on case. Be sure
manual lever shaft and overdrive 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 diag-
onal pattern to 12 N´m (105 in. lbs.) torque. Do not
overtighten valve body bolts. This could result in
distortion and cross leakage after installation.
CAUTION: It is possible for the park rod to displace
into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into the cavity.
(33) Install new filter on valve body. Tighten filter
screws to 4 N´m (35 in. lbs.).
(34) Adjust front and rear bands.
(35) Install seal on park/neutral position switch.
Then install and tighten switch to 34 N´m (25 ft.
lbs.).
(36) Install magnet in oil pan. Magnet goes on
small protrusion at corner of pan.
(37) Position new oil pan gasket on case and
install oil pan. Tighten pan bolts to 17 N´m (13 ft.
lbs.).
(38) Install new valve body manual shaft seal in
case (Fig. 60). Lubricate seal lip and manual shaft
with petroleum jelly. Start seal over shaft and into
case. Seat seal with 15/16 inch, deep well socket.
(39) Install throttle valve and shift selector levers
on valve body manual lever shaft.INSTALLATION
(1) Check torque converter hub and hub drive
notches for sharp edges burrs, scratches, or nicks.
Polish the hub and notches with 320/400 grit paper
and crocus cloth if necessary. The hub must be
smooth to avoid damaging pump seal during installa-
tion.
(2) Lubricate oil pump seal lip with transmission
fluid.
(3) Align converter and oil pump.
(4) Carefully insert converter in oil pump. Then
rotate converter back and forth until fully seated in
pump gears.
(5) Check converter seating with steel scale and
straightedge (Fig. 61). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con-
verter is fully seated.
(6) Temporarily secure converter with C-clamp.
(7) Position transmission on jack and secure it
with chains.
(8) Check condition of converter driveplate.
Replace the plate if cracked, distorted or damaged.
Also be sure transmission dowel pins are seated in
engine block and protrude far enough to hold trans-
mission in alignment.
(9) Apply a light coating of MopartHigh Temp
grease to the torque converter hub pocket in the rear
of the crankshaft
(10) Raise transmission and align converter with
drive plate and converter housing with engine block.
Fig. 60 Installing Manual Lever Shaft Seal
1 - 15/1688SOCKET
2 - SEAL
Fig. 61 Checking Torque Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
WJAUTOMATIC TRANSMISSION - 42RE 21 - 41
AUTOMATIC TRANSMISSION - 42RE (Continued)

(11) Move transmission forward. Then raise, lower
or tilt transmission to align converter housing with
engine block dowels.
(12) Carefully work transmission forward and over
engine block dowels until converter hub is seated in
crankshaft.
(13) Install two bolts to attach converter housing
to engine.
(14) Install the upper transmission bending braces
to the torque converter housing and the overdrive
unit. Tighten the bolts to 41 N´m (30 ft.lbs.).
(15) Install remaining torque converter housing to
engine bolts. Tighten to 68 N´m (50 ft.lbs.).
(16) Install rear transmission crossmember.
Tighten crossmember to frame bolts to 68 N´m (50
ft.lbs.).
(17) Install rear support to transmission. Tighten
bolts to 47 N´m (35 ft.lbs.).
(18) Lower transmission onto crossmember and
install bolts attaching transmission mount to cross-
member. Tighten clevis bracket to crossmember bolts
to 47 N´m (35 ft.lbs.). Tighten the clevis bracket to
rear support bolt to 68 N´m (50 ft.lbs.).
(19) Remove engine support fixture.
(20) Install crankshaft position sensor. (Refer to 14
- FUEL SYSTEM/FUEL INJECTION/CRANKSHAFT
POSITION SENSOR - INSTALLATION)
(21) Install new plastic retainer grommet on any
shift cable that was disconnected. Grommets should
not be reused. Use pry tool to remove rod from grom-
met and cut away old grommet. Use pliers to snap
new grommet into cable and to snap grommet onto
lever.
(22) Connect gearshift and throttle valve cable to
transmission.
(23) Connect wires to park/neutral position switch
and transmission solenoid connector. Be sure trans-
mission harnesses are properly routed.CAUTION: It is essential that correct length bolts be
used to attach the converter to the driveplate. Bolts
that are too long will damage the clutch surface
inside the converter.
(24) Install all torque converter-to-driveplate bolts
by hand.
(25) Verify that the torque converter is pulled
flush to the driveplate. Tighten bolts to 31 N´m (270
in. lbs.).
(26) Install converter housing access cover. Tighten
bolt to 23 N´m (200 in.lbs.).
(27) Install the bell housing brace to the torque
converter cover and the engine to transmission bend-
ing brace. Tighten the bolts and nut to 41 N´m (30
ft.lbs.).
(28) Install starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - INSTALLA-
TION) and cooler line bracket.
(29) Connect cooler lines to transmission.
(30) Install transmission fill tube. Install new seal
on tube before installation.
(31) Install exhaust components.
(32) Install transfer case. Tighten transfer case
nuts to 35 N´m (26 ft.lbs.).
(33) Install the transfer case shift cable to the
cable support bracket and the transfer case shift
lever.
(34) Align and connect propeller shaft(s).
(35) Adjust gearshift linkage and throttle valve
cable if necessary.
(36) Lower vehicle.
(37) Fill transmission with MopartATF +4, type
9602, fluid.
21 - 42 AUTOMATIC TRANSMISSION - 42REWJ
AUTOMATIC TRANSMISSION - 42RE (Continued)

BRAKE TRANSMISSION SHIFT
INTERLOCK MECHANISM
DESCRIPTION
The Brake Transmission Shifter/Ignition Interlock
(BTSI), is a cable and solenoid operated system. It
interconnects the automatic transmission floor
mounted shifter to the steering column ignition
switch (Fig. 71).
OPERATION
The system locks the shifter into the PARK posi-
tion. The interlock system is engaged whenever the
ignition switch is in the LOCK or ACCESSORY posi-
tion. An additional electrically activated feature will
prevent shifting out of the PARK position unless the
brake pedal is depressed approximately one-half an
inch. A magnetic holding device in the shifter assem-
bly is energized when the ignition is in the RUN
position. When the key is in the RUN position and
the brake pedal is depressed, the shifter is unlocked
and will move into any position. The interlock system
also prevents the ignition switch from being turned
to the LOCK or ACCESSORY position, unless the
shifter is fully locked into the PARK position.
DIAGNOSIS AND TESTING - BRAKE
TRANSMISSION SHIFT INTERLOCK
(1) Verify that the key can only be removed in the
PARK position
(2) When the shift lever is in PARK And the shift
handle pushbutton is in the ªOUTº position, the igni-
tion key cylinder should rotate freely from OFF to
LOCK. When the shifter is in any other gear or neu-
tral position, the ignition key cylinder should not
rotate to the LOCK position.
(3) Shifting out of PARK should not be possible
when the ignition key cylinder is in the OFF posi-
tion.
(4) Shifting out of PARK should not be possible
while applying normal pushbutton force and ignition
key cylinder is in the RUN or START positions
unless the foot brake pedal is depressed approxi-
mately 1/2 inch (12mm).
(5) Shifting out of PARK should not be possible
when the ignition key cylinder is in the ACCESSORY
or LOCK positions.
(6) Shifting between any gears, NEUTRAL or into
PARK may be done without depressing foot brake
pedal with ignition switch in RUN or START posi-
tions.
Fig. 71 Ignition Interlock Cable
1 - SHIFT MECHANISM 4 - STEERING COLUMN ASSEMBLY
2 - SHIFTER BTSI LEVER 5 - INTERLOCK CABLE
3 - ADJUSTMENT CLIP
WJAUTOMATIC TRANSMISSION - 42RE 21 - 63

ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK
The park interlock cable is part of the brake/shift
lever interlock system. Correct cable adjustment is
important to proper interlock operation. The gear
shift and park lock cables must both be correctly
adjusted in order to shift out of PARK.
ADJUSTMENT PROCEDURE
(1) Remove floor console as necessary for access to
the brake transmission shift interlock cable. (Refer to
23 - BODY/INTERIOR/FLOOR CONSOLE -
REMOVAL)
(2) Shift the transmission into the PARK position.
(3) Turn ignition switch to LOCK position.Be
sure ignition key cylinder is in the LOCK posi-
tion. Cable will not adjust correctly in any
other position.
(4) Pull cable lock button up to release cable (Fig.
72).
(5) Ensure that the cable is free to self-adjust by
pushing cable rearward and releasing.
(6) Push lock button down until it snaps in place.
BTSI FUNCTION CHECK
(1) Verify removal of ignition key allowed in PARK
position only.
(2) When the shift lever is in PARK, and the shift
handle push-button is in the out position, the igni-
tion key cylinder should rotate freely from off to lock.
When the shifter is in any other position, the ignition
key should not rotate from off to lock.
(3) Shifting out of PARK should be possible when
the ignition key cylinder is in the off position.
(4) Shifting out of PARK should not be possible
while applying normal push-button force, and igni-
tion key cylinder is in the run or start positions,
unless the foot brake pedal is depressed approxi-
mately 1/2 inch (12mm).
(5) Shifting out of PARK should not be possible
when the ignition key cylinder is in the accessory or
lock position.
(6) Shifting between any gear and NEUTRAL, or
PARK, may be done without depressing foot brake
with ignition switch in run or start positions.
(7) The floor shifter lever and gate positions
should be in alignment with all transmission detent
positions.
Fig. 72 Brake Transmission Shift Interlock Cable
1 - SHIFT MECHANISM 4 - STEERING COLUMN ASSEMBLY
2 - SHIFTER BTSI LEVER 5 - INTERLOCK CABLE
3 - ADJUSTMENT CLIP
21 - 64 AUTOMATIC TRANSMISSION - 42REWJ
BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM (Continued)

INCORRECT if the engine starts in 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 or TRS
may be faulty.
(1) Shift transmission into PARK.
(2) Remove floor console as necessary for access to
the shift cable adjustment. (Refer to 23 - BODY/IN-
TERIOR/FLOOR CONSOLE - REMOVAL)
(3) Loosen the shift cable adjustment screw (Fig.
106).
(4) Raise vehicle.
(5) Unsnap cable eyelet from transmission shift
lever (Fig. 107).
(6) Verify transmission shift lever is in PARK
detent by moving lever fully rearward. Last rearward
detent is PARK position.
(7) Verify positive engagement of transmission
park lock by attempting to rotate propeller shaft.
Shaft will not rotate when park lock is engaged.
(8) Snap cable eyelet onto transmission shift lever.
(9) Lower vehicle
(10) Tighten the shift cable adjustment screw to 7
N´m (65 in.lbs.).
(11) Verify correct operation.
(12) Install any floor console components removed
for access. (Refer to 23 - BODY/INTERIOR/FLOOR
CONSOLE - INSTALLATION)
OIL PUMP
DESCRIPTION
The oil pump (Fig. 108) is located in the pump
housing inside the bell housing of the transmission
case. The oil pump consists of an inner and outer
gear (Fig. 109), a housing, and a cover that also
serves as the reaction shaft support.
OPERATION
As the torque converter rotates, the converter hub
rotates the inner and outer gears. As the gears
rotate, the clearance between the gear teeth
increases in the crescent area, and creates a suction
at the inlet side of the pump. This suction draws
fluid through the pump inlet from the oil pan. As the
clearance between the gear teeth in the crescent area
decreases, it forces pressurized fluid into the pump
outlet and to the valve body.
Fig. 106 Shift Cable at the Shifter
1 - SHIFT LEVER PIN
2 - ADJUSTMENT SCREW
3 - SHIFT CABLE
4 - SHIFTER ASSEMBLY BRACKET
Fig. 107 Shift Cable at Transmission
1 - TRANSMISSION SHIFTER CABLE
2 - THROTTLE VALVE CABLE
3 - TRANSFER CASE SHIFTER CABLE
4 - TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT(S)
5 - THROTTLE VALVE CABLE BRACKET RETAINING BOLT
6 - ELECTRICAL CONNECTORS
7 - TRANSMISSION FLUID LINES
21 - 80 AUTOMATIC TRANSMISSION - 42REWJ
GEARSHIFT CABLE (Continued)

PARK/NEUTRAL POSITION
SWITCH
DIAGNOSIS AND TESTING - PARK/NEUTRAL
POSITION SWITCH
The center terminal of the park/neutral position
switch is the starter-circuit terminal. It provides the
ground for the starter solenoid circuit through the
selector lever in PARK and NEUTRAL positions only.
The outer terminals on the switch are for the backup
lamp circuit.
SWITCH TEST
To test the switch, remove the wiring connector.
Test for continuity between the center terminal and
the transmission case. Continuity should exist only
when the transmission is in PARK or NEUTRAL.Shift the transmission into REVERSE and test
continuity at the switch outer terminals. Continuity
should exist only when the transmission is in
REVERSE. Continuity should not exist between the
outer terminals and the case.
Check gearshift linkage adjustment before replac-
ing a switch that tests faulty.
REMOVAL
(1) Raise vehicle and position drain pan under
switch.
(2) Disconnect switch wires.
(3) Remove switch from case.
INSTALLATION
(1) Move shift lever to PARK and NEUTRAL posi-
tions. Verify that switch operating lever fingers are
centered in switch opening in case (Fig. 198).
Fig. 197 Brake Transmission Shift Interlock
1 - SHIFT MECHANISM 4 - STEERING COLUMN ASSEMBLY
2 - SHIFTER BTSI LEVER 5 - INTERLOCK CABLE
3 - ADJUSTMENT CLIP
WJAUTOMATIC TRANSMISSION - 42RE 21 - 109
PARK LOCK CABLE (Continued)

3-4 ACCUMULATOR
(1) Position converter clutch valve and 3-4 shift
valve springs in housing (Fig. 324).
(2) Loosely attach accumulator housing with right-
side screw (Fig. 324). Install only one screw at this
time as accumulator must be free to pivot upward for
ease of installation.
(3) Install 3-4 shift valve and spring.
(4) Install converter clutch timing valve and
spring.
(5) Position plug on end of converter clutch valve
spring. Then compress and hold springs and plug in
place with fingers of one hand.
(6) Swing accumulator housing upward over valve
springs and plug.
(7) Hold accumulator housing firmly in place and
install remaining two attaching screws. Be sure
springs and clutch valve plug are properly seated
(Fig. 325). Tighten screws to 4 N´m (35 in. lbs.).
VALVE BODY FINAL
(1) Install boost valve, valve spring, retainer and
cover plate. Tighten cover plate screws to 4 N´m (35
in. lbs.) torque.
(2) Insert manual lever detent spring in upper
housing.
(3) Position detent ball on end of spring. Then hold
detent ball and spring in detent housing with
Retainer Tool 6583 (Fig. 326).(4) Install throttle lever in upper housing. Then
install manual lever over throttle lever and start
manual lever into housing.
(5) Align manual lever with detent ball and man-
ual valve. Hold throttle lever upward. Then press
down on manual lever until fully seated. Remove
detent ball retainer tool after lever is seated.
(6) Then install manual lever seal, washer and
E-clip.
(7) Verify that throttle lever is aligned with end of
kickdown valve stem and that manual lever arm is
engaged in manual valve (Fig. 327).
(8) Position line pressure adjusting screw in
adjusting screw bracket.
(9) Install spring on end of line pressure regulator
valve.
(10) Install switch valve spring on tang at end of
adjusting screw bracket.
(11) Install manual valve.
(12) Install throttle valve and spring.
(13) Install kickdown valve and detent.
(14) Install pressure regulator valve.
(15) Install switch valve.
(16) Position adjusting screw bracket on valve
body. Align valve springs and press bracket into
place. Install short, upper bracket screws first and
long bottom screw last. Verify that valve springs and
bracket are properly aligned. Then tighten all three
bracket screws to 4 N´m (35 in. lbs.) torque.
(17) Perform Line Pressure and Throttle Pressure
adjustments. (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC/VALVE BODY - ADJUST-
MENTS)
(18) Lubricate solenoid case connector O-rings and
shaft of manual lever with light coat of petroleum
jelly.
Fig. 324 Converter Clutch And 3-4 Shift Valve
Springs
1 - RIGHT-SIDE SCREW
2 - 3-4 ACCUMULATOR
3 - 3-4 SHIFT VALVE SPRING
4 - CONVERTER CLUTCH VALVE SPRING
Fig. 325 Seating 3-4 Accumulator On Lower
Housing
1 - ACCUMULATOR BOX
2 - CONVERTER CLUTCH VALVE PLUG
WJAUTOMATIC TRANSMISSION - 42RE 21 - 173
VALVE BODY (Continued)

TORQUE CONVERTER LEAK POINTS
Possible sources of converter leaks are:
(1) Leaks at the weld joint around the outside
diameter weld (Fig. 7).
(2) Leaks at the converter hub weld (Fig. 7).
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, or
equivalent, 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.
REMOVAL
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo-
nent damage. The converter driveplate, converter
hub o-ring, or oil seal can be damaged if the con-
verter is left attached to the driveplate during
removal. Be sure to remove the transmission and
converter as an assembly.
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle
(3) Mark propeller shaft and axle yokes for assem-
bly alignment.
(4) Remove the rear propeller shaft
(5) Remove the front propeller shaft.
(6) Remove the engine to transmission collar (Fig.
8).
(7) Remove the exhaust support bracket from the
rear of the transmission.
(8) Disconnect and lower or remove any necessary
exhaust components.
(9) Remove the starter motor.
(10) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.
(11) Disconnect wires from solenoid and pressure
switch assembly, input and output speed sensors, and
line pressure sensor.
Fig. 7 Torque Converter Assembly
1 - TURBINE ASSEMBLY
2-STATOR
3 - CONVERTER HUB
4 - O-RING
5 - IMPELLER ASSEMBLY
6 - CONVERTER CLUTCH PISTON
7 - TURBINE HUB
Fig. 8 Transmission Collar
1 - ENGINE
2 - ENGINE TO TRANSMISSION COLLAR
3 - TRANSMISSION
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 183
AUTOMATIC TRANSMISSION - 545RFE (Continued)