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    95ZJ_21.PDF 95ZJ_21.PDF Document Transcript

    • ZJ TRANSMISSION AND TRANSFER CASE 21 - 1 TRANSMISSION AND TRANSFER CASE CONTENTS page page42RE AUTOMATIC TRANSMISSION . . . . . . . . . 36 NP231 TRANSFER CASE . . . . . . . . . . . . . . . . . 29146RH AUTOMATIC TRANSMISSION . . . . . . . . 164 NP242 TRANSFER CASE . . . . . . . . . . . . . . . . . 315AX 15 MANUAL TRANSMISSION . . . . . . . . . . . . 1 NP249 TRANSFER CASE . . . . . . . . . . . . . . . . . 343 AX 15 MANUAL TRANSMISSION INDEX page pageGeneral Information . . . . . . . . . . . . . . . . . . . . . . . . 1 Transmission Identification . . . . . . . . . . . . . . . . . . . 2Speedometer Service . . . . . . . . . . . . . . . . . . . . . . . 3 Transmission Installation . . . . . . . . . . . . . . . . . . . . . 5Transmission Assembly and Adjustment . . . . . . . . . 22 Transmission Lubricant . . . . . . . . . . . . . . . . . . . . . . 2Transmission Diagnosis . . . . . . . . . . . . . . . . . . . . . 2 Transmission Removal . . . . . . . . . . . . . . . . . . . . . . 4Transmission Disassembly and Overhaul . . . . . . . . . 6 Transmission Shift Pattern . . . . . . . . . . . . . . . . . . . . 2Transmission Gear Ratios . . . . . . . . . . . . . . . . . . . . 2 Transmission Switch and Plug Locations . . . . . . . . . 2GENERAL INFORMATION mounted in the shift tower portion of the adapter The AX 15 is a five speed, synchromesh, manual housing (Fig. 1). The AX 15 is used with 4.0L (I6) en-transmission. Fifth gear is an overdrive range with a gines.ratio of 0.79:1. The shift mechanism is integral and Fig. 1 AX 15 Manual Transmission
    • 21 - 2 AX 15 MANUAL TRANSMISSION ZJTRANSMISSION IDENTIFICATION TRANSMISSION SWITCH AND PLUG LOCATIONS The AX 15 identification code numbers are on the The fill plug is at the driver side of the gear casebottom surface of the transmission gear case (Fig. 2). (Fig. 4). The first number represents year of manufacture. The drain plug and backup light switch are on theFor example, 4 would represent 1994. The second passenger side of the gear case (Fig. 5).and third numbers indicate month of manufacture.For example, 11 would represent November. The lastseries of numbers is the transmission serial number.TRANSMISSION SHIFT PATTERN Fig. 4 Fill Plug Location Fig. 2 Transmission Identification Code Location The AX 15 shift pattern is shown in Figure 3. Firstand second and third and fourth gear ranges are inan H pattern. Fifth and reverse gear ranges are alsoin line at the right of the H pattern (Fig. 3). Fig. 5 Drain Plug And Backup Light Switch Location TRANSMISSION GEAR RATIOS AX 15 transmission gear ratios are: First gear - 3.83:1 Second gear - 2.33:1 Third gear - 1.44:1 Fourth gear - 1.00:1 Fifth gear - 0.79:1 Fig. 3 AX 15 Shift Pattern Reverse - 4.22:1TRANSMISSION LUBRICANT Recommended lubricant for AX 15 transmissions is TRANSMISSION DIAGNOSISMopar SAE 75W-90, API Grade GL-5 gear lubricant. LOW LUBRICANT LEVEL Correct lubricant level is from the bottom edge, to A low transmission lubricant level is generally theno more than 6 mm (1/4 in.) below the bottom edge of result of a leak, inadequate lubricant fill, or an incor-the fill plug hole. rect lubricant level check. Lubricant capacity is approximately 3.10 liters Leaks can occur at the mating surfaces of the gear(3.27 qts.). case, intermediate plate and adapter housing, or
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 3from the front/rear seals. A suspected leak could also recommended lubricants is noise, excessive wear,be the result of an overfill condition. internal bind and hard shifting. Leaks at the rear of the adapter housing will be Improper clutch release is a frequent cause of hardfrom the housing oil seals. Leaks at component mat- shifting. Incorrect adjustment or a worn, damageding surfaces will probably be the result of inadequate pressure plate or disc can cause incorrect release. Ifsealer, gaps in the sealer, incorrect bolt tightening, or the clutch problem is advanced, gear clash duringuse of a non-recommended sealer. shifts can result. A leak at the front of the transmission are from the Worn or damaged synchro rings can cause gear clashfront bearing retainer or retainer seal. Lubricant may when shifting into any forward gear. In some new or re-be seen dripping from the clutch housing after extended built transmissions, new synchro rings may tend tooperation. If the leak is severe, it may also contaminate stick slightly causing hard or noisy shifts. In mostthe clutch disc causing slip, grab and chatter. cases, this condition will decline as the rings wear-in. Transmissions filled from air or electrically poweredlubricant containers can be underfilled. This generally TRANSMISSION NOISEhappens when the container delivery mechanism is im- Most manual transmissions make some noise duringproperly calibrated. Always check the lubricant level af- normal operation. Rotating gears can generate a mildter filling to avoid an under fill condition. whine that may only be audible at extreme speeds. A correct lubricant level check can only be made Severe transmission noise is generally the result ofwhen the vehicle is level; use a drive-on hoist to en- a lubricant problem, or internal component damage.sure this. Also allow the lubricant to settle for a Insufficient, improper, or contaminated lubricant canminute or so before checking. These recommenda- promote rapid wear of gears, synchros, shift rails,tions will ensure an accurate check and avoid an un- forks and bearings. The overheating caused by a lu-der-or-overfill condition. bricant problem, can also lead to gear breakage.HARD SHIFTING Hard shifting is usually the result of a low lubri- SPEEDOMETER SERVICEcant level, improper or contaminated lubricants, com- Rear axle gear ratio and tire size determine speed-ponent damage, incorrect clutch adjustment, or by a ometer pinion requirements. If the pinion must be re-damaged clutch pressure plate or disc. placed, refer to the parts catalogue information for Substantial lubricant leaks can result in gear, shift the correct part.rail, synchro and bearing damage. If a leak goes un-detected for an extended period, the first indications SPEEDOMETER ASSEMBLY REMOVALof a problem are hard shifting and noise. (1) Raise vehicle. Incorrect or contaminated lubricants also contrib- (2) Disconnect wires from vehicle speed sensor.ute to hard shifting. The consequence of using non- (3) Remove adapter clamp and screw (Fig. 6). Fig. 6 Speedometer Components
    • 21 - 4 AX 15 MANUAL TRANSMISSION ZJ (4) Remove speed sensor and speedometer adapteras 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. 6). Re-move and discard O-rings if worn or damaged. (8) Inspect terminal pins in speed sensor. Cleanpins with Mopar electrical spray cleaner if dirty oroxidized. Replace sensor if faulty, or pins are loose,severely corroded, or damaged.SPEEDOMETER INSTALLATION ANDINDEXING (1) Thoroughly clean adapter flange and adaptermounting surface in housing. Surfaces must be cleanfor proper adapter alignment and speedometer oper- Fig. 7 Location Of Index Numbers On Speedometeration. Adapter (2) Install new O-rings on speed sensor and speed-ometer adapter if necessary (Fig. 6). (3) Lubricate sensor and adapter O-rings withtransmission fluid. (4) Install vehicle speed sensor in speedometeradapter. Tighten sensor attaching screw to 2-3 N⅐m(15-27 in. lbs.) torque. (5) Install speedometer pinion in adapter. (6) Count number of teeth on speedometer pinion.Do this before installing assembly in housing. Thenlubricate pinion teeth with transmission fluid. (7) Note index numbers on adapter body (Fig. 7).These numbers will correspond to number of teeth onpinion. (8) Install speedometer assembly in housing. (9) Rotate adapter until required range numbersare at 6 o-clock position. Be sure range index num- Fig. 8 Marking Propeller Shaft And Axle Yokebers correspond to number of teeth on pinion gear. (9) Disconnect wires at transfer case electrical (10) Install speedometer adapter clamp and retain- switch.ing screw. Tighten clamp screw to 10-12 N⅐m (90-110 (10) Support transmission with transmission jack.in. lbs.) torque. Secure transmission on jack with safety chains. (11) Connect wires to vehicle speed sensor. (11) Support engine with jack positioned under (12) Lower vehicle and top off transmission fluid clutch housing or oil pan flange.level if necessary. (12) Remove bolts/nuts attaching rear mount to crossmember (Fig. 9).TRANSMISSION REMOVAL (13) Remove rear crossmember. (1) Shift transmission into Neutral. (14) Remove transfer case attaching nuts and re- (2) Raise vehicle on hoist. move transfer case from transmission. (3) Remove skid plate. (15) Lower transmission enough to provide access (4) Mark front and rear propeller shafts for instal- to shift lever.lation alignment (Fig. 8). Then remove shafts. (5) Disconnect transfer case shift linkage from (16) Reach up and around transmission case andshift lever, or range lever. unseat shift lever dust boot from transmission shift (6) Disconnect harness wires at vehicle speed sen- tower (Fig. 10). Move boot upward on shift lever forsor (Fig. 6). access to lever retainer. (7) Remove harness wires from clips on transmis- (17) Disengage transmission shift lever as follows:sion case. (a) Reach up and around transmission case and (8) Disconnect transmission and transfer case vent press shift lever retainer downward with your fin-hoses. gers.
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 5 Fig. 9 Transmission Rear Mounting Fig. 10 Shift Lever Attachment (b) Turn retainer counterclockwise to release it. (6) Reach up and around transmission and insert (c) Lift lever and retainer out of shift tower (Fig. shift lever in shift tower. Press lever retainer down- 10). It is not necessary to remove shift lever ward and turn it clockwise to lock it in place. Then from floorpan boot. Simply leave lever in install lever dust boot on shift tower. place for later installation. (7) Align transfer case and transmission shafts and (18) Disconnect and remove engine timing sensor. install transfer case. Tighten transfer attaching nutsRetain sensor attaching screws. to 35 N⅐m (26 ft. lbs.) torque. (19) Remove clutch slave cylinder from clutch (8) Move adjustable support stand from under en-housing. Move cylinder aside for working clearance gine and reposition it under transmission. Then re-and access to other components. move transmission jack. (20) Remove bolts attaching clutch housing to en- (9) Install rear crossmember. Tighten crossmem-gine. ber-to-frame bolts to 41 N⅐m (30 ft. lbs.) torque. (21) Pull transmission rearward until clutch hous- Tighten transmission-to-rear support bolts/nuts to 45ing is clear of engine. Then remove transmission N⅐m (33 ft. lbs.) torque.from under vehicle. (10) Install slave cylinder in clutch housing. Tighten cylinder attaching nuts securely.TRANSMISSION INSTALLATION (11) Connect or install engine timing sensor, if re- (1) Mount transmission and clutch housing assem- moved.bly on transmission jack. Secure assembly with (12) Connect transfer case electrical switch wires.safety chains. (13) Connect transfer case shift rod to range lever. (2) Lubricate pilot bearing and transmission input (14) Connect transmission and transfer case ventshaft splines with Mopar high temperature grease. hoses and indicator switch wires. (3) Align transmission input shaft and clutch disc (15) Connect backup light switch wires.splines and seat clutch housing on engine. (16) Connect vehicle speed sensor wires. (4) Install and tighten bolts that clutch housing to (17) Align and install front/rear propeller shafts.engine. Tighten bolts to 61 N⅐m (45 ft. lbs.) torque. Tighten shaft U-joint clamp bolts to 19 N⅐m (170 in. (5) Lower transmission for access to transmissionshift tower. lbs.) torque.
    • 21 - 6 AX 15 MANUAL TRANSMISSION ZJ (18) Install skid plate if removed. Tighten bolts to (4) Remove gasket from shift tower (Fig. 3).42 N⅐m (31 ft. lbs.) torque. Tighten stud nuts to 17N⅐m (150 in. lbs.) torque. (19) Top off transmission and transfer lubricantlevels. (20) Lower vehicle.TRANSMISSION DISASSEMBLY AND OVERHAULADAPTER HOUSING REMOVAL (1) Remove release bearing, release lever and re-lease fork from clutch housing. Then remove clutchhousing from transmission. (2) Remove backup light switch. Then removedrain plug (Fig. 1) and drain transmission lubricantinto pan. Fig. 3 Shift Tower Gasket Removal/Installation (5) Remove shift arm retainer bolt (Fig. 4).Fig. 1 Drain Plug And Backup Light Switch Location (3) Remove shift tower bolts and remove towerfrom adapter or extension housing (Fig. 2). Fig. 4 Shift Arm Retainer Bolt Removal/Installation (6) Loosen and remove restrictor pins (Fig. 5). Fig. 2 Shift Tower Removal/Installation Fig. 5 Removing/Installing Restrictor Pins
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 7(7) Remove shift arm shaft plug (Fig. 6). (10) Remove plug for reverse shift head lock ball. Plug is at right side of adapter housing near backup light switch (Fig. 9). Fig. 6 Removing/Installing Shift Arm Shaft Plug (4WD) Fig. 9 Removing/Installing Lock Ball Plug (8) Remove shift arm shaft with large magnet (Fig. (11) Remove lock ball spring with pencil magnet7). (Fig. 10). Fig. 10 Removing/Installing Lock Ball Spring Fig. 7 Removing/Installing Shift Arm Shaft (4WD) (12) Remove shift head lock ball with pencil mag- (9) Remove shift arm (Fig. 8). net (Fig. 11). Fig. 11 Removing/Installing Shift Head Lock Ball Fig. 8 Shift Arm Removal/Installation
    • 21 - 8 AX 15 MANUAL TRANSMISSION ZJ (13) Remove adapter housing bolts (Fig. 12). (14) Loosen adapter/extension housing with rubber mallet (Fig. 13). Fig. 13 Loosening Adapter Housing (15) Remove housing after loosening it (Fig. 14) Fig. 14 Adapter Housing Removal (16) Remove adapter housing oil seal with a pry tool (Fig. 15). Fig. 15 Removing Adapter Housing Seal Fig. 12 Adapter Housing Bolt Locations
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 9GEAR CASE REMOVAL (1) Remove bearing retainer bolts and remove re-tainer (Fig. 16). Fig. 18 Removing Input Shaft Bearing Snap Ring Fig. 16 Front Bearing Retainer Removal (2) Remove retainer oil seal with pry tool (Fig. 17). Fig. 19 Removing Cluster Gear Front Bearing Snap Ring Fig. 17 Front Bearing Retainer Seal Location (3) Remove input shaft bearing snap ring (Fig. 18). (4) Remove cluster gear front bearing snap ring(Fig. 19). (5) Loosen gear case by tapping it away from inter-mediate plate with rubber mallet (Fig. 20). Fig. 20 Loosening Gear Case
    • 21 - 10 AX 15 MANUAL TRANSMISSION ZJ (6) Remove gear case from geartrain and interme- (2) Remove three lock ball springs and lock ballsdiate plate (Fig. 21). from intermediate plate with pencil magnet (Fig. 23). (7) Remove speedometer gear snap ring and re-move speedometer gear and spacer from outputshaft. Fig. 21 Gear Case RemovalFIFTH GEAR AND SYNCHRO ASSEMBLYREMOVAL (1) Remove three lock ball plugs from intermediateplate (Fig. 22). Fig. 23 Removing/Installing Lock Ball And Spring Fig. 22 Lock Ball Plug Locations
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 11 Fig. 24 Mounting Intermediate Plate And Geartrain In Vise (3) Mount intermediate plate and geartrain assem- (5) Remove E-ring that secures reverse shift armbly in vise as follows: to fork (Fig. 26). (a) Insert two spare bolts in one bottom bolt hole in intermediate plate. Insert bolts from opposite sides of plates (Fig. 24). (b) Install enough flat washers under each bolt head to prevent bolts from touching (Fig. 24). (c) Tape bolts and washers in place and mount intermediate plate in vise (Fig. 24). (d) Clamp vise jaws securely against bolt heads (Fig. 24). Do not clamp vise jaws on intermedi- ate plate. Clamp only on bolt heads. (4) Remove fifth gear snap ring (Fig. 25). Retainsnap ring for assembly reference. It is a select fitcomponent. Fig. 26 Reverse Shift Arm E-Ring Removal Fig. 25 Fifth Gear Snap Ring Removal
    • 21 - 12 AX 15 MANUAL TRANSMISSION ZJ (6) Remove bolts attaching reverse shift armbracket to intermediate plate. Then remove bracket(Fig. 27). Fig. 29 Fifth Gear Fork Set Screw Removal Fig. 27 Reverse Shift Arm Bracket Removal (7) Remove reverse shift arm and shoe (Fig. 28). Fig. 30 Fifth Gear Shift Fork Removal Fig. 28 Reverse Shift Arm And Shoe Removal (8) Remove fifth gear shift fork set screw (Fig. 29). (9) Move fifth gear shift rail forward until it clearsshift fork. (10) Remove fifth gear shift fork from synchrosleeve (Fig. 30). (11) Remove reverse shift rail and reverse shifthead as assembly (Fig. 31). (12) Measure thrust clearance between counterfifth gear and thrust ring with feeler gauge. Clear-ance should be 0.10 to 0.40 mm (0.003 to 0.019 in.).If clearance exceeds limits, gear and/or ring will haveto be replaced. Fig. 31 Reverse Shift Head And Rail Removal
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 13 (13) Loosen fifth spline gear with standard two-jawpuller (Fig. 32). Position puller jaws behind fifthcounter gear as shown. Fig. 34 Fifth Gear Synchro Ring Removal Fig. 32 Loosening Fifth Spline Gear (14) Remove fifth spline gear (Fig. 33). Fig. 35 Counter Fifth Gear And Synchro Assembly Removal Fig. 33 Fifth Spline Gear Removal (15) Remove fifth gear synchro ring (Fig. 34). (16) Remove fifth gear synchro and sleeve assem-bly (Fig. 35). (17) Remove counter fifth gear thrust ring (Fig.36). Fig. 36 Fifth Gear Thrust Ring Removal
    • 21 - 14 AX 15 MANUAL TRANSMISSION ZJ (18) Remove thrust ring lock ball with pencil mag-net (Fig. 37). Fig. 39 Output Shaft Rear Bearing Retainer Removal Fig. 37 Thrust Ring Lock Ball Removal (19) Remove bolts attaching output shaft rearbearing retainer to intermediate plate (Fig. 38). Fig. 40 Reverse Idler Gear And Shaft Removal Fig. 38 Output Shaft Rear Bearing Retainer Bolt Removal (20) Remove rear bearing retainer (Fig. 39). (21) Remove reverse idler gear and shaft (Fig. 40).
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 15 Fig. 41 Shift Rail IdentificationSHIFT RAIL AND FORK REMOVAL There are a total of five shift rails in the AX 15transmission. The 1-2, 3-4, fifth gear and front re-verse shift rails are shown in Figure 41. Two shift rails are used for reverse gear range. Thefront reverse rail is at the forward side of the inter-mediate plate (Fig. 41). The short rear reverse railand reverse shift head are at the rear side of the in-termediate plate. It is not necessary to remove the shift rails ifthey are in good condition. Only the shift forksneed be removed for access to the shafts andgears. (1) Remove fifth gear shift rail (Fig. 41). Catch lockball in your hand as rail comes out of intermediateplate. (2) Remove 1-2 and 3-4 shift rail C-rings with twoscrewdrivers of equal size and length (Fig. 42). Fig. 42 Shift Rail C-Ring Removal
    • 21 - 16 AX 15 MANUAL TRANSMISSION ZJ (3) Remove shift fork set screws (Fig. 43). (6) Remove 1-2 shift rail from shift fork and inter- mediate plate (Fig. 46). Fig. 43 Shift Fork Set Screw Removal Fig. 46 Removing 1-2 Shift Rail (4) Remove 3-4 shift rail from shift fork and inter- (7) Remove 1-2 shift rail interlock pin from shiftmediate plate (Fig. 44). rail (Fig. 47). Fig. 47 Removing 1-2 Shift Rail Interlock Pin Fig. 44 Removing 3-4 Shift Rail (8) Remove 1-2 shift rail interlock plug from inter- (5) Remove 3-4 shift rail interlock plug from inter- mediate plate (Fig. 48).mediate plate with magnet (Fig. 45). Fig. 48 Removing 1-2 Shift Rail Interlock Plug Fig. 45 Removing 3-4 Shift Rail Interlock Plug
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 17 (9) Lift reverse shift fork upward and remove fifthgear shift rail lock ball (Fig. 49). Fig. 49 Fifth Gear Shift Rail Lock Ball Removal (10) Remove 3-4 shift fork (Fig. 50). (11) Remove 1-2 shift fork (Fig. 50). Fig. 51 Reverse Shift Rail C-Ring Removal Fig. 52 Reverse Shift Rail And Fork Removal Fig. 50 Shift Fork Removal (12) Remove reverse shift rail C-ring with twoequal length and size screwdrivers (Fig. 51). (13) Remove reverse shift rail and fork (Fig. 52).
    • 21 - 18 AX 15 MANUAL TRANSMISSION ZJ (14) Remove interlock pin from reverse shift rail (3) Tap end of output shaft with mallet to unseat and(Fig. 53). start rear bearing out of intermediate plate (Fig. 55). (15) Position shift rails, shift forks, lock balls, in-terlock plugs and interlock pins on the workbench inorder of removal. This will help in identifying compo-nents during inspection and assembly. Fig. 55 Unseating Output Shaft Rear Bearing (4) Remove output shaft by rocking it lightly until rear bearing comes out of intermediate plate (Fig. 56). Fig. 53 Reverse Shift Rail Interlock Pin RemovalOUTPUT SHAFT AND CLUSTER GEARREMOVAL (1) Remove output shaft rear bearing snap ring(Fig. 54). (2) Remove cluster gear rear bearing snap ring(Fig. 54). Fig. 56 Input And Output Shaft Removal (5) Remove cluster gear by pulling it straight out of rear bearing (Fig. 57). Fig. 57 Cluster Gear Removal Fig. 54 Removing Bearing Snap Rings
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 19 (6) Remove cluster gear rear bearing from interme- (9) Remove synchro ring from input shaft (Fig. 61).diate plate (Fig. 58). (10) Remove bearing snap ring and press bearing off input shaft (Fig. 61). Fig. 58 Removing Cluster Gear Rear Bearing Fig. 61 Input Shaft Components (7) Remove input shaft from output shaft (Fig. 59). OUTPUT SHAFT DISASSEMBLY (1) Measure thrust clearance of output shaft first, second and third gears with feeler gauge (Fig. 62). • First gear clearance should be 0.10 to 0.40 mm (0.003 to 0.0197 in). • Second-third gear clearance should be 0.10 to 0.30 mm (0.003 to 0.0118 in.). (2) If first gear thrust clearance is incorrect, re- place gear and thrust washer. If second or third gear clearance is incorrect, either gear and bearing, or output shaft flange is worn. Refer to output shaft inspection in Cleaning and Inspec- tion section. Fig. 59 Input Shaft Removal (8) Remove output shaft pilot bearing from inputshaft (Fig. 60). Fig. 62 Checking Output Shaft Gear Thrust Fig. 60 Input Shaft Pilot Bearing Removal Clearance
    • 21 - 20 AX 15 MANUAL TRANSMISSION ZJ Fig. 63 Output Shaft And Gears (3) Press fifth gear and rear bearing off rear of Inspect the transmission case. Replace the case ifoutput shaft. cracked or porous or if any of the bearing and gear (4) Remove thrust washer, pin, and first gear and bores are damaged.bearing (Fig. 62). (5) Remove first/reverse hub snap ring (Fig. 63). Output Shaft Inspection (6) Remove synchro ring. Measure thickness of the output shaft flange with (7) Press reverse gear and first/reverse hub off a micrometer (Fig. 64). Minimum allowable flangeshaft as assembly. thickness is 4.70 mm (0.185 in). (8) Remove remaining synchro ring and second If shaft flange thickness is OK but previouslygear and bearing (Fig. 63). measured second/third gear thrust clearance (9) Remove snap ring at front of output shaft (Fig. was incorrect (Fig. 62), replace the necessary63). gear and needle bearing as an assembly. (10) Press 3-4 hub and sleeve off output shaft as Check diameter of the first, second and third gearassembly (Fig. 63). bearing surfaces of the output shaft (Fig. 64). Mini- (11) Remove synchro ring. mum allowable diameters are: (12) Remove third gear and needle bearing (Fig. • 38.86 mm (1.529 in.) for first gear surface63). • 46.86 mm (1.844 in.) for second gear surface • 37.86 mm (1.490 in.) for third gear surfaceTRANSMISSION CLEANING AND INSPECTION Check output shaft runout with V-blocks and a dial Clean the transmission components in solvent. indicator (Fig. 64). Maximum allowable runout isThen dry the cases, gears, shift mechanism and 0.06 mm (0.0024 in.).shafts with compressed air. Dry the bearings with Replace the output shaft if any surface measuredclean, dry shop towels only. Never use com- fails to meet stated tolerance.pressed air on the bearings. This could damagethe bearing rollers. Cluster Gear Inspection Replace components that are obviously worn, Inspect the cluster gear teeth. Replace the gear ifcracked, chipped or damaged. any teeth are worn or damaged or if the bearing sur- faces are damaged.
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 21 GEAR AND SYNCHRO INSPECTION Install the synchro rings on their respective gears. Rotate each ring on the gear and note synchro action. Replace any synchro ring that exhibits a lack of braking action or binds on the gear. Also replace any ring that is worn or has chipped or broken teeth. Measure end clearance between the synchro ring and the gear with a feeler gauge (Fig. 66). Clearance should be 0.06 mm to 1.6 mm (0.024 to 0.063 in.). Fig. 66 Checking Synchro Ring End Clearance Install the needle bearings in the first, second and third gears. Then install the gears on the output shaft and check shaft-to-gear clearance with a dial indicator (Fig. 67). Fig. 64 Checking Output Shaft Tolerances Check diameter of the cluster gear journal with amicrometer (Fig. 65). Minimum allowable diameter is27.860 mm (1.096 in.). Fig. 65 Checking Cluster Gear Journal Diameter Check condition of the cluster gear front bearing.Replace the bearing if worn, noisy, or damaged. Fig. 67 Checking Gear-To-Shaft Clearance
    • 21 - 22 AX 15 MANUAL TRANSMISSION ZJ Maximum allowable clearance is 0.16 mm (0.0063 Inspect the threads in the case, housing and plate.in.). If any gear exhibits excessive clearance, replace Minor thread damage can be repaired with steelthe gear and needle bearing. thread inserts if necessary. However, do not attempt Check clearance between the shift forks and syn- to repair if the cracks are evident around anychro sleeves with a feeler gauge (Fig. 68). Clearance threaded hole.should not exceed 1.0 mm (0.039 in.). Replace the Inspect the reverse pin in the adapter/extensionsynchro sleeve (and matching hub) if clearance ex- housing. Replace the pin if worn or damaged. Referceeds the stated limit. to the replacement procedure in the Transmission As- sembly section. TRANSMISSION ASSEMBLY AND ADJUSTMENT Lubricate the transmission components with gear lubricant during assembly. Use petroleum jelly to lu- bricate seal lips and/or hold parts in place during in- stallation. FRONT BEARING/BEARING SEAL/REVERSE SHAFT PIN INSTALLATION (1) Press front bearing on input shaft. Then secure bearing with thickest snap ring that will fit in shaft groove (Fig. 70). Fig. 68 Checking Shift Fork-To-Sleeve Clearance Check condition of the reverse idler gear bushing(Fig. 69). Replace the gear if the bushing is scored orworn. Fig. 70 Selecting Input Shaft Front Bearing Snap Ring (2) Press front bearing on cluster gear. Then se- cure bearing with thickest snap ring that will fit in ring groove on gear (Fig. 71). (3) Install new oil seals in front bearing retainer and adapter housing (Fig. 72). Installation depth for Fig. 69 Reverse Idler Gear Bushing bearing retainer seal is 10.5 to 11.5 mm (0.414 toGear Case, Housing And Intermediate Plate 0.453 in.). (4) Install reverse shaft and shaft retaining pin in Clean the case, housing and plate with solvent and adapter housing. Then install access hole plug withdry with compressed air. Replace any component that torx bit (Fig. 73).is cracked, warped or damaged in any way.
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 23 Fig. 71 Selecting Cluster Gear Front Bearing Snap Fig. 73 Installing Reverse Shaft Pin Ring OUTPUT SHAFT ASSEMBLY (1) Lubricate output shaft journals, gears and nee- dle bearings with recommended gear lubricant. (2) Install third gear and needle bearing on shaft (Fig. 63) (3) Install synchro ring on third gear (Fig. 63). (4) Assemble 1-2 and 3-4 synchro hubs and sleeves (Fig.74). Fig. 74 Synchro Sleeve And Hub Identification Fig. 72 Oil Seal Installation (5) Lubricate reverse shaft and gear componentswith Mopar 75W-90 gear lubricant.
    • 21 - 24 AX 15 MANUAL TRANSMISSION ZJ (5) Install inserts and springs in synchro sleeves.Position open ends of springs 180° apart as shown(Fig. 75). Fig. 77 Checking Third Gear Clearance Fig. 75 Insert Spring Position (12) Assemble first/reverse hub, insert springs, in- serts, reverse gear and 1-2 sleeve (Fig. 78). Be sure (6) Install 3-4 synchro hub and sleeve on output spring ends are 180° apart. Note that splines inshaft. Press hub onto shaft if necessary. hub bore are chamfered on one side. Install (7) Install 3-4 synchro hub snap ring (Fig. 76). Use hub so chamfered side faces front of outputthickest snap ring that will fit in shaft groove. shaft. (13) Press assembled hub and sleeve on output shaft. (14) Install selective snap ring (Fig. 78). Use thick- est snap ring that will fit in output shaft groove. Fig. 76 Installing 3-4 Synchro Hub Snap Ring (8) Verify third gear thrust clearance with feelergauge (Fig. 56). Clearance should be 0.10 to 0.25 mm(0.004 to 0.010 in.). (9) Lubricate remaining output shaft gears and Fig. 78 Second Gear And Synchro Assemblybearings with gear lubricant. (15) Install synchro ring on first gear (Fig. 79). (10) Install second gear and needle bearing on (16) Install first gear spacer on shaft and againstshaft (Fig. 78). selective fit snap ring (Fig. 79). (11) Install synchro ring on second gear (Fig. 78). (17) Install first gear and needle bearing (Fig. 79) on output shaft.
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 25 (18) Install locating pin and thrust washer on (22) Lubricate input shaft pilot bearing with petro-shaft (Fig. 79). leum jelly and install bearing in shaft (Fig. 60). (23) Install input shaft on output shaft (Fig. 59). Be sure output shaft hub is fully seated in pilot bearing. OUTPUT SHAFT AND CLUSTER GEAR INSTALLATION (1) Mount intermediate plate in vise (Fig. 24). (2) Lubricate cluster gear journal and rear bearing with petroleum jelly or gear lubricant. (3) Install cluster gear rear bearing in intermedi- ate plate (Fig. 81). Be sure snap ring groove in bear- ing is rearward as shown. Fig. 79 First And Fifth Gear Components (19) Press rear bearing on shaft. Position bearingsnap ring groove so it is closest to end of output shaft. (20) Check first and second gear thrust clearancewith feeler gauge (Fig. 62).• First gear clearance should be 0.10 to 0.40 mm(0.003 to 0.0197 in.)• Second gear clearance should be 0.10 to 0.30 mm(0.003 to 0.0118 in.) (21) Press fifth gear onto output shaft. Then installselect fit snap ring (Fig. 80). Use thickest snap ringthat will fit in shaft groove. Fig. 81 Installing Cluster Gear Rear Bearing (4) Start cluster gear into bearing (Fig. 57). Then hold bearing and push gear into place. Use plastic or rawhide mallet to seat bearing if necessary. (5) Start output shaft rear bearing in intermediate plate. Push shaft rearward and tap intermediate plate with mallet to seat bearing. (6) Install snap rings on cluster and output shaft rear bearings only (Fig. 82). Do not install front bearing snap rings at this time. Fig. 80 Selecting Fifth Gear Snap Ring Fig. 82 Installing Rear Bearing Snap Rings
    • 21 - 26 AX 15 MANUAL TRANSMISSION ZJ Fig. 83 Installing Reverse Idler Gear And Shaft Fig. 84 Installing Rear Bearing Retainer (7) Install reverse idler gear and shaft (Fig. 83). SHIFT RAIL AND FORK INSTALLATION (8) Position rear bearing retainer over output shaft The shift rail interlock pins, balls and plugs mustand rear bearing. Be sure bearing retainer tab is be installed in the correct sequence for proper shift-engaged in reverse idler shaft notch (Fig. 84). ing. Refer to the installation diagram (Fig. 85) during (9) Install and tighten rear bearing retainer bolts assembly.to 18 N⅐m (13 ft-lbs). Coat the intermediate plate shift rail bores and the interlock balls, pins and plugs with a thick covering of petroleum jelly before assem- Fig. 85 Shift Rail Ball-Plug-Pin Position
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 27bly. The jelly will hold the interlock compo-nents in place making installation easier. Use apencil magnet to hold and insert the interlocks.Then use a small screwdriver to push the inter-lock components into place. (1) Coat reverse rail interlock pin with petroleumjelly and install pin in rail (Fig. 86). (2) Install reverse shift rail in intermediate plate(Fig. 87). (3) Install reverse shift rail C-ring (Fig. 51). Fig. 86 Installing Reverse Shift Rail Interlock Pin Fig. 88 Shift Fork Installation Fig. 87 Installing Reverse Shift Rail And Fork (4) Position 1-2 and 3-4 shift forks in synchro Fig. 89 Installing Reverse Shift Rail Lock Ballsleeves (Fig. 88). (9) Coat 3-4 shift rail interlock plug with petro- (5) Coat reverse rail lock ball with petroleum jelly. leum jelly and install plug in intermediate plate (Fig.Then tilt reverse shift fork upward and insert ball in 93).intermediate plate (Fig. 89). (10) Install 3-4 shift rail in intermediate plate and (6) Coat 1-2 shift rail interlock plug with petro- in both shift forks (Fig. 94).leum jelly and install it in intermediate plate bore (11) Verify that none of the interlock balls, plugs,(Fig. 90). or pins were displaced during shift rail installation. (7) Coat 1-2 shift rail interlock pin with petroleum (12) Install and tighten shift fork setscrews to 20jelly and insert it in shift rail (Fig. 91). N⅐m (14 ft. lbs.) torque (Fig. 95). (8) Install 1-2 shift rail in intermediate plate and1-2 fork (Fig. 92).
    • 21 - 28 AX 15 MANUAL TRANSMISSION ZJ Fig. 90 Installing 1-2 Shift Rail Interlock Plug Fig. 93 Installing 3-4 Shift Rail Interlock Plug Fig. 91 Installing 1-2 Shift Rail Interlock Pin Fig. 94 Installing 3-4 Shift Rail Fig. 92 Installing 1-2 Shift Rail Fig. 95 Installing Shift Fork Set Screws
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 29 (13) Install 1-2 and 3-4 shift rail C-rings (Fig. 96). (14) Insert fifth gear shift rail through reverseshift fork. Then slide rail into intermediate platejust far enough to secure interlock ball. Do notfully install shift rail at this time. Fig. 98 Installing Fifth Gear Thrust Ring Fig. 96 Installing Shift Rail C-RingsFIFTH-REVERSE GEAR AND SHIFTCOMPONENT INSTALLATION (1) Install thrust ring lock ball in cluster gear jour-nal (Fig. 97). Use petroleum jelly to hold ball inplace. (2) Install fifth gear thrust ring (Fig. 98). Be surethrust ring notch fits over lock ball. Fig. 99 Assembling Fifth Gear And Synchro Assembly Fig. 97 Installing Thrust Ring Lock Ball (3) Assemble counter fifth gear, synchro sleeve, in-serts and insert springs (Fig. 99). (4) Lubricate two-piece bearing with petroleumjelly and install it in counter fifth gear (Fig. 100). Fig. 100 Installing Counter Fifth Gear Bearing
    • 21 - 30 AX 15 MANUAL TRANSMISSION ZJ (5) Install counter fifth gear and synchro assembly (8) Install fifth gear selective snap ring (Fig. 104).on cluster gear journal (Fig. 101). Use thickest snap ring that will fit in shaft groove. Fig. 101 Installing Counter Fifth Gear And Sleeve (6) Install synchro ring in synchro sleeve (Fig. 102). Fig. 104 Installing Fifth Gear Snap Ring (9) Install reverse shift head and rail (Fig. 105). Then install lock ball in shift head. Fig. 102 Installing Fifth Gear Synchro Ring (7) Install fifth spline gear on cluster journal (Fig.103). Tap spline gear into place with plastic mallet ifnecessary. Fig. 105 Installing Reverse Shift Head And Rail (10) Position fifth gear shift fork in synchro sleeve (Fig. 106). (11) Install fifth gear shift rail (Fig. 107). Slide rail through fork, shift head, intermediate plate and re- verse shift fork. Be sure interlock ball is not dis- Fig. 103 Installing Fifth Spline Gear placed during installation.
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 31 Fig. 106 Fifth Gear Shift Fork Installation Fig. 109 Detent Ball And Spring Installation (14) Install reverse shift arm bracket (Fig. 110). Tighten bracket bolts to 18 N⅐m (13 ft. lbs.) torque. (15) Install reverse shift arm (Fig. 110). Position Fig. 107 Fifth Gear Shift Rail Installation arm on reverse fork pin and engage it with pin on shift arm bracket. (12) Align screw holes in shift fork and rail and in- (16) Verify that shift arm shoe is engaged in re-stall set screw (Fig. 108). Tighten screw to 20 N⅐m verse idler gear. Then secure shift arm to pin on re-(15 ft. lbs.) torque. verse fork with new E-clip. Fig. 108 Shift Fork Set Screw Installation (13) Install lock balls and springs in intermediate Fig. 110 Reverse Shift Arm And Bracket Installationplate (Fig. 109). Then install and tighten lock ball GEAR CASE AND ADAPTER INSTALLATIONplugs to 19 N⅐m (14 ft. lbs.) torque. (1) Dismount intermediate plate and gear assem- blies from vise.
    • 21 - 32 AX 15 MANUAL TRANSMISSION ZJ (2) Clean mating surfaces of intermediate plateand transmission gear case with wax and grease re-mover. Then wipe dry with a clean cloth. (3) Apply 3 mm (1/8 in.) wide bead of Mopar Gas-ket Maker, or Loctite 518 to mating surface of gearcase. Keep sealer bead inside bolt holes as shown(Fig. 111). Fig. 113 Front Bearing Snap Ring Installation Fig. 111 Applying Sealer To Gear Case (10) Align and install front bearing retainer (Fig. (4) Install gear case (Fig. 112). Align shift rails and 114). Be sure retainer is properly seated on case andbearings in case and tap case into position. bearings. (5) Verify that gear case is seated on intermediateplate dowel pins. Fig. 114 Installing Front Bearing Retainer (11) Install and tighten front bearing retainer bolts Fig. 112 Gear Case Installation to 17 N⅐m (12 ft. lbs.) torque. (6) Install front bearing snap rings (Fig. 113). (12) On models with extension housing, install (7) Clean gear case and front bearing retainer seal- speedometer gear, lock ball and retaining rings (Fig.ing surfaces with wax and grease remover. Then 115). Be sure lock ball is engaged in gear.wipe dry with a clean cloth. (13) Inspect condition of reverse pin in adapter/ex- (8) Install new seal in front bearing retainer. Then tension housing (Fig. 116). If pin is worn or damaged,lubricate seal lip with petroleum jelly. Installation replace it as follows:depth for seal is 10.5 to 11.5 mm (0.413 to 0.453 (a) Remove roll pin access plug (Fig. 117).in.). (b) Tap roll pin out of housing with pin punch (9) Apply a 3 mm (1/8 in.) wide bead of Mopar (Fig. 118). Then remove old reverse pin.Gasket Maker, or Loctite 518 to front bearing re-tainer sealing surface.
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 33 Fig. 115 Speedometer Gear Installation (2WD Fig. 118 Roll Pin Removal/Installation Models) (14) Clean sealing surfaces of adapter or extension housing and intermediate plate with wax and grease remover. Then wipe dry with a clean cloth. (15) Apply 3 mm (1/8 in.) wide bead of Mopar Gas- ket Maker, or Loctite 518 to sealing surface of adapter or extension housing. Keep sealer bead in- side bolt holes as shown in Figure 111. (16) Align and install adapter or extension housing on intermediate plate (Fig. 119). Be sure housing is seated on intermediate plate dowel pins. (17) Coat threads of housing attaching bolts with Mopar silicone sealer. Then install and tighten bolts to 37 N⅐m (27 ft. lbs.) torque. Fig. 116 Reverse Pin Position Fig. 119 Adapter/Extension Housing Installation (18) Install detent ball (Fig. 120). (19) Install detent spring (Fig. 121). (20) Install detent access plug (Fig. 122). Tighten plug to 19 N⅐m (14 ft. lbs.) torque. Fig. 117 Access Plug Removal/Installation (21) Lubricate shift arm shaft and install it in (c) Install new reverse pin and secure it with roll adapter housing (Fig. 123). pin. Then install and tighten access plug to 19 N⅐m (22) Position shift arm in adapter housing (Fig. (14 ft. lbs.) torque. 124). Be sure arm is engaged in shift rails. (23) Align shift arm with shaft and push shaft into arm.
    • 21 - 34 AX 15 MANUAL TRANSMISSION ZJ Fig. 120 Installing Detent Ball Fig. 123 Installing Shift Arm Shaft Fig. 121 Installing Detent Spring Fig. 124 Shift Arm Installation (26) Install and tighten restrictor pins to 19 N⅐m (14 ft. lbs.) torque (Fig. 125). Fig. 122 Installing Detent Access Plug (24) Rotate shift arm shaft until set screw holes inshaft and arm are aligned. Fig. 125 Set Screw And Restrictor Pin Installation (25) Install and tighten shift arm set screw to 38N⅐m (28 ft. lbs.) torque (Fig. 125).
    • ZJ AX 15 MANUAL TRANSMISSION 21 - 35 (27) Install and tighten shift arm shaft access plugto 19 N⅐m (14 ft. lbs.) torque (Fig. 126). Fig. 127 Shift Tower Gasket Installation Fig. 126 Access Plug Installation (28) Position new shift tower gasket on adapterhousing (Fig 127). (29) Install shift tower (Fig. 128). Tighten towerattaching bolts to 18 N⅐m (13 ft. lbs.) torque. (30) Install new gasket on backup light switch andinstall switch. Tighten switch to 37 N⅐m (27 ft. lbs.)torque. (31) Install new washer on drain plug. Then installand tighten plug to 37 N⅐m (27 ft. lbs.) torque. (32) If transmission will be filled with gear lubri-cant before installation, place transmission in a levelposition. Then fill with Mopar 75W-90, grade GL-5gear lubricant. Fig. 128 Shift Tower Installation (33) Install new washer on fill plug. Then installand tighten plug to 37 N⅐m (27 ft. lbs.) torque. (34) Install clutch housing and hydraulic concen-tric bearing. (35) On models with extension housing, install newseal in housing with suitable size installer tool (Fig.129). Lubricate seal lips with petroleum jelly beforeinstallation. (36) On models with extension housing, installspeedometer driven gear, speedometer adapter andspeed sensor. Fig. 129 Installing Extension Housing Seal
    • 21 - 36 42RE AUTOMATIC TRANSMISSION ZJ 42RE AUTOMATIC TRANSMISSION CONTENTS page pageGENERAL INFORMATION . . . . . . . . . . . . . . . . . 36 42RE TRANSMISSION OVERHAUL . . . . . . . . . . 9842RE TRANSMISSION DIAGNOSIS . . . . . . . . . . 42 42RE TRANSMISSION/OVERDRIVE42RE OVERDRIVE UNIT OVERHAUL . . . . . . . . 146 REMOVAL AND INSTALLATION . . . . . . . . . . . 8942RE IN-VEHICLE SERVICE . . . . . . . . . . . . . . . 77 GENERAL INFORMATION INDEX page pageConverter Clutch Engagement . . ... . . . . . . . . . . . 40 Recommended Fluid . . . . . . . . . . . . . . . . . . . . . . . 38Converter Drainback Valve . . . . ... . . . . . . . . . . . 40 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . . 38Electronic Governor Components .. . . . . . . . . . . . 38 Transmission Changes and PartsGear Ratios . . . . . . . . . . . . . . . ... . . . . . . . . . . . 38 Interchangeability . . . . . . . . . . . . . . . . . . . . . . . . 41Governor Pressure Curves . . . . ... . . . . . . . . . . . 40 Transmission Description . . . . . . . . . . . . . . . . . . . . 36Overdrive Off Switch . . . . . . . . . ... . . . . . . . . . . . 40 Transmission Identification . . . . . . . . . . . . . . . . . . 38Quick Fill Valve . . . . . . . . . . . . . ... . . . . . . . . . . . 40 Transmission Shifting . . . . . . . . . . . . . . . . . . . . . . 40TRANSMISSION DESCRIPTION The overdrive clutch is applied in fourth gear only. The Chrysler 42RE is a 4-speed, fully automatic The direct clutch is applied in all ranges excepttransmission with an electronic governor. It is used fourth gear.with 4.0L engines. The 42RE valve body transfer plate is different. It Mechanical and hydraulic components in the 42RE is designed to accept a governor body and differentare similar to those in RH series transmissions. The hydraulic circuitry. The governor pressure solenoidmain difference involves the method of producing valve and sensor are mounted in this body. Thegovernor pressure for shift control. The 42RE uses transfer plate channels line pressure to the solenoidelectronic components to develop governor pressure. valve through the governor body. It also channelsA mechanical governor is used to generate governor governor pressure from the solenoid valve to the gov-pressure in the RH series. ernor circuit. It is the solenoid valve that develops First through third gear ranges are provided by the necessary governor pressure.clutches, bands, overrunning clutch and planetary The 42RE overdrive unit is different from previousgear sets in the transmission unit. Fourth gear range overdrive units. It is shorter in length as a result ofis provided by the overdrive unit which contains an eliminating the mechanical governor assembly in-overdrive clutch, direct clutch, planetary gear set and cluding the governor tubes and governor support.overrunning clutch.
    • ZJ 42RE AUTOMATIC TRANSMISSIONFig. 1 42RE Automatic Transmission (4 x 2 Model) 21 - 37
    • 21 - 38 42RE AUTOMATIC TRANSMISSION ZJTORQUE CONVERTER A three element torque converter is used for all ap-plications (Fig. 1). Converter elements consist of theturbine, stator and impeller. The converter also con-tains an overrunning clutch and a converter clutchmechanism. The converter clutch is an electronically controlledmechanism. The clutch provides reduced enginespeed and greater fuel economy when engaged.Clutch engagement also provides reduced transmis-sion fluid temperatures. The converter clutch is engaged in fourth gear andin third gear when the overdrive control switch is inthe OFF position. An overrunning clutch is mounted in the statorhub. This one-way clutch prevents the stator from Fig. 2 Transmission Identification Number Andturning in a direction opposite to engine rotation. Code LocationThis retains the torque multiplication feature of theconverter. • governor pressure sensor The torque converter is not a serviceable compo- • fluid temperature thermisternent. It should be replaced as an assembly when di- • transmission speed sensoragnosis indicates a malfunction has occurred, or • throttle position sensorwhen a major malfunction causes debris to enter the • transmission control module (TCM)converter. Governor Pressure Solenoid ValveGEAR RATIOS The solenoid valve generates the governor pressure Forward Gear ratios for the 42RE transmission needed for upshifts and downshifts. It is an electro-are: hydraulic device and is located in the governor body• First gear = 2.74:1 on the valve body transfer plate (Fig. 3).• Second gear = 1.54:1 The inlet side of the solenoid valve is exposed to• Third gear = 1.00:1 normal transmission line pressure. The outlet side of• Fourth gear = 0.69:1. the valve leads to the valve body governor circuit. The solenoid valve regulates line pressure to pro-RECOMMENDED FLUID duce governor pressure. The average current sup- The only fluid recommended for the 42RE trans- plied to the solenoid controls governor pressure. Onemission is Mopar ATF Plus, type 7176. amp current produces zero kPa/psi governor pres- Dexron II is not really recommended and should sure. Zero amps sets the maximum governor pres-only be used when ATF Plus is not available. sure. The transmission control module (TCM) suppliesTRANSMISSION IDENTIFICATION electrical power to the solenoid valve. Operating volt- The transmission part/identification numbers andcodes are stamped on the left side of the case just age is 12 volts (DC) and is provided through the bat-above the oil pan gasket surface (Fig. 2). tery terminal on the module. The first letter/number group is the assembly part The solenoid is polarity sensitive. The TCM ener-number. The next number group the transmission gizes the solenoid by grounding it through the powerbuild date. The last number group is the transmis- ground terminal on the transmission control module.sion serial number. Refer to this information whenordering replacement parts. Governor Pressure Sensor The governor pressure sensor measures outputELECTRONIC GOVERNOR COMPONENTS pressure of the governor pressure solenoid valve (Fig. Governor pressure is developed and controlled elec- 4).tronically in the 42RE transmission. Components The sensor output signal provides the necessaryused for development and control of governor pres- feedback to the transmission control module. Thissure include: feedback is needed to adequately control governor• governor body pressure.• new design valve body transfer plate• governor pressure solenoid valve
    • ZJ 42RE AUTOMATIC TRANSMISSION 21 - 39 clutch, when fluid temperature is below approxi- mately 1°C (30°F). If fluid temperature exceeds 126°C (260°F), the transmission control module will cause a 4-3 down- shift and engage the converter clutch. Engagement is according to the third gear converter clutch engage- ment 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 Fig. 3 Governor Pressure Solenoid Valve 110°C (230°F). The thermistor is mounted on the solenoid assem- bly (Fig. 6). It is immersed in transmission fluid at all times. Fig. 4 Governor Pressure SensorGovernor Body And Transfer Plate A different transfer plate is used with the 42RE Fig. 6 Thermister Locationvalve body. The transfer plate is designed to supplytransmission line pressure to the governor pressure Transmission Speed Sensorsolenoid valve and to return governor pressure. The The speed sensor (Fig. 7), is located in the over-governor pressure solenoid valve is mounted in the drive gear case. The sensor is positioned over thegovernor body. The body is bolted to the lower side of park gear and monitors transmission output shaft ro-the transfer plate (Fig. 5). tating speed. The sensor used with the 42RE trans- mission 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 sen- sor are shared with the powertrain control module. Fig. 5 Governor BodyTransmission 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 tocontrol engagement of the fourth gear overdriveclutch, the converter clutch, and governor pressure.Normal resistance value for the thermister at roomtemperature is approximately 1000 ohms. The transmission control module (TCM) prevents Fig. 7 Transmission Speed Sensorengagement of the converter clutch and overdrive
    • 21 - 40 42RE AUTOMATIC TRANSMISSION ZJThrottle Position Sensor (TPS) CONVERTER CLUTCH ENGAGEMENT The TPS provides throttle position input signals to The torque converter clutch is engaged by theboth the transmission control module and powertrain clutch solenoid on the valve body. The clutch can becontroller. This input signal is used to determine engaged in third and fourth gear ranges dependingoverdrive and converter clutch shift schedule and to on overdrive control switch position.select the proper governor curve. If the overdrive control switch is in the normal ON position, the clutch will engage after the shift toTransmission Control Module (TCM) fourth gear, and above approximately 72 km/h (45 The TCM controls operation of the converter clutch, mph).overdrive clutch, and governor pressure solenoid. If the control switch is in the OFF position, the The control module determines transmission shift clutch will engage after the shift to third gear, at ap-points based on input signals from the transmission proximately 56 km/h (35 mph) at light throttle.thermistor, transmission output shaft speed sensor,crankshaft position sensor, vehicle speed sensor and OVERDRIVE OFF SWITCHthrottle position sensor. The overdrive Off switch is located in the instru- Operating voltage is supplied through the battery ment panel. The switch is a momentary contact de-terminal on the control module. The ignition voltage vice that signals the TCM to toggle current status ofsignal is supplied through a terminal on the ABS the overdrive function. At key-on, overdrive operationcontrol module. is allowed. The DRB scan tool can be used to check operation Pressing the switch once causes the overdrive Offof the control module and transmission electrical mode to be entered and the overdrive Off switchcomponents. The diagnostic connector (for the scan lamp to be illuminated. Pressing the switch a secondtool) is located under the driver side of the instru- time causes normal overdrive operation to be re-ment panel. The connector has a 6-way terminal and stored and the overdrive lamp to be turned off.is blue in color. The normal position for the control switch is the ON position. The switch must be in this position toGOVERNOR PRESSURE CURVES energize the solenoid and allow a fourth gear upshift. There are four governor pressure curves pro- The control switch has an indicator light. The lightgrammed into the transmission control module. The illuminates when the overdrive switch is turned todifferent curves allow the control module to adjust the OFF position, or when illuminated by the trans-governor pressure for varying conditions. mission control module. One curve is used for operation when fluid temper- The control switch indicator light is also used toature is at, or below 10°C (50°F). A second curve is used when fluid temperature is signal fault flash codes for diagnostic purposes.at, or above 10°C (50°F) during normal city, or high-way driving. QUICK FILL VALVE A third curve is used during wide open throttle op- The 3-4 quick fill valve provides faster engagementeration. The fourth curve is used when driving with of the overdrive clutch during 3-4 upshifts. The valvethe transfer case in low range. temporarily bypasses the clutch piston feed orifice at the start of a 3-4 upshift. This exposes a larger pas-TRANSMISSION SHIFTING sage into the piston retainer resulting in a much Shift valve operation with the electronic governor faster clutch fill and apply sequence.is basically unchanged. The 1-2 and 2-3 upshift se- The quick fill valve does not bypass the regularquence occurs exactly the same as in non-electronic clutch feed orifice throughout the 3-4 upshift. In-governor transmissions. stead, once a predetermined pressure develops within The shift valves are still moved by a combination of the clutch, the valve closes the bypass. Clutch fill isthrottle and governor pressure. The only real differ- then completed through the regular feed orifice.ence is that governor pressure is generated by elec-trical components instead of a mechanical valve and CONVERTER DRAINBACK VALVEweight assembly. The drainback valve is located in the transmission The conditions under which a shift to fourth will cooler outlet (pressure) line. The valve prevents fluidnot occur, also remain the same. These being: from draining from the converter into the cooler and• shift to third not yet completed lines when the vehicle is shut down for lengthy peri-• overdrive switch is in OFF position ods.• vehicle speed too low for 3-4 shift to occur Production valves have a hose nipple at one end,• transmission fluid temperature is below 10°C while the opposite end is threaded for a flare fitting.(50°F) or above 121°C (250°F). Some early valves have hose nipples at both ends. All
    • ZJ 42RE AUTOMATIC TRANSMISSION 21 - 41valves have an arrow mark (or similar mark) to in- annulus support hub has been remachined to accom-dicate direction of flow through the valve. modate the new plate tabs. Plastic check balls are now used in some valve bod-TRANSMISSION CHANGES AND PARTS ies. The new check balls entered production as a run-INTERCHANGEABILITY ning change. The plastic and steel check balls are not 1995 transmissions are similar to previous models interchangeable.but only in appearance. Current transmissions are A converter drainback check valve has been addeddimensionally different and have different hydraulic to the fluid cooler system. The one-way valve is lo-circuitry. Do not interchange parts. cated in the transmission outlet (pressure) line. The Transmission changes affect the governor weight valve prevents fluid drainback when the vehicle isassembly, low-reverse drum, front annulus, boost parked for lengthy periods.valve tube retainer, fluid cooling system, and valve The boost valve tube retainer has been lengthenedbody check balls. and an extra tab added to better secure the tube. The thrust plate and front annulus have changed.The thrust plate now has two locating tabs and the
    • 21 - 42 42RE TRANSMISSION DIAGNOSIS ZJ 42RE TRANSMISSION DIAGNOSIS INDEX page pageAir Testing Transmission Clutch and Band Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Effects of Incorrect Fluid Level . . . . . . . . . . . . . . . 43Analyzing the Road Test . . . . . . . . . . . . . . . . . . . . 44 Fluid Contamination . . . . . . . . . . . . . . . . . . . . . . . 43Causes of Burned Fluid . . . . . . . . . . . . . . . . . . . . . 43 Hydraulic Pressure Test . . . . . . . . . . . . . . . . . . . . 45Checking Fluid Level and Condition . . . . . . . . . . . . 42 Overdrive Electrical Controls . . . . . . . . . . . . . . . . . 43Converter Housing Fluid Leak Diagnosis . . . . . . . . 49 Preliminary Diagnosis . . . . . . . . . . . . . . . . . . . . . . 42Converter Stall Test . . . . . . . . . . . . . . . . . . . . . . . . 47 Road Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Diagnosis and Hydraulic Flow Charts . . . . . . . . . . . 51 Stall Test Analysis . . . . . . . . . . . . . . . . . . . . . . . . . 48Diagnosis Procedures . . . . . . . . . . . . . . . . . . . . . . 42 Transmission Throttle Valve and Shift Cables . . . . . 44Diagnostic Trouble Flash Codes . . . . . . . . . . . . . . 44DIAGNOSIS PROCEDURES (7) Perform air pressure test to check clutch-band Begin diagnosis by checking the easily accessible operation.items such as fluid level, fluid condition and throttlecable/shift linkage adjustments. A road test will de- VEHICLE IS DISABLEDtermine if further diagnosis is necessary. (1) Check fluid level and condition. Procedures outlined in this section should be per- (2) Check for broken, disconnected, binding throt-formed in the following sequence to realize the most tle valve cable, or lever.accurate results: (3) Check for cracked, leaking cooler lines, or loose, (1) Preliminary diagnosis missing pressure port plugs. (2) Fluid Level and condition (4) Raise vehicle, start engine, shift transmission (3) Leak tests (if fluid level is low) into gear and note following: (4) Linkage Adjustment (a) If propeller shafts turn but wheels do not, (5) Overdrive control switch test problem is with differential or axle shafts. (6) Road test (b) If propeller shafts do not turn and transmis- (7) Stall test sion is noisy, stop engine. Remove oil pan, and (8) Hydraulic pressure test check for debris. If pan is clear, remove transmis- (9) Air pressure tests sion and check for damaged drive plate, converter, (10) Analyze test results and consult diagnosis oil pump or input shaft.charts (c) If propeller shafts do not turn and transmis- sion is notPRELIMINARY DIAGNOSIS noisy, perform hydraulic pressure test to deter- Two basic procedures are required. One procedure mine if problem is a hydraulic or mechanical.for vehicles that are driveable and an alternate pro-cedure for disabled vehicles (will not back up or move CHECKING FLUID LEVEL AND CONDITIONforward). (1) Place vehicle on level surface. This is important for an accurate reading.VEHICLE IS DRIVEABLE (2) Do not check level until fluid is at normal hot (1) Check for TCM fault codes with DRB scan tool, operating temperature of approximately 180°F. Thisor with fault flash codes at lamp in overdrive Off is necessary to avoid false readings which could pro-switch. duce under or over fill condition. (2) Check fluid level and condition. (3) Start and run engine at curb idle speed and ap- (3) Adjust throttle and gearshift linkage if com- ply parking brakes.plaint was based on delayed, erratic, or harsh shifts. (4) Shift transmission through all gear ranges and (4) Road test and note how transmission upshifts, back to Neutral.downshifts and engages. (5) Clean top of filler tube and dipstick to keep dirt (5) Perform stall test if complaint is based on slug- out of tube.gish acceleration. Or, if abnormal throttle opening is (6) Remove dipstick and check fluid level as fol-needed to maintain normal speeds with a properly lows:tuned engine. (a) Dipstick has three fluid level indicating (6) Perform hydraulic pressure test if shift prob- marks which are a MIN dot mark, an OK marklems were noted during road test. and a MAX fill arrow mark:
    • ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 43 (b) Correct level is to Full, or MAX arrow mark an auxiliary transmission fluid cooler, a heavy duty on dipstick. This is correct maximum hot fluid cooling system, and the engine/axle ratio combination level. Acceptable level is between OK mark and needed to handle heavy loads. max arrow mark on dipstick. (c) If level is at, or below MIN/ADD level, add FLUID CONTAMINATION only enough fluid to restore correct level. Mopar Fluid contamination is generally a result of: ATF Plus, type 7176 is the required fluid. • adding incorrect fluid • failure to clean dipstick and fill tube when check-CAUTION: Do not overfill the transmission. Overfill- ing leveling may cause leakage out the pump vent which • engine coolant entering fluidcan be mistaken for a pump seal leak. In addition, • internal failure that generates debrisoverfilling will also cause fluid aeration and foam- • overheat that generates sludge (fluid breakdown)ing as the excess fluid is picked up and churned by • failure to reverse flush cooler and lines after re-the gear train. This will reduce the life of the fluid pairsignificantly. • failure to replace contaminated converter during (7) Check fluid condition. Fluid color should range repairfrom dark rad to pink and be free of particles and The use of non-recommended fluids can result insludge. transmission failure. The usual results are erratic (a) If fluid is discolored, or smells burned but shifts, slippage, abnormal wear and eventual failure transmission operation was OK, flush cooler and due to fluid breakdown and sludge formation. Avoid lines and change fluid and filter. Then road test this condition by using recommended fluids only. again to confirm proper operation. The dipstick cap and fill tube should be wiped (b) If fluid is black, dark brown, turned to clean before checking fluid level. Dirt, grease and sludge, contains extensive amount of metal or fric- other foreign material on the cap and tube could fall tion material particles, transmission will need over- into the tube if not removed beforehand. Take the haul (especially if shift problems were evident time to wipe the cap and tube clean before withdraw- during road test). ing the dipstick. Engine coolant in the transmission fluid is gener-EFFECTS OF INCORRECT FLUID LEVEL ally caused by a cooler malfunction. The only remedy A low fluid level allows the pump to take in air is to replace the radiator as the cooler in the radiatoralong with the fluid. Air in the fluid will cause fluid is not a serviceable part. If coolant has circulatedpressures to be low and develop slower than normal. through the transmission for some time, an overhaul If the transmission is overfilled, the gears churn may also be necessary; especially if shift problemsthe fluid into foam, aerating the fluid and causing had developed.the same conditions that occur with a low level. In The transmission cooler and lines should be reverseeither case, air bubbles cause fluid overheating, oxi- flushed whenever a malfunction generates sludgedation and varnish buildup which interferes withvalve, clutch and servo operation. and/or debris. The torque converter should also be re- Foaming also causes fluid expansion which can re- placed at the same time.sult in fluid overflow from the transmission vent or Failure to flush the cooler and lines will result infill tube. Fluid overflow can easily be mistaken for a re-contamination and a shop comeback. Flushing ap-leak if inspection is not careful. plies to auxiliary coolers as well. The torque con- verter and drainback valve should also be replacedCAUSES OF BURNED FLUID whenever a failure generates sludge and debris. This Burned, discolored fluid is a result of overheating is necessary because converter flushing procedureswhich has two primary causes. will not remove all of the contaminants. The first cause is a result of restricted fluid flowthrough the main and/or auxiliary cooler. This condi- OVERDRIVE ELECTRICAL CONTROLStion is usually the result of a faulty or improperly in- The electrical controls governing the shift intostalled drainback valve, a damaged main cooler, or fourth gear consist of the overdrive off switch in thesevere restrictions in the coolers and lines caused by instrument panel and the overdrive solenoid on thedebris. valve body. The second primary cause is heavy duty operation The overdrive off switch, valve body solenoid, casewith a vehicle not properly equipped for this type of connectors and related wiring can all be tested withoperation. Trailer towing or similar high load opera- a 12 volt test lamp or a volt/ohmmeter. Check conti-tion will overheat the transmission fluid if the vehi- nuity of each component when diagnosis indicatescle is improperly equipped. Such vehicles should have this is necessary.
    • 21 - 44 42RE TRANSMISSION DIAGNOSIS ZJ Switch and solenoid continuity should be checked the valve body throttle valve which controls shiftwhenever the transmission fails to shift into fourth speed, quality and part throttle downshift sensitivity.gear range. If cable setting is too short, early shifts and slip- page between shifts may occur. If the setting is tooDIAGNOSTIC TROUBLE FLASH CODES long, shifts may be delayed and part throttle down- Diagnostic trouble flash codes are provided for di- shifts may be very sensitive. Refer to the In-Vehicleagnosis purposes. The lamp in the overdrive off Service section for adjustment procedure.switch is used to signal the various flash codes. Shift cable adjustment is important because it po- The flash codes and type of fault indicated are out- sitions the valve body manual valve. Incorrect adjust-lined in the Flash Code Chart (Fig. 1). ment will cause creep in Neutral, premature clutch To view flash codes, proceed as follows: wear, delayed engagement in all gear ranges, or a no- (a) Turn ignition key on and off three times. start in Park or Neutral. Then leave overdrive off switch in normal overdrive Proper operation of the park/neutral position (on) position. switch will provide a quick check of linkage adjust- (b) Immediately begin counting number of ment. Refer to the In-Vehicle Service section for link- flashes displayed by overdrive off switch indicator age adjustment procedure. lamp. (c) Flash codes will correspond to powertrain ROAD TESTING control module in duration and spacing. Before road testing, be sure the fluid level and all (d) A code 55 identifies end of flash code trans- cable adjustments have been checked and reset if mission necessary. Observe engine performance during the road test. A poorly tuned engine will not allow an ac- curate 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 clutch, 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 Applica- tion chart (Fig. 2) provides a basis for analyzing road test results. 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 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 Fig. 1 42RE DIAGNOSTIC TROUBLE FLASH CODE and 2 range but not in 1 range, the transmission CHART overrunning clutch is faulty. Similarly, if slippage oc- curs in any two forward gears, the rear clutch is slip-TRANSMISSION THROTTLE VALVE AND SHIFT ping.CABLES Applying the same method of analysis, note that Transmission throttle cable adjustment is impor- the front and rear clutches are applied simulta-tant to proper operation. This adjustment positions neously only in D range third and fourth gear. If the
    • ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 45 Fig. 2 Clutch And Band Application Charttransmission slips in third gear, either the front HYDRAULIC PRESSURE TESTclutch or the rear clutch is slipping. Hydraulic test pressures range from a low of one If the transmission slips in fourth gear but not in psi (6.895 kPa) governor pressure, to 300 psi (2068third gear, the overdrive clutch is slipping. By select- kPa) at the rear servo pressure port in reverse.ing another gear which does not use these clutches, An accurate tachometer and test gauges are re-the slipping unit can be determined. For example, if quired for the pressure test. Test Gauge C-3292 has athe transmission also slips in Reverse, the front 100 psi range and is used at the accumulator, gover-clutch is slipping. If the transmission does not slip in nor, front servo, and overdrive pressure ports. TestReverse, the rear clutch is slipping. Gauge C-3293-SP has a 300 psi range and is used at If slippage occurs during the 3-4 shift or only in the rear servo port where pressures range from 250fourth gear, the overdrive clutch is slipping. Simi- to 290 psi. In cases where two test gauges are re-larly, if the direct clutch were to fail, the transmis- quired, the 300 psi gauge can be used at any of thesion would lose both reverse gear and overrun other test ports.braking in 2 position (manual second gear). If thetransmission slips in any other two forward gears, PRESSURE TEST PORT LOCATIONSthe transmission rear clutch is probably slipping. Test ports are located at both sides of the transmis- If the transmission will not shift to fourth gear, the sion case (Fig. 3).control switch, overdrive solenoid or related wiring Line pressure is checked at the accumulator portmay also be the problem cause. on the right side of the case. The front servo pressure This process of elimination can be used to identify port is at the right side of the case just behind thea slipping unit and check operation. Proper use of filler tube opening.the Clutch and Band Application Chart is the key. The rear servo and governor pressure ports are at Although road test analysis will help determine the the right rear of the transmission case. The overdriveslipping unit, the actual cause of a malfunction usu- clutch pressure port is at the left rear of the caseally cannot be determined until hydraulic and air (Fig. 3).pressure tests are performed. Practically any condi-tion can be caused by leaking hydraulic circuits or HYDRAULIC PRESSURE TEST PROCEDUREsticking valves. Unless a malfunction is obvious, such as no Test One—Transmission In 1 Rangedrive in D range first gear, do not disassemble This test checks pump output, pressure regu-the transmission. Perform the hydraulic and lation, and condition of the rear clutch andair pressure tests to help pinpoint the problem servo circuit. Test Gauges C-3292 and C-3293-SPcause.
    • 21 - 46 42RE TRANSMISSION DIAGNOSIS ZJ 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) Leave vehicle in place on hoist and leave Test Gauge C-3292 connected to accumulator port. (2) Have helper start and run engine at 1000 rpm. (3) Move transmission shift lever one detent rear- ward from full forward position. This is 2 range. (4) Move transmission throttle lever from full for- ward to full rearward position and read pressure on gauge: (5) Line pressure should be 54-60 psi (372-414 kPa) with throttle lever forward and gradually in- crease to 90-96 psi (621-662 kPa) as lever is moved rearward. Test Three—Transmission In D Range Third Gear This test checks pressure regulation and con- dition of the clutch circuits. Use both pressure Test Gauges C-3292 and C-3293-SP for this test. (1) Turn OD switch off. (2) Leave vehicle on hoist and also leave Gauge C-3292 in place at accumulator port. (3) Move Gauge C-3293-SP over to front servo port for this test. (4) Have helper start and run engine at 1600 rpm Fig. 3 Pressure Test Port Locations for this test.are required for this test. Gauge C-3292 has a (5) Move transmission shift lever two detents rear-100 psi range. Gauge C-3293-SP has a 300 psi ward from full forward position. This is D range.range. (6) Read pressures on both gauges as transmission (1) Connect tachometer to engine. Position tachom- throttle lever is gradually moved from full forward toeter so it can be observed from driver seat if helper full rearward position:will be operating engine. Raise vehicle on hoist that (a) Line pressure at accumulator in D rangewill allow rear wheels to rotate freely. third gear, should be 54-60 psi (372-414 kPa) with (2) Connect 100 psi Gauge C-3292 to accumulator throttle lever forward and increase as lever isport. Then connect 300 psi Gauge C-3293-SP to rear moved rearward.servo port (Fig. 3). (b) Front servo pressure in D range third gear, (3) Disconnect throttle and gearshift cables from should be within 3 psi (21 kPa) of line pressure uplevers on transmission valve body manual shaft. to kickdown point. (4) Have helper start and run engine at 1000 rpm. (5) Move transmission shift lever fully forward into Test Four—Transmission In Reverse1 range. This test checks pump output, pressure regu- (6) Gradually move transmission throttle lever lation and the front clutch and rear servo cir-from full forward to full rearward position and note cuits. Use 300 psi Test Gauge C-3293-SP for thispressures on both gauges: test. (a) Line pressure at accumulator port should be (1) Leave vehicle on hoist and leave gauge C3292 54-60 psi (372-414 kPa) with throttle lever forward in place at accumulator port. and gradually increase to 90-96 psi (621-662 kPa) (2) Move 300 psi Gauge C-3293-SP back to rear as throttle lever is moved rearward. servo port. (b) Rear servo pressure should be same as line (3) Have helper start and run engine at 1600 rpm pressure within 3 psi (20.68 kPa). for test. (4) Move transmission shift lever four detents rear- ward from full forward position. This is Reverse range.
    • ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 47 (5) Move transmission throttle lever fully forward occurs and note gauge pressure.then fully rearward and note reading at Gauge (8) Pressure should be 469-496 kPa (68-72 psi)C-3293-SP. with closed throttle and increase to 620-827 kPa (90- (6) Pressure should be 145 - 175 psi (1000-1207 120 psi) at 1/2 to 3/4 throttle. Note that pressure cankPa) with throttle lever forward and increase to 230 - increase to around 896 kPa (130 psi) at full throttle.280 psi (1586-1931 kPa) as lever is gradually moved (9) Return to shop or move vehicle off chassisrearward. dyno.Test Five—Governor Pressure This test checks governor operation by mea-suring governor pressure response to changesin vehicle speed. It is usually not necessary tocheck governor operation unless shift speedsare incorrect or if the transmission will notdownshift. The test should be performed on ahoist that will allow the rear wheels to rotatefreely. (1) Move 100 psi Test Gauge C-3292 to governorpressure port (Fig. 3). (2) Move transmission shift lever two detents rear-ward from full forward position. This is D range. (3) Have helper start and run engine at curb idlespeed. Then firmly apply service brakes so wheelswill not rotate. (4) Note governor pressure: (a) Governor pressure should be no more than 20.6 kPa (3 psi) at curb idle speed and wheels not rotating. (b) If pressure exceeds 20.6 kPa (3 psi), a fault exists in governor pressure control system. (5) Release brakes, slowly increase engine speed,and observe speedometer and pressure test gauge.Governor pressure should increase in proportion tovehicle speed. Or approximately 6.89 kPa (1 psi) forevery 1 mph. (6) Pressure rise should be smooth and drop backto no more than 20.6 kPa (3 psi) after engine returnsto curb idle and brakes are applied to prevent wheelsfrom rotating. (7) Compare results of pressure test with analysis Fig. 4 Pressure Test Analysis Chartchart (Fig. 4). CONVERTER STALL TEST Stall testing involves determining maximum engineTest Six—Transmission In Overdrive Fourth Gear rpm obtainable at full throttle with the rear wheels This test checks line pressure at the over- locked and the transmission in D range. This testdrive clutch in fourth gear range. Use 300 psi checks the holding ability of the converter overrun-Test Gauge C-3292 for this test. The test should ning clutch and both of the transmission clutches.be performed on the road or on a chassis dyno. When stall testing is completed, refer to the Stall (1) Remove tachometer. It will not be used for thistest. Speed Analysis. (2) Move 300 psi Gauge to overdrive clutch pres- WARNING: NEVER ALLOW ANYONE TO STAND DI-sure test port. Then remove other gauge and reinstall RECTLY IN LINE WITH THE VEHICLE FRONT ORtest port plug. REAR DURING A STALL TEST. ALWAYS BLOCK (3) Lower vehicle. (4) Turn OD switch on. THE WHEELS AND APPLY THE SERVICE AND (5) Secure test gauge so it can be viewed from driv- PARKING BRAKES DURING THE TEST.ers seat. (6) Start engine and shift into D range. (7) Increase vehicle speed gradually until 3-4 shift
    • 21 - 48 42RE TRANSMISSION DIAGNOSIS ZJSTALL TEST PROCEDURE originating from the converter, operate the vehicle at (1) Connect tachometer to engine. Position tachom- light throttle in Drive and Neutral on a hoist and lis-eter so it can be viewed from driver seat. ten for noise coming from the converter housing. (2) Check transmission fluid level. Add fluid if nec-essary. AIR TESTING TRANSMISSION CLUTCH AND BAND (3) Drive vehicle to bring transmission fluid up to OPERATIONnormal operating temperature. Vehicle can be driven Air pressure testing can be used to check transmis-on road, or on chassis dyno if shop is so equipped. sion front/rear clutch and band operation with the (4) Block front wheels. transmission either in the vehicle, or on the work (5) Fully apply service and parking brakes. bench as a final check after overhaul. (6) Open throttle completely and record maximum Air pressure testing requires that the oil pan andengine rpm registered on tachometer. It takes 4-10 valve body be removed from the transmission. Theseconds to reach max rpm. However, once max servo and clutch apply passages are shown in Figurerpm has been achieved, do not hold wide open 5.throttle for more than 4-5 seconds.CAUTION: Stalling the converter causes a rapid in-crease in fluid temperature. To avoid fluid overheat-ing, hold the engine at maximum rpm for no morethan 5 seconds. If engine exceeds 2300 rpm duringthe test, release the accelerator pedal immediately;transmission clutch slippage is occurring. (7) Stall speeds should be in 1800-2300 rpm range. (8) If a second stall test is required, cool fluiddown before proceeding. Shift into Neutral and runengine at 1000 rpm for 20-30 seconds to cool fluid. (9) Refer to Stall Test Analysis.STALL TEST ANALYSISSTALL SPEED TOO HIGH If stall speed exceeds 2300 rpm, transmissionclutch slippage is indicated.STALL SPEED LOW Fig. 5 Air Pressure Test Passages Low stall speeds with a properly tuned engine in-dicate a torque converter overrunning clutch prob- FRONT CLUTCH AIR TESTlem. The condition should be confirmed by road Place one or two fingers on the clutch housing andtesting before to converter replacement. apply air pressure through front clutch apply passage Stall speeds 250-350 rpm below normal indicates (Fig. 5). Piston movement can be felt and a soft thudthe converter overrunning clutch is slipping. The ve- heard as the clutch applies.hicle will also exhibit poor acceleration but operatenormally once highway cruise speeds are reached. REAR CLUTCH AIR TESTTorque converter replacement will be necessary. Place one or two fingers on the clutch housing and apply air pressure through rear clutch apply passage.STALL SPEED NORMAL BUT ACCELERATION Piston movement can be felt and a soft thud heard asPOOR the clutch applies. If stall speeds are normal (1800-2300 rpm) but ab-normal throttle opening is required for acceleration, FRONT SERVO AIR TESTor to maintain cruise speed, the converter overrun- Apply air pressure to the front servo apply passage.ning clutch is seized. The torque converter will have The servo rod should extend and cause the band toto be replaced. tighten around the drum. Spring tension should re- lease the servo when air pressure is removed.CONVERTER NOISE DURING TEST A whining noise caused by fluid flow is normal dur- REAR SERVO AIR TESTing a stall test. However, loud metallic noises indi- Apply air pressure to the rear servo apply passage.cate a damaged converter. To confirm that noise is The servo rod should extend and cause the band to
    • ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 49tighten 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, twoitems must be established before repair. First, itmust be verified that a leak condition actually exists.And second, the true source of the leak must be de-termined. Some suspected converter housing fluid leaks maynot be leaks at all. They may only be the result ofresidual fluid in the converter housing, or excessfluid spilled during factory fill or refill after repair. Converter housing leaks have several potential Fig. 7 Converter Housing Leak Test Probesources. Through careful observation, a leak source (5) Have a helper run engine at 2500 rpm (withcan be identified before removing the transmission transmission in Neutral) for two minutes; then stopfor repair. engine. Pump seal leaks tend to move along the drive hub (6) Inspect test probe and converter housing. Ifand onto the rear of the converter. Pump O-ring or leak is evident, note color of fluid:pump body leaks follow the same path as a seal leak (a) If fluid is red/pink, leak is from transmission(Fig. 6). part. Proceed with diagnosis. Pump vent or pump attaching bolt leaks are gener- (b) If fluid is brown or green, oil leak is from en-ally deposited on the inside of the converter housing gine. Refer to engine leak diagnosis procedures inand not on the converter itself (Fig. 6). Group 9. Pump seal or gasket leaks usually travel down the (7) Determine where transmission fluid is leakinginside of the converter housing. from: Front band lever shaft plug leaks are generally de- (a) If probe upper surface is wet with trans-posited on the housing and not on the converter. mission fluid, converter or seal are at fault. Fluid across probe upper surface indicates converter or seal leak. (b) If transmission fluid is leaking under probe, it is coming from pump housing area (Fig. 8). (8) Fluid leaking under probe could be from: pump seal and/or bushing, pump vent, front band lever shaft access plug, pump bolts, or porous spots in pump body or transmission case (Fig. 8). Fig. 6 Converter Housing Leak PathsLEAK DIAGNOSIS PROCEDURE (1) Raise rear of vehicle and allow accumulatedfluid to drain out of converter housing. (2) Check and adjust transmission fluid level. (3) Raise vehicle. Remove converter housing dustcover and wipe as much fluid as possible from con-verter housing. (4) Fabricate test probe (Fig. 7). Attach probe toconverter housing with a dust shield bolt. Fig. 8 Pump Area Inspection Points
    • 21 - 50 42RE TRANSMISSION DIAGNOSIS ZJ (9) If porous spots in transmission case or pumpbody are suspected leak source, pressurize transmis-sion as described in Leak Testing With Air Pressure.TORQUE CONVERTER LEAK POINTS Possible sources of converter leaks are: (a) leaks atthe weld joint around the outside diameter weld and(b) leaks at the converter hub weld (Fig. 9). Fig. 10 Converter Hub Seal Cup Fig. 9 Converter Potential Leak PointsLEAK TESTING WITH AIR PRESSURE This test involves closing off all openings and pres-surizing the transmission to 8 psi with Air Pump7700. A soapy water solution is applied to suspected leakpoints before and during the pressure test. Leaks willbe indicated by the presence of air bubbles coming Fig. 11 Seal Cup Retaining Strapthrough the solution. Some transmission openings such as the fill tubeand front cooler line fitting can be closed off with arubber plug or similar device. Plugs can secured withwire or duct tape. The transmission rear output shaft opening isclosed off simply by leaving the transfer case boltedin place. However, if the transfer case has been re-moved, a shipping plug can used to close off thisopening. The torque converter hub opening in the pump andthe pump vent require special tools to close them off.The converter hub seal cap is made from thin walltube and a 3.17 mm (1/8 in.) thick disc (Fig. 10). Aretaining strap is needed to secure the seal cup fortesting. The strap can be made from 31.75 mm (1-1/4in.) wide stock (Fig. 11). The strap attaching hole po-sitions are approximate only. Measure hole positionon the converter housing before drilling. The pump vent tool is made from 6.35 mm (1/4 in.) Fig. 12 Pump Vent Plugrod and 4.76 mm (3/16 in.) plate (Fig. 12). CAUTION: Be sure the surfaces of the hub seal cup The fabricated tools can all be made from mild are smooth and free of nicks, scratches, or burrs.steel or aluminum stock. Surface irregularities on the cup will damage the pump seal if not removed. Sand and/polish the cupAIR PRESSURE LEAK TEST PROCEDURE with 400 grit sandpaper or crocus cloth to smooth (1) Install vent plug, converter hub seal cup and the surface if necessary.cup retaining strap (Fig. 13).
    • ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 51 (2) Close off remaining transmission openings withrubber plugs, or stoppers or similar devices. Do notclose off rear cooler line fitting. Hand operatedair pump will be attached to this fitting. (3) Attach Air Pump 7700 to rear cooler line fit-ting. Connect a length of copper tube to fitting. Thenattach pump hose to tube with hose clamp (Fig. 14). (4) Apply a thick soapy water solution to suspectedleak areas.CAUTION: The recommended test pressure is 8 psi.The maximum allowable test pressure is 10 psi. Donot exceed specified pressure. Fig. 14 Typical Method Of Pressurizing (5) Pressurize transmission to 8 psi with air pump. Transmission (6) Observe suspected leak areas. Air bubbles ap- (3) Remove oil pump and remove pump seal. In-pearing in soapy water solution indicate leak points. spect pump housing drainback and vent holes for ob- (7) Remove test tools and plugs after test comple- structions. Clear holes with solvent and wire.tion and make necessary repairs as described in Leak (4) Inspect pump bushing and converter hub. IfCorrection procedure. bushing is scored, replace it. If converter hub is scored, either polish it with crocus cloth 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 front band lever shaft access plug three turns. Apply Mopar silicone sealant, or Permatex No. 2 or equivalent to plug threads and tighten plug to 17 N⅐m (150 in-lbs) torque. (7) Adjust front band. (8) Lubricate pump seal and converter hub with transmission fluid or petroleum jelly and install con- verter. (9) Install transmission and converter housing dust shield. (10) Lower vehicle. DIAGNOSIS AND HYDRAULIC FLOW CHARTS Fig. 13 Vent Plug And Hub Seal Cup Installation The diagnosis charts are generic. They apply to RE and RH transmissions equally except for RH me-CONVERTER HOUSING AREA LEAK chanical governor fault information. The charts pro-CORRECTION vide information on transmission, overdrive, and (1) Remove converter. converter faults. (2) Tighten front band adjusting screw until band The flow charts outline hydraulic circuitry for allis tight around front clutch retainer. This prevents operating ranges including park and neutral. Circuitfront/rear clutches from coming out when oil pump is flow for converter clutch application in fourth gear isremoved. also provided.
    • 21 - 52 42RE TRANSMISSION DIAGNOSIS ZJ TRANSMISSION DIAGNOSIS
    • ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 53 TRANSMISSION DIAGNOSIS
    • 21 - 54 42RE TRANSMISSION DIAGNOSIS ZJ TRANSMISSION DIAGNOSIS
    • ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 55 TRANSMISSION DIAGNOSIS
    • 21 - 56 42RE TRANSMISSION DIAGNOSIS ZJ TRANSMISSION DIAGNOSIS
    • ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 57 TRANSMISSION DIAGNOSIS
    • 21 - 58 42RE TRANSMISSION DIAGNOSIS ZJ TRANSMISSION DIAGNOSIS
    • ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 59 TRANSMISSION DIAGNOSIS
    • 21 - 60 42RE TRANSMISSION DIAGNOSIS ZJ OVERDRIVE DIAGNOSIS
    • ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 61 OVERDRIVE DIAGNOSIS
    • 21 - 62 42RE TRANSMISSION DIAGNOSIS ZJ OVERDRIVE DIAGNOSIS
    • ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 63 TORQUE CONVERTER DIAGNOSIS
    • 21 - 64 42RE TRANSMISSION DIAGNOSIS ZJ TORQUE CONVERTER DIAGNOSIS
    • ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 65 TORQUE CONVERTER DIAGNOSIS
    • 21 - 66 42RE TRANSMISSION DIAGNOSIS ZJ HYDRAULIC FLOW IN PARK
    • ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 67 HYDRAULIC FLOW IN NEUTRAL
    • 21 - 68 42RE TRANSMISSION DIAGNOSIS ZJ HYDRAULIC FLOW IN REVERSE
    • ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 69 HYDRAULIC FLOW IN DRIVE FIRST GEAR
    • 21 - 70 42RE TRANSMISSION DIAGNOSIS ZJ HYDRAULIC FLOW IN DRIVE SECOND GEAR
    • ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 71 HYDRAULIC FLOW IN DRIVE THIRD GEAR
    • HYDRAULIC FLOW IN DRIVE FOURTH GEAR (CONVERTER CLUTCH NOT APPLIED) 21 - 72 42RE TRANSMISSION DIAGNOSIS ZJ
    • HYDRAULIC FLOW IN DRIVE FOURTH GEAR (CONVERTER CLUTCH APPLIED) ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 73
    • 21 - 74 42RE TRANSMISSION DIAGNOSIS ZJ HYDRAULIC FLOW IN MANUAL LOW (1)
    • ZJ 42RE TRANSMISSION DIAGNOSIS 21 - 75HYDRAULIC FLOW IN MANUAL SECOND (2)
    • HYDRAULIC FLOW DURING FULL THROTTLE 3-2 DOWNSHIFT 21 - 76 42RE TRANSMISSION DIAGNOSIS ZJ
    • ZJ 42RE IN-VEHICLE SERVICE 21 - 77 42RE IN-VEHICLE SERVICE INDEX page pageAluminum Thread Repair . . . . . . ....... . . . . . . . 87 Refilling After Overhaul or Fluid/Filter Change . . . . 78Converter Drainback Check Valve Service . . . . . . . 86 Speedometer Service . . . . . . . . . . . . . . . . . . . . . . 81Fluid and Filter Change . . . . . . . ....... . . . . . . . 77 Transmission Control Module (TCM) Service . . . . . 84Front Band Adjustment . . . . . . . ....... . . . . . . . 80 Transmission Cooler Flow Testing . . . . . . . . . . . . . 87Gearshift Cable Adjustment . . . . ....... . . . . . . . 79 Transmission Cooler Line and Fitting Service . . . . . 85Oil Pump Seal . . . . . . . . . . . . . ....... . . . . . . . 77 Transmission Cooler Replacement . . . . . . . . . . . . . 87Park Interlock Cable Adjustment ....... . . . . . . . 79 Transmission Cooler Reverse Flushing . . . . . . . . . 87Park Lock Service . . . . . . . . . . . ....... . . . . . . . 77 Transmission Fluid Level Check . . . . . . . . . . . . . . 77Park/Neutral Position Switch . . . ....... . . . . . . . 82 Transmission Throttle Valve Cable Adjustment . . . . 78Rear Band Adjustment . . . . . . . ....... . . . . . . . 80 Valve Body Service . . . . . . . . . . . . . . . . . . . . . . . . 82Recommended Fluid . . . . . . . . . ....... . . . . . . . 77PARK LOCK SERVICE (2) Position vehicle on level surface. This is ex- The park lock components are located within the tremely important for accurate fluid level check.overdrive unit and cannot be serviced in the vehicle. (3) Start and run engine at curb idle speed.The overdrive unit must be removed and disassem- (4) Apply parking brakes.bled for access to the park lock components. (5) Shift transmission momentarily into all gear Refer to the sections dealing with transmission/ ranges. Then shift transmission back to Neutral.overdrive removal, installation and overhaul sections (6) Clean top of filler tube and dipstick to keep dirtfor overdrive unit repair procedures. from entering tube. (7) Remove dipstick and check fluid level as fol-OIL PUMP SEAL lows: The transmission and torque converter must be re- (a) Dipstick has three fluid level indicator levelsmoved for access to the oil pump seal. Oil pump seal which are a MIN dot, an OK area, and a MAX fillreplacement procedures are described in the Trans- arrow.mission Removal/Installation section. (b) Correct maximum level is to MAX arrow mark on dipstick. Correct acceptable level is to OKRECOMMENDED FLUID mark within crosshatch area. Incorrect level is at The recommended and preferred fluid for 42RE or below MIN dot.transmissions is Mopar ATF Plus, type 7176. (c) If fluid is low, add only enough Mopar ATF Dexron II fluid is not really recommended and Plus to restore correct level. Do not overfill.should only be used when ATF Plus is not available. CAUTION: Do not overfill the transmission. Overfill-TRANSMISSION FLUID LEVEL CHECK ing may cause leakage out the pump vent which Transmission fluid level should be checked monthly can be mistaken for a pump seal leak. Overfillingunder normal operation. If the vehicle is used for will also cause fluid aeration and foaming as the ex-trailer towing or similar heavy load hauling, check cess fluid is picked up and churned by the gearfluid level and condition weekly. train. This will significantly reduce fluid life. Fluid level is checked with the engine running atcurb idle speed, the transmission in Neutral, parking (8) If transmission is overfilled, fluid can be re-brakes applied, and the transmission fluid at normal moved with 1/8 to 3/16 in. diameter tubing and suc-operating temperature (hot). tion gun. Tubing will have to be adapted to nozzle of Transmission fluid level should be checked monthly gun and be long enough to extend down fill tube andunder normal operation. If the vehicle is used for into transmission oil pan.trailer towing or similar heavy load hauling, checkfluid level and condition weekly. FLUID AND FILTER CHANGEFLUID LEVEL CHECK PROCEDURE NORMAL CHANGE INTERVAL (1) Transmission fluid must be at normal operating The fluid and filter should be changed (and thetemperature for accurate fluid level check. Drive ve- bands adjusted) at recommended maintenance inter-hicle if necessary to bring fluid temperature up to vals, or whenever the transmission has been disas-normal hot operating temperature of 82°C (180°F). sembled for any reason.
    • 21 - 78 42RE IN-VEHICLE SERVICE ZJ (b) If transmission was completely overhauled and torque converter was replaced or drained, add 12 pints (6 quarts) of ATF Plus to transmission. (4) Apply parking brakes. (5) Start and run engine at normal curb idle speed. (6) Apply service brakes and shift transmission through all gear ranges then back to Neutral but leave engine running. (7) Remove funnel, insert dipstick and check fluid Fig. 1 Typical Dipstick Fluid Level Marks level. Add only enough fluid to bring level to Full mark on dipstick. Do not overfill. Refer to the Driveline section in Group O, Lubrica- (8) When fluid level is correct, shut engine off, re-tion and Maintenance for recommended change inter- lease park brake, remove funnel, and reseat dipstickvals. Refer to the fluid/filter replacement and band in fill tube.adjustment procedures in this section.SEVERE USAGE CHANGE INTERVAL TRANSMISSION THROTTLE VALVE CABLE Under severe usage, the fluid and filter should be ADJUSTMENTchanged and the bands adjusted at 12,000 mile (19 The transmission throttle valve is operated by a000 Km) intervals. cam on the throttle lever. The throttle lever is oper- Severe usage is defined as: ated by an adjustable cable (Fig. 2). The cable is at- (a) More than half of vehicle operation occurs in tached to an arm mounted on the throttle lever shaft. heavy city traffic during hot weather (above 90° F). A lock button at the engine-end of the cable is pro- (b) Vehicle is used for taxi, police, limousine, or vided for cable adjustment. similar commercial operation. A correctly adjusted throttle valve cable will cause (c) Vehicle is used for trailer towing or heavy the throttle lever on the transmission to move simul- load hauling. taneously with the throttle body lever from the idle When the factory fluid is drained, refill the trans- position. Proper adjustment will allow simultaneousmission with Mopar ATF Plus, type 7176 fluid. movement without causing the transmission throttle lever to either move ahead of, or lag behind the leverFLUID/FILTER REPLACEMENT PROCEDURE on the throttle body. (1) Raise vehicle. (2) Remove oil pan and drain fluid. CHECKING THROTTLE VALVE CABLE (3) Clean oil pan and pan magnet. Then clean re- ADJUSTMENTmaining gasket material from gasket surface of (1) Turn ignition key to OFF position.transmission case. (2) Remove air cleaner. (4) Remove fluid filter screws and remove filter. (5) Position new filter on valve body and install fil- (3) Verify that lever on throttle body is at curb idleter screws. Tighten screws to 4 N⅐m (35 in. lbs.) position. Then verify that transmission throttle levertorque. (Fig. 3) is also at idle (fully forward) position. (6) Position new gasket on oil pan and install pan (4) Slide cable off attachment stud on throttle bodyon transmission. Tighten pan bolts to 150 in. lbs. (17 lever (Fig. 4).N⅐m) torque. (5) Compare position of cable end to attachment (7) Lower vehicle and refill transmission with Mo- stud on throttle body lever (Fig. 4):par ATF Plus, type 7176 fluid. (a) Cable end and attachment stud should be aligned (or centered on one another) to within 1REFILLING AFTER OVERHAUL OR FLUID/FILTER mm (0.039 in.) in either direction.CHANGE (b) If cable end and attachment stud are mis- The best way to refill the transmission after a fluid aligned (off center), cable will have to be adjustedchange or overhaul is as follows: as described in Throttle Valve Cable Adjustment (1) If transmission has been overhauled, install procedure.transmission in vehicle. (6) Reconnect cable end to attachment stud. Then (2) Remove dipstick and insert clean funnel in with aid of a helper, observe movement of transmis-transmission fill tube. sion throttle lever and lever on throttle body. (3) Add following initial quantity of Mopar ATF (a) If both levers move simultaneously from idlePlus to transmission: to half-throttle and back to idle position, adjust- (a) If fluid/filter change was performed, add 3 ment is correct. pints (1-1/2 quarts) of ATF Plus to transmission.
    • ZJ 42RE IN-VEHICLE SERVICE 21 - 79 (b) 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 posi- tion, cable adjustment will be necessary.THROTTLE VALVE CABLE ADJUSTMENTPROCEDURE (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 pullcable off. (4) Verify that transmission throttle lever is infully closed position. Then be sure lever on throttlebody is at curb idle position. (5) Press cable lock button inward to release cable Fig. 3 Throttle Cable Attachment At Transmission(Fig. 4). Lock button only has to move about 2 mm(0.070 in.) to release cable in adjuster head. (6) Center cable end on attachment stud to within1 mm (0.039 in.) and release lock button. (7) Check cable adjustment. Be sure transmissionthrottle lever and lever on throttle body move simul-taneously as described in cable adjustment checkingprocedure. Fig. 4 Throttle Valve Cable Adjustment Fig. 2 Throttle Cable Attachment At Engine (5) Check transmission shift lever position by mov- ing it all the way rearward into Park detent.GEARSHIFT CABLE ADJUSTMENT (6) Verify positive engagement of park lock by at- Check adjustment by starting the engine in Park tempting to rotate propeller shaft. Shaft will not ro-and Neutral. Adjustment is OK if the engine starts tate when park lock is engaged.only in these positions. Adjustment is incorrect if the (7) Snap cable into cable bracket on transmission.engine starts in one but not both positions. If the en- (8) Lock shift cable by pressing cable adjustergine starts in any position other than Park or Neu- clamp down until it snaps into place.tral, or if the engine will not start at all, the park/ (9) Check engine starting. Engine should start onlyneutral position switch may be faulty. in Park and Neutral.Gearshift Adjustment Procedure (10) Lower vehicle. (1) Shift transmission into Park. PARK INTERLOCK CABLE ADJUSTMENT (2) Raise vehicle. (1) Shift transmission into Park. (3) Release cable adjuster clamp (at transmission (2) Turn ignition switch to Accessory position.end of cable) to unlock cable (Fig. 5). (4) Unsnap cable from cable bracket (Fig. 5).
    • 21 - 80 42RE IN-VEHICLE SERVICE ZJ Fig. 5 Shift Cable Attachment At Transmission Fig. 6 Shift And Park Interlock CablesCAUTION: Be sure the ignition switch is in the Ac- (2) Loosen band adjusting screw locknut. Thencessory position for cable adjustment. The cable back locknut off 4-5 turns. Be sure adjusting screwand lever mechanism will not adjust correctly if the turns freely in case. Lubricate screw threads if nec-switch lock cylinder is in Park position. essary. (3) Tighten band adjusting screw to 8 N⅐m (72 in. (3) Remove shift lever bezel and console screws. lbs.) torque with inch pound Torque WrenchRaise bezel and console for access to cable. C-3380-A, a 3-in. extension and 5/16 socket (Fig. 7). (4) Pull cable lock button up to release cable (Fig.6). CAUTION: If Adapter C-3705 is needed to reach the (5) Pull cable forward. Then release cable and adjusting screw (Fig. 8), tighten the screw to only 5press cable lock button down until it snaps in place. N⅐m (47-50 in. lbs.) torque. (6) Check cable adjustment as follows: (4) Back off band adjusting screw 3-5/8 turns. (a) Place shift lever in Park. (5) Hold adjuster screw in position and tighten (b) Check shift handle release button and igni- locknut to 41 N⅐m (30 ft. lbs.) torque. tion lock cylinder operation. Release button should (6) Lower vehicle. be in released (out) position and ignition lock cylin- der should rotate freely from Off to Lock. REAR BAND ADJUSTMENT (c) Next, place shift lever in D or R position and The transmission oil pan must be removed for ac- check ignition lock cylinder operation again. Cylin- cess to the rear band adjusting screw. der should not rotate from Off to Lock position. (1) Raise vehicle. (d) Check shift lever operation. Shifting out of (2) Remove transmission oil pan and drain fluid. Park position should only be possible when ignition (3) Loosen band adjusting screw locknut 5-6 turns. lock cylinder is in Off, Run, or Start positions. Shift Be sure adjusting screw turns freely in lever. Lubri- lever should be locked-in when lock cylinder is in cate screw threads if necessary. Accessory and Lock positions. (4) Tighten adjusting screw to 8 N⅐m (72 in. lbs.) torque (Fig. 9). Use inch-pound Torque WrenchFRONT BAND ADJUSTMENT C-3380-A for adjustment. The front band adjusting screw is located on the (5) Back off band adjusting screw 4 turns.driver side of the transmission case above the man- (6) Hold adjusting screw in place and tighten lock-ual valve and throttle valve levers. nut to 34 N⅐m (25 ft. lbs.) torque. (7) Clean oil pan, pan magnet and gasket surfaceADJUSTMENT PROCEDURE of case. Also inspect and replace fluid filter if neces- (1) Raise vehicle. sary.
    • ZJ 42RE IN-VEHICLE SERVICE 21 - 81 Fig. 9 Rear Band Adjusting Screw Location (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, Fig. 7 Front Band Adjustment severely corroded, or damaged. SPEEDOMETER INSTALLATION AND INDEXING (1) Thoroughly clean adapter flange and adapter mounting surface in housing. Surfaces must be clean for proper adapter alignment and speedometer oper- ation. (2) Install new O-rings on speed sensor and speed- ometer adapter if necessary (Fig. 10). (3) Lubricate sensor and adapter O-rings with transmission fluid.Fig. 8 Using Band Adjustment Adapter Tool C-3705 (4) Install vehicle speed sensor in speedometer (8) Position new gasket on oil pan and install pan adapter. Tighten sensor attaching screw to 2-3 N⅐mon transmission. Tighten pan bolts to 17 N⅐m (150 in. (15-27 in. lbs.) torque.lbs.) torque. (5) Install speedometer pinion in adapter. (9) Lower vehicle and refill transmission with rec- (6) Count number of teeth on speedometer pinion.ommended fluid. Do this before installing assembly in housing. Then lubricate pinion teeth with transmission fluid.SPEEDOMETER SERVICE (7) Note index numbers on adapter body (Fig. 11). Rear axle gear ratio and tire size determine speed- These numbers will correspond to number of teeth onometer pinion requirements. If the pinion must be re- pinion.placed, refer to the parts catalogue information for (8) Install speedometer assembly in housing.the correct part. (9) Rotate adapter until required range numbers are at 6 o-clock position. Be sure range index num-SPEEDOMETER ASSEMBLY REMOVAL bers correspond to number of teeth on pinion gear. (1) Raise vehicle. (10) Install speedometer adapter clamp and retain- (2) Disconnect wires from vehicle speed sensor. ing screw. Tighten clamp screw to 10-12 N⅐m (90-110 (3) Remove adapter clamp and screw (Fig. 10). in. lbs.) torque. (4) Remove speed sensor and speedometer adapter (11) Connect wires to vehicle speed sensor.as assembly. (12) Lower vehicle and top off transmission fluid (5) Remove speed sensor retaining screw and re- level if necessary.move sensor from adapter. (6) Remove speedometer pinion from adapter.
    • 21 - 82 42RE IN-VEHICLE SERVICE ZJ Fig. 10 Speedometer Components (3) Shift transmission into reverse and test conti- nuity at switch outer terminals. (a) Continuity should exist only when transmis- sion is in Reverse. (b) Continuity should not exist between outer terminals and case. PARK/NEUTRAL POSITION SWITCH REPLACEMENT (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 cen- tered in switch opening in case (Fig. 12).Fig. 11 Location Of Index Numbers On Speedometer (4) Install new seal on switch and install switch in Adapter case. Tighten switch to 34 N⅐m (25 ft. lbs.) torque.PARK/NEUTRAL POSITION SWITCH (5) Connect switch wires, lower vehicle and top off transmission fluid level. The center terminal of the switch is the starter cir-cuit terminal. It provides the ground for the starter VALVE BODY SERVICEsolenoid circuit through the selector lever in Parkand Neutral positions only. The outer terminals on GENERAL SERVICE INFORMATIONthe switch are for the backup lamp circuit. The valve body can be removed for service without having to remove the entire transmission assembly.SWITCH TEST The valve body can be disassembled for cleaning (1) Verify that gearshift linkage is correctly ad- and inspection of the individual components. Refer tojusted before testing. Switch will not operate prop- the procedures in the Transmission Unit Subassem-erly if linkage adjustment is incorrect. bly Overhaul section. (2) To test switch, remove wiring connector. Then The only replaceable valve body components are:test continuity between center terminal and trans- • manual levermission case. Continuity should exist only when • manual lever washer, seal, E-clip and shaft sealtransmission is in Park or Neutral. • manual lever detent ball
    • ZJ 42RE IN-VEHICLE SERVICE 21 - 83 (10) Lower valve body enough to remove accumula- tor piston and springs. (11) Work manual lever shaft and electrical con- nector out of transmission case. Then lower valve body, rotate it away from case, pull park rod out of sprag and remove valve body (Fig. 14). Fig. 12 Park/Neutral Position Switch Contacts• throttle lever• fluid filter• pressure adjusting screw bracket• governor pressure solenoid• governor pressure sensor• converter clutch/overdrive solenoid assembly andharness (includes sump temperature thermister)• governor housing gasket• solenoid case connector O-rings The remaining valve body components are servicedonly as part of a complete valve body assembly. Fig. 14 42RE Valve BodyVALVE BODY REMOVAL VALVE BODY INSTALLATION (1) Shift transmission into Neutral. (1) Verify that park/neutral position switch has (2) Raise vehicle. NOT been installed in case. Valve body cannot be in- (3) Remove gearshift and throttle levers from shaft stalled if switch is in place.of valve body manual lever. (2) Check condition of O-ring seals on valve body (4) Disconnect wires at park/neutral position harness connector (Fig. 15). Replace seals on connec-switch. tor body if cut or worn. (5) Disconnect wires at park/neutral positionswitch and solenoid case connector (Fig. 13). Fig. 13 Transmission Case Connector Locations (6) Position drain pan under transmission oil pan. Fig. 15 Valve Body Harness Connector O-Ring Seal (7) Remove transmission oil pan and gasket. Locations (8) Remove fluid filter from valve body. (9) Remove bolts attaching valve body to transmis-sion case.
    • 21 - 84 42RE IN-VEHICLE SERVICE ZJ (3) Check condition of manual lever shaft seal in (9) Install accumulator springs and piston in case.transmission case. Replace seal if lip is cut, or worn. Then swing valve body over piston and outer springInstall new seal with 15/16 deep well socket (Fig. 16). to hold it in place. (4) Check condition of seals on accumulator piston (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 N⅐m (100 in. lbs.) torque. (12) Install new fluid filter on valve body. Tighten filter screws to 4 N⅐m (35 in. lbs.) 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 nec- essary. (16) Connect valve body overdrive and converter Fig. 16 Manual Lever Shaft Seal Installation clutch solenoid wires to case connector. (17) Install oil pan and new gasket. Tighten pan(Fig. 17). Install new piston seals if necessary. bolts to 17 N⅐m (13 ft. lbs.) torque. (18) Lower vehicle and fill transmission with Mo- par ATF Plus, type 7176 fluid. (19) Check and adjust gearshift and throttle valve cables if necessary. TRANSMISSION CONTROL MODULE (TCM) SERVICE Use the DRB scan tool to diagnose TCM function whenever a fault is suspected. Replace the module only when scan tool diagnosis indicates a fault has actually occurred. Fig. 17 Accumulator Piston Components TCM REPLACEMENT (5) Place valve body manual lever in low (1 posi- The TCM is located on the driver side of the dashtion) so ball on park lock rod will be easier to install adjacent to the steering column. The module andin sprag. harness connector are accessible from under the in- (6) Lubricate shaft of manual lever with petroleum strument panel (Fig. 18).jelly. This will ease inserting shaft through seal in The module has integral mounting studs for at-case. tachment to the dash panel. A retaining plate and (7) Lubricate seal rings on valve body harness con- two locknuts secure the module to the dash (Fig. 18).nector with Ru-Glyde, or petroleum jelly. Although the module is inside the vehicle, the retain- ing plate and locknuts are on the engine compart- (8) Position valve body on case and work end of ment side of the dash panel.park lock rod into and through pawl sprag. Turn pro-peller shaft to align sprag and park lock teeth if nec- TCM REMOVALessary. Rod will make click noise as it enters pawl. (1) In engine compartment, remove module lock-Move rod to check engagement. nuts and remove module retaining plate. Locknuts and retaining plate are on driver side of engineCAUTION: It is possible for the park rod to displace compartment near brake booster.into a cavity just above the pawl sprag during in- (2) In vehicle interior, reach up under instrumentstallation. Make sure the rod is actually engaged in panel and slide module out of dash.the pawl and has not displaced into this cavity. If (3) Work module downward until module harnessthe rod enters the cavity during installation, it will connector is accessible.become bent when the overdrive bolts are tight- (4) Lift release tab on harness connector (Fig. 18).ened. The rod will then have to be replaced be- Pull connector out of module and remove modulecause it is not repairable. from vehicle.
    • ZJ 42RE IN-VEHICLE SERVICE 21 - 85 Cooler Line And Fitting Service The cooler lines and fittings are NOT serviceable. Damaged fittings or cooler lines are to be replaced as assemblies. Fittings swedged into cooler line hoses (Fig. 21) are serviced only as part of the entire cooler line. Fig. 19 Disconnecting Cooler Line With Release Tool (Type 2 Fitting) Fig. 18 TCM Location And MountingTCM INSTALLATION (1) Carefully align and plug harness connector intomodule. Verify that connector is fully seated beforeproceeding. Fig. 20 New Style Fitting With Release Tabs On (2) Work module upward into position on dash. InsertThen slide module studs into mounting holes in dash. (3) In engine compartment, install retaining plateon module studs. Then install and tighten locknuts to14-16 N⅐m (129-144 in. lbs.) torque.TRANSMISSION COOLER LINE AND FITTINGSERVICE The transmission cooler lines are attached withquick connect fittings. Two types of fitting will beused. Some early production models will have the type 2fitting used in prior years. This fitting requires a re-lease tool to disconnect the cooler line from the fit-ting (Fig. 19). Later production models will have a new style fit-ting that does not require any type of release tool. Fig. 21 Cooler Line Fitting PlacementThis fitting has a plastic insert with built-in releasetabs (Fig. 20). DISCONNECTING COOLER LINES WITH NEW STYLE FITTING The new style fitting does not require any kind of release tool. The fittings have built-in release tabs.
    • 21 - 86 42RE IN-VEHICLE SERVICE ZJThe tabs only require finger pressure to compress (4) Cover open ends of cooler lines and fittings tothem and release the cooler line. prevent dirt entry. Note that the fitting insert remains on the cooler (5) Inspect condition of fitting. Replace transmis-line after release (Fig. 22). It is not necessary to sion fitting as an assembly if fitting body or retainerremove the insert from the cooler line unless clip is damaged. Replace cooler line as assembly, ifthe insert is damaged. fitting swedged into cooler line hose, is damaged. If the fitting insert is damaged, simply spread therelease tabs far enough to release the insert and CONNECTING COOLER LINES (ALL TYPES)slide it off the cooler line (Fig. 23). (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 clean, 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. CAUTION: The wire retainer clips in Type 2 fittings secure the cooler lines in the fittings. If the clips are deformed, or distorted, normal fluid pressure could unseat the lines resulting in fluid loss and transmission damage. Be very sure the cooler lines are firmly secured by the retainer clip as described in step (4) above. CONVERTER DRAINBACK CHECK VALVE SERVICE Fig. 22 Disconnecting New Style Fitting From The converter drainback check valve is located in Cooler Line the cooler outlet (pressure) line near the radiator lower tank. The valve prevents fluid drainback when the vehicle is parked for lengthy periods. The valve check ball is spring loaded and has an opening pres- sure of approximately 2 psi. The valve is serviced as an assembly; it is not re- pairable. Do not clean the valve if restricted, or con- taminated by sludge, or debris. If the valve fails, or if a transmission malfunction occurs that generates sludge and/or clutch particles and metal shavings, the valve must be replaced. The valve must be removed whenever the cooler and lines are reverse flushed. The valve can be flow Fig. 23 Removing Fitting Insert From Cooler Line tested when necessary. The procedure is exactly theDISCONNECTING COOLER LINES WITH TYPE same as for flow testing a cooler.2 FITTING If the valve is restricted, installed backwards, or in (1) If fitting and cooler line are encrusted with the wrong line, it will cause an overheat conditiondirt, mud, or grease, clean fitting and cooler line with and possible transmission failure.Mopar spray type carburetor or brake cleaner. Plasticrelease tool will not fit into retainer clip if fitting is CAUTION: The drainback valve is a one-way valve.full of foreign material. As such, it must be properly oriented in terms of (2) Slide small plastic release tool into fitting until flow direction. In addition, the valve must only betool bottoms against cooler line flange (Fig. 19). installed in the pressure line. Otherwise flow will be (3) Push and turn release tool to spread retainer blocked causing overheat and eventual transmis-clip and pull cooler line out of fitting (Fig. 19). sion failure.
    • ZJ 42RE IN-VEHICLE SERVICE 21 - 87TRANSMISSION COOLER FLOW TESTING is preferred, reverse flushing can be performed with The transmission main and auxiliary coolers, plus hand operated equipment as follows.the drainback valve, should be flow tested whenever (1) Disconnect cooler pressure and return lines atfluid overheating is noted. transmission (Fig. 24). Restricted flow caused by contamination, or a (2) Remove and discard drainback valve. Installcooler malfunction, reduces lubrication fluid flow fabricated hose and fitting in place of valve.throughout the transmission. This can result in fluid (3) Position drain pan under cooler pressure line tooverheating, fluid breakdown, bushing wear, shift catch material flushed through cooler and lines.problems and component failure. (4) Reverse flush cooler using hand operated suc- Normal color of transmission fluid varies from tion gun filled with mineral spirits. Insert gun nozzlebright red, to light pink. Fluid overheating is indi- (or hose) into cooler return line. Then force mineralcated when fluid color ranges from orange-brown to spirits into line and through cooler.black, and the fluid smells burned, or contains (5) Continue reverse flushing until fluid comingsludge. out of cooler pressure line is clear. Replace cooler if fluid cannot be pumped through.CAUTION: If a transmission malfunction contami- (6) Clear flushing materials from cooler and linesnates the fluid with clutch disc and metal particles, with short pulses of compressed air. Insert air gunthe cooler and lines must be reverse flushed thor- nozzle into cooler return line and continue short airoughly. Flushing will prevent sludge and particles pulses until all fluid is cleared from cooler and lines.from flowing back into the transmission and con- (7) Pump one quart of fresh automatic transmis-verter after repair. sion fluid through cooler and lines before reconnect- ing lines. Cooler flow is tested by measuring the amount of (8) Install new drainback valve in pressure line.fluid pumped through the cooler in a specified time (9) Check and adjust transmission fluid level asby the transmission oil pump. The same flow test described in this section.procedure is used for the drainback valve, maincooler, and auxiliary cooler. TRANSMISSION COOLER REPLACEMENTCooler And Drainback Valve Flow Test Procedure Main Cooler Replacement (1) Test flow through drainback valve as follows: The main transmission cooler is located in the ra- (a) Add extra quart of ATF Plus to transmission. diator lower tank. The cooler is not a serviceable (b) Disconnect pressure line at radiator fitting, or component. If the cooler is damaged in any way, the at drainback valve and position hose or valve end radiator will have to be replaced. in one quart test container. (c) Shift transmission into neutral, run engine at Auxiliary Cooler Replacement idle speed for 20 seconds, and note flow from valve. (1) Remove grille. Use stopwatch to check test time. (2) Remove screws and U-nuts securing cooler to (d) Replace drainback valve if flow is less than radiator support. one quart in 20 seconds, is intermittent, or does (3) Tag cooler hoses for installation reference. not flow at all. (4) Position drain pan under cooler hoses. (e) Connect pressure hose to radiator fitting and (5) Loosen cooler connecting hose clamps and dis- proceed to cooler flow test. connect hoses. (2) Test flow through main cooler as follows: (6) Remove auxiliary cooler. Replace cooler hoses if (a) Disconnect cooler return (rear) line at trans- cracked or leaking. mission and place it in one quart test container. (7) Connect cooler hoses. (b) Add extra quart of fluid to transmission. (8) Position cooler on radiator and install cooler at- (c) Shift transmission into neutral, run engine at taching U-nuts and screws. idle speed for 20 seconds, and note flow from valve. (9) Tighten cooler hose clamps securely. Use stopwatch to check test time. (10) Install grille. (d) Replace cooler if fluid flow is less than one (11) Check and adjust transmission fluid level. quart in 20 seconds, is intermittent, or does not flow at all. ALUMINUM THREAD REPAIR (3) If vehicle is equipped with auxiliary cooler, Damaged or worn threads in the aluminum trans-test cooler flow as described in step (2). mission case and in the valve body can be repaired with Heli-Coil or similar quality thread inserts. Es-TRANSMISSION COOLER REVERSE FLUSHING sentially, repair consists of drilling out the worn or The flushing procedure applies to standard and damaged threads, tapping the hole with a special tapauxiliary coolers alike. Although pressure equipment and installing the thread insert into the tapped hole.
    • 21 - 88 42RE IN-VEHICLE SERVICE ZJ Fig. 24 Transmission Cooler Line IdentificationThis procedure returns the hole threads to original readily available from most automotive parts suppli-size. Heli-Coil, or equivalent, tools and inserts are ers. Stainless steel inserts are recommended.
    • ZJ 42RE TRANSMISSION/OVERDRIVE REMOVAL AND INSTALLATION 21 - 89 42RE TRANSMISSION/OVERDRIVE REMOVAL AND INSTALLATION INDEX page pageGeneral Information . . . . . . . . . . . . . . . . . . . . . . . 89 Torque Converter and Drive Plate Service . . . . . . . 90Oil Pump Seal Replacement . . . . . . . . . . . . . . . . . 90 Transmission Installation (2-Wheel Drive) . . . . . . . . 91Overdrive Unit Installation (2-Wheel Drive) . . . . . . . 97 Transmission Installation—4-Wheel Drive . . . . . . . . 93Overdrive Unit Installation (4-Wheel Drive) . . . . . . . 94 Transmission Removal (2-Wheel Drive) . . . . . . . . . 89Overdrive Unit Removal (2-Wheel Drive) . . . . . . . . 96 Transmission Removal (4-Wheel Drive) . . . . . . . . . 89Overdrive Unit Removal (4-Wheel Drive) . . . . . . . . 94GENERAL INFORMATION (17) Lower transmission for access to converter The overdrive unit can be removed for service with- housing upper bolts and crankshaft position sensor.out having to remove the entire transmission assem- (18) Disconnect crankshaft position sensor. Retainbly. However if the transmission, torque converter, sensor attaching screws.converter driveplate, or oil pump requires service, (19) Remove transmission fill tube and tube O-ringthe complete transmission assembly must be re- seal.moved for access to these components. (20) Remove bolts attaching transmission to engine If only the overdrive unit must be removed, refer to block.the Overdrive Unit Removal/Installation procedures. (21) Slide transmission away from engine and in-If the complete transmission assembly must be re- stall C-clamp on converter housing to hold convertermoved, refer to the Transmission Removal/Installa- in place.tion procedures. (22) Lower transmission and move from under ve- hicle.TRANSMISSION REMOVAL (2-WHEEL DRIVE) (23) If transmission is to be serviced, remove it (1) Disconnect battery negative cable. from jack and position it on bench. (2) Raise vehicle on hoist. (3) Remove skid plate if equipped. TRANSMISSION REMOVAL (4-WHEEL DRIVE) (4) If transmission is being removed for repair, re- (1) Raise vehicle on hoist.move oil pan, drain fluid and reinstall pan on case. (2) Remove skid plate, if equipped. (5) Mark propeller shaft for installation reference. (3) Mark front and rear propeller shafts andThen disconnect and remove propeller shaft. U-joints for alignment reference (Fig. 1). (6) Disconnect vehicle speed sensor wires, trans- (4) Disconnect and remove both propeller shafts.mission solenoid wires and park/neutral positionswitch wires. (7) Disconnect wires from transmission speed sen-sor at rear of overdrive unit. (8) Remove exhaust system Y-pipe for workingclearance. (9) Unclip wire harnesses from transmission clips. (10) Disconnect throttle valve and gearshift cablesfrom levers on valve body manual shaft. Move cablesaside and secure them to underbody. (11) Remove dust cover from transmission con-verter housing. (12) Disconnect and remove starter motor. (13) Remove bolts attaching converter to drive-plate. (14) Disconnect cooler lines at transmission fit-tings. Refer to In-Vehicle Service section for proce-dures. Fig. 1 Marking Propeller Shaft And Yoke For (15) Support transmission with transmission jack. Alignment Reference (16) Remove bolts/nuts attaching rear insulator to (5) Disconnect vehicle speed sensor and transmis-rear crossmember. Then remove rear crossmember. sion output shaft speed sensor wires.
    • 21 - 90 42RE TRANSMISSION/OVERDRIVE REMOVAL AND INSTALLATION ZJ (6) Disconnect electrical wires from clips on trans- fere with transmission removal. Peen this part ofmission and transfer case. flange over with a mallet if necessary. (7) Disconnect transfer case shift linkage at trans- (29) Secure torque converter in housing with smallfer case range lever. Then remove linkage bracket C-clamp.bolts and remove linkage and bracket from transfer (30) Lower transmission and remove it from undercase. Move linkage aside for clearance. vehicle. (8) Remove nuts attaching transfer case to over- (31) Remove C-clamp and remove converter fromdrive unit gear case. transmission. Place converter on workbench for in- (9) Remove transfer case. Support transfer case spection or reassembly. Cover converter hub withwith transmission jack. Secure transfer case to jack clean, lint free cloth.with safety chains. Then move transfer case rear- (32) Oil pump, converter and driveplate can nowward and off transmission. be serviced if necessary. Refer to information in this (10) Remove transfer case from transmission jack section.and place transfer case on bench. (11) Support transmission with transmission jack. OIL PUMP SEAL REPLACEMENT (12) Remove nuts and bolts attaching transmission The pump oil seal can be replaced without remov-mount to crossmember. ing the pump and reaction shaft support assembly (13) Remove bolts and nuts attaching crossmember from the transmission case.to frame rails. (14) Rotate crossmember diagonally to clear frame Seal Removalrails and remove crossmember. Remove the seal with Special Tool C-3861-B (Fig. (15) Disconnect exhaust pipes at manifold and at 2). To use the remover tool, First start the tool intoconverter and/or muffler connections as needed. Then the seal by hand. Next, thread the tool into the sealremove Y-pipe from vehicle and move remaining as far as it will go. Use a wrench on the tool hex topipes aside for working clearance. turn the tool. Continue tightening until all the tool (16) Disconnect crankshaft position sensor. threads firmly grip the metal part of the seal. Then (17) Disconnect transmission shift linkage at shift tighten the tool puller screw to withdraw the seallever on transmission. from the pump body. (18) Remove transmission shift linkage torqueshaft assembly from retainers on transmission andframe rail. Move linkage aside for working clearance. (19) Remove brackets that attach transmission toengine block, if equipped. (20) Remove dust shield cover from front side oftransmission converter housing. (21) Remove starter motor bolts. Pull starter rear-ward until clear of housing and position it out of wayon 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 todrive plate. (23) Disconnect cooler lines at quick disconnect fit-tings in transmission. Refer to In-Vehicle Service sec-tion for procedures. Fig. 2 Oil Pump Seal Removal (24) Disconnect solenoid and park/neutral position Seal Installationswitch wires at transmission. Use Installer Tool C-4193-A (Fig. 3). To use the (25) Remove transmission fill tube and dipstick. (26) Lower transmission for access to converter tool, place the seal in the pump opening with the sealhousing upper bolts. lip facing inward. Then tap the seal into place with (27) Remove bolts attaching transmission con- the installer tool.verter housing to engine. Note that some bolts maybe accessible only from front (engine) side of housing. TORQUE CONVERTER AND DRIVE PLATE SERVICE (28) Move transmission rearward until clear of en- After the transmission has been removed, the drivegine block dowels. On some models, part of hem plate and torque converter can removed for serviceflange joining vehicle cab and dash panel may inter- access, or replacement.
    • ZJ 42RE TRANSMISSION/OVERDRIVE REMOVAL AND INSTALLATION 21 - 91 (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. Fig. 3 Oil Pump Seal InstallationTorque Converter The torque converter is not a serviceable compo-nent. If the converter is contaminated by a transmis-sion malfunction, or damaged in any way, it must bereplaced as an assembly. Do not attempt to flush aconverter contaminated by metal or clutch fac-ing particles. Flushing will not remove thesecontaminants. Different length bolts are used with the varioussize torque converters; they are not all the samelength. Therefore, it is essential that correct lengthbolts be used to attach the converter to the drive-plate. Bolts that are too long will damage the modu-lated clutch surfaces inside the converter. If newbolts are required, use the bolts specified in the parts Fig. 4 Checking Torque Converter Seatingcatalogue only. (5) Temporarily secure converter with C-clamp at- tached to housing or with metal strap attachedDriveplate across converter housing. The driveplate should be inspected whenever the (6) Check condition of converter driveplate. Re-torque converter is removed. Replace the plate if place driveplate if cracked, distorted or damaged.bent, distorted, or if cracks around the bolt holes are (7) Verify that transmission dowel pins are seatedevident. in engine block and protrude far enough to held New bolts should be used to secure the driveplate ifremoved or replaced. Apply Mopar Lock N’ Seal or transmission in alignment.Loctite 242 to the bolt threads before installation to (8) Coat torque converter pilot hub of crankshaftensure retention. with light coat of Mopar high temperature wheel bearing grease.TRANSMISSION INSTALLATION (2-WHEEL DRIVE) (9) Move transmission under vehicle and position it at rear of engine. Remove C-clamp or strap used toCAUTION: The transmission cooler and lines must secure converter in housing.be flushed if repair was to correct a problem that (10) Align transmission with engine dowels andgenerated sludge, metal particles, or clutch friction align converter with driveplate.material. The torque converter should also be re- (11) Move transmission forward until seated on en-placed when contaminated by a malfunction. The gine block dowels. Then install one or two transmis-transmission, fluid and converter will be contami- sion attaching bolts to hold transmission in placenated again if residue/debris is not flushed from the (Fig. 5).cooler and lines beforehand. (1) Mount transmission on jack. Secure transmis-sion to jack with safety chains.
    • 21 - 92 42RE TRANSMISSION/OVERDRIVE REMOVAL AND INSTALLATION ZJ Fig. 5 Transmission And Fill Tube MountingCAUTION: It is essential that correct length bolts be (20) Connect wires to solenoids, park/neutral posi-used to attach the converter to the driveplate. Bolts tion switch, transmission speed sensor and vehiclethat are too long will damage the modulated clutch speed sensor.surfaces in the converter. If new bolts are required, (21) Install transmission fill tube and O-ring.use the bolts specified in the parts catalogue only. (22) Install rear crossmember and attach rear in- sulator to transmission and crossmember. (12) Verify converter bolt length. Bolt measure- (23) Connect cooler lines to fittings. Pull lines out-ment is from bottom (underside) of bolt head to end ward to verify that they are securely seated and re-of bolt threads. On 9.5 in. 3-lug converter bolts tained in fittings.should be 11.7 mm (0.46 in.). On 10.75 in. 4-lug con- (24) Align and install propeller shaft. Clean andverter bolts should be 11.2 mm (0.44 in.). lubricate slip yoke before installation. (13) Install torque converter bolts. Tighten bolts to (25) Install exhaust system components.following torques: 54 N⅐m (40 ft. lbs.) with 9.5 in. (26) Lower vehicle.3-lug converter, or 31 N⅐m (270 in. lbs.) with 10.75 in (27) Connect battery negative cable.4-lug converter (28) Fill or top off transmission fluid level with (14) Install and tighten remaining transmission at- Mopar ATF Plus, type 7176.taching bolts (Fig. 6). (29) Check transmission control cable adjustments. (15) Connect crankshaft position sensor. Readjust cables if necessary. (16) Install dust cover on transmission converterhousing. Two small vise grip pliers van be used tohold and align cover during installation. (17) Install and connect starter motor. (18) Connect transmission shift and throttle valvecables to valve body manual shaft and transmissionbrackets. (19) Fasten wire harnesses in clips on transmis-sion case.
    • ZJ 42RE TRANSMISSION/OVERDRIVE REMOVAL AND INSTALLATION 21 - 93TRANSMISSION INSTALLATION—4-WHEEL DRIVE (13) Install torque converter bolts. Tighten bolts to following torques: 54 N⅐m (40 ft. lbs.) with 9.5 in.CAUTION: The transmission cooler and lines must 3-lug converter, or 31 N⅐m (270 in. lbs.) with 10.75 inbe flushed if repair was to correct a problem that 4-lug converter.generated sludge, metal particles, or clutch friction (14) Install and tighten remaining transmission at-material. The converter and drainback valve should taching bolts (Fig. 5).also be replaced when contaminated. The transmis- (15) Install dust cover on transmission convertersion, fluid and converter will be contaminated again housing. Two small vise grip pliers van be used toif residue/debris is not flushed from the cooler and hold and align cover during installation.lines beforehand. (16) Install starter motor. (17) Install strut brackets that secure transmission (1) Mount transmission on jack. Secure transmis- to engine block and front axle.sion to jack with safety chains. (18) Connect crankshaft position sensor. (2) Check torque converter hub and hub drive (19) Install transmission fill tube. Install newnotches for sharp edges burrs, scratches, or nicks. O-ring seal on tube before installation (Fig. 6).Polish hub and notches with crocus cloth or 400 grit (20) Connect exhaust Y-pipe to engine exhaustpaper if necessary. Hub must be smooth to avoid manifolds.damaging pump seal. (21) Install shift linkage torque bracket. (3) Lubricate converter hub and pump seal lip with (22) Connect shift linkage to transmission.Mopar high temperature wheel bearing grease. (23) Connect solenoid and park/neutral position (4) Verify that converter is fully seated. Use switch wires.straight edge and steel ruler to check seating (Fig. 4). (24) Connect wires to transmission speed sensorSurface of converter lugs should be 12.7 mm (1/2 in.) and vehicle speed sensor.to rear of straight edge when converter is fully (25) Install crossmember on frame rails. Placeseated. crossmember at 45° angle to rails. Insert crossmem- (5) Temporarily secure converter with C-clamp at- ber between rails and rotate crossmember into place.tached to housing or with metal strap attached (26) Install rear mount bolts/nuts.across converter housing. (27) Install crossmember bolts/nuts. (6) Check condition of converter driveplate. Re- (28) Remove transmission jack.place driveplate if cracked, distorted or damaged. (29) Install transfer case (Fig. 6). (7) Verify that transmission dowel pins are seatedin engine block and protrude far enough to heldtransmission in alignment. (8) Coat torque converter pilot hub of crankshaftwith light coat of Mopar high temperature wheelbearing grease. (9) Move transmission under vehicle and positionit at rear of engine. Remove C-clamp or strap used tosecure converter in housing. (10) Align transmission with engine dowels andalign converter with driveplate. (11) Move transmission forward until seated on en-gine block dowels. Then install one or two transmis-sion attaching bolts to hold transmission in place.CAUTION: It is essential that correct length bolts beused to attach the converter to the driveplate. Bolts Fig. 6 Transfer Case Attachmentthat are too long will damage the modulated clutchsurfaces in the converter. If new bolts are required, (30) Install and tighten 3/8 transfer case attachinguse the bolts specified in the parts catalogue only. nuts to 47 N⅐m (35 ft. lbs.) torque, or 5/16 nuts to 35 N⅐m (26 ft. lbs.) torque. (12) Verify converter bolt length. Bolt measure- (31) Install damper on transfer case rear retainerment is from bottom (underside) of bolt head to end if equipped. Tighten damper nuts to 54 N⅐m (40 ft.of bolt threads. lbs.) torque.• On 9.5 in. 3-lug converter bolts should be 11.7 mm (32) Install and connect transfer case shift linkage.(0.46 in.) (33) Connect transmission cooler lines to quick• On 10.75 in. 4-lug converter bolts should be 11.2 connect fittings on transmission case. Pull outwardmm (0.44 in.) on lines to be sure they are secured in fittings.
    • 21 - 94 42RE TRANSMISSION/OVERDRIVE REMOVAL AND INSTALLATION ZJ (34) Align and install remaining exhaust compo- (17) Remove bolts attaching overdrive unit tonents. Tighten all clamp and bracket bolts and nuts transmission (Fig. 8).securely. Be sure exhaust components are clear of allchassis and driveline components. CAUTION: The overdrive unit must be fully sup- (35) Align and install front and rear propeller ported during removal. This is necessary to preventshafts. Tighten U-joint clamp bolts to 19 N⅐m (170 in. damaging the intermediate shaft. Do not allow the shaft to support the entire weight of the overdrivelbs.) torque. unit. (36) Verify that all linkage components, hoses andelectrical wires have been connected. (18) Carefully slide overdrive unit off intermediate (37) Check transfer case fluid level. Add Mopar shaft. Do not tilt overdrive unit during removal.ATF Plus, or Dexron II fluid if necessary. Correct Keep it as level as possible.level is to edge of fill plug hole. Be sure transfer case (a) If overdrive unit does not require service, im-is level before checking or adding fluid. mediately insert Alignment Tool 6227-2 in (38) Install transfer case skid plate, if equipped. splines of planetary gear and overrunning (39) Lower vehicle. clutch (Fig. 9). If misalignment occurs, over- (40) Connect battery negative cable. drive unit may have to be disassembled in or- (41) Refill transmission with Mopar ATF Plus, type der to realign splines.7176 fluid. (b) If overdrive unit requires service, refer to (42) Check and adjust engine oil level as necessary. Overdrive Unit Overhaul procedures. (43) Check and adjust transmission and transfer (19) Remove and retain bearing and select fitcase shift linkage if necessary. spacer. These parts may remain on overdrive piston, (44) Check and adjust transmission shift and rear of transmission case, sliding hub, or intermedi-throttle valve cables if necessary. ate shaft during removal. (20) Place several clean shop towels on a bench.OVERDRIVE UNIT REMOVAL (4-WHEEL DRIVE) Then position unit on towels to absorb spilled fluid. (1) Disconnect battery negative cable. (21) Position overdrive unit over drain pan and tilt (2) Raise vehicle on hoist. unit to drain residual fluid from case. Examine fluid (3) Remove transfer case skid plate, if equipped. for clutch material or metal fragments. If fluid con- (4) Mark front and rear propeller shafts and tains these items, overhaul will be necessary.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. (7) Disconnect vacuum or indicator switch hoses/wires at transfer case. (8) Disconnect transfer case shift linkage at trans-fer case range lever. Then remove linkage bracketbolts and remove linkage and bracket from transfercase. Move linkage aside for clearance. (9) Remove nuts attaching transfer case to over-drive unit. (10) Remove transfer case. Support transfer casewith transmission jack (secure transfer case to jackwith safety chains). Then move transfer case rear-ward and off overdrive case. (11) Remove transfer case from jack and position it Fig. 7 Removing/Installing Overdrive Unit Attachingon bench. Bolts (12) Support transmission with adjustable jackstand. Position wood block between jack and trans- OVERDRIVE UNIT INSTALLATION (4-WHEELmission case. DRIVE) (13) Remove nuts and bolts attaching transmission (1) Be sure Alignment Tool 6227-2 is still fullymount to center crossmember. seated in splines of overdrive planetary gear and (14) Remove nuts and bolts attaching crossmember overrunning clutch. If misalignment occurs, overdriveto frame rails. will have to be disassembled in order to realign (15) Rotate crossmember diagonally to clear frame splines.rails and remove crossmember. (2) If original case gasket is in good condition, pro- (16) Support overdrive unit with transmission jack. ceed to step (6). If overdrive piston retainer was not
    • ZJ 42RE TRANSMISSION/OVERDRIVE REMOVAL AND INSTALLATION 21 - 95 Fig. 10 Intermediate Shaft Selective Spacer Location (8) Install thrust bearing in overdrive clutch hub. Use liberal quantity of petroleum jelly to hold bear- ing in position. Fig. 8 Overdrive Spline Alignment Tool Installationremoved during service and original case gasket is CAUTION: Be sure the shoulder on the inside diam-not reusable, prepare new gasket as described in eter of the bearing is facing forward.steps (3) through (5). (9) Install thrust plate in overdrive piston hub (3) Cut out old case gasket around piston retainer (Fig. 11). Use liberal amount of petroleum jelly towith razor knife. hold thrust plate in position. (4) Use old gasket as template and trim new gas-ket to fit (Fig. 9). Fig. 11 Installing Overdrive Piston Thrust Plate Fig. 9 Trimming Replacement Overdrive Case (10) Verify that splines in overdrive planetary gear Gasket and overrunning clutch hub are aligned with Tool 6227-2 (Fig. 9). Overdrive unit cannot be fully in- (5) Position new gasket over piston retainer and on stalled if splines have rotated out of alignment.transmission case. Use petroleum jelly to hold gasket If misaligned has occurred, overdrive will havein place if necessary. Do not use any type of to be disassembled in order to realign splines.sealer to secure gasket. Use petroleum jelly (11) Install overdrive unit as follows:only. (a) Raise overdrive unit and carefully slide it (6) Install selective spacer on intermediate shaft, if straight onto intermediate shaft. Avoid tiltingremoved. Spacer goes in groove just rearward of overdrive unit during installation as plane-shaft rear splines (Fig. 10). tary gear and overrunning clutch splines (7) Install overdrive piston in retainer, if removed. could rotate out of alignment. If misalignmentLubricate piston seals with Ru-Glyde, Door-Eze or occurs, overdrive will have to be disassem-petroleum jelly to ease installation. Be sure piston lo- bled in order to realign splines.cating lugs are aligned in piston retainer. (b) Align and carefully insert park rod into park pawl. Rod will make click noise as it enters pawl. Move rod rearward slightly.
    • 21 - 96 42RE TRANSMISSION/OVERDRIVE REMOVAL AND INSTALLATION ZJCAUTION: It is possible for the park rod to displace (24) Check and adjust transmission fluid level. Useinto a cavity just above the pawl sprag during in- Mopar ATF Plus, type 7176 fluid.stallation. Make sure the rod is actually engaged inthe pawl and has not displaced into this cavity. If OVERDRIVE UNIT REMOVAL (2-WHEEL DRIVE)the rod enters the cavity during installation, it will (1) Disconnect battery negative cable.become bent when the overdrive bolts are tight- (2) Raise vehicle on hoist.ened. The rod will then have to be replaced be- (3) Remove exhaust Y-pipe, catalytic converter andcause it is not repairable. tailpipe. (4) Mark propeller shaft and U-joint for alignment (c) Work overdrive unit forward on intermediate reference (Fig. 1). shaft until seated against transmission case. If unit (5) Disconnect and remove propeller shaft. is not fully seated, tighten overdrive bolts to draw (6) Disconnect vehicle speed sensor and transmis- unit against transmission case. sion speed sensor wires. (12) Apply Mopar Lock N’ Seal or Loctite 242 to (7) Support transmission with adjustable jackthreads of overdrive attaching bolts. stand and wood block. (13) Install and tighten overdrive unit attaching (8) Remove nuts and bolts attaching transmissionbolts to 34 N⅐m (25 ft. lbs.). mount to center crossmember. (14) Install transfer case. Tighten 5/16 nuts to 35 (9) Remove nuts and bolts attaching crossmemberN⅐m (26 ft. lbs.) and 3/8 nuts to 47 N⅐m (35 ft. lbs.). to frame rails. (15) Connect transmission throttle valve and gear (10) Rotate crossmember diagonally to clear frameshift cables and connect transfer case shift linkage. rails and remove crossmember. (16) Install crossmember and rear mount. (11) Support overdrive unit with transmission jack. (17) Connect all necessary electrical wires. (12) Remove bolts attaching overdrive unit to (18) Install and index speedometer adapter and transmission (Fig. 8).pinion if removed (Fig. 12). (19) Align and connect propeller shafts. Tighten U- CAUTION: The overdrive unit must be fully supportedjoint clamp bolts to 19 N⅐m (170 in. lbs.) torque. during removal. This is necessary to prevent damag- (20) Check and adjust fluid level in transfer case. ing the intermediate shaft. Do not allow the shaft toUse Mopar Dexron II. support the entire weight of the overdrive unit. (21) Install skid plate, if equipped. (22) Check and adjust transmission and transfer (13) Carefully slide overdrive unit off intermediatecase shift linkage if necessary. shaft. Do not tilt overdrive unit during removal. (23) Lower vehicle. Keep it as level as possible. Fig. 12 Speedometer Components
    • ZJ 42RE TRANSMISSION/OVERDRIVE REMOVAL AND INSTALLATION 21 - 97 (a) If overdrive unit does not require service, im- (10) Verify that splines in overdrive planetary gear mediately insert Alignment Tool 6227-2 in and overrunning clutch hub are aligned with Tool splines of planetary gear and overrunning 6227-2 (Fig. 8). Overdrive unit cannot be fully in- clutch (Fig. 9). If misalignment occurs, over- stalled if splines have rotated out of alignment. drive unit may have to be disassembled in or- If misaligned has occurred, overdrive will have der to realign splines. to be disassembled in order to realign splines. (b) If overdrive unit requires service, refer to (11) Install overdrive unit as follows: Overdrive Unit Overhaul procedures. (a) Raise overdrive unit and carefully slide it (14) Remove and retain bearing and select fit straight onto intermediate shaft. Avoid tiltingspacer. These parts may remain on overdrive piston, overdrive unit during installation as plane-rear of transmission case, sliding hub, or intermedi- tary gear and overrunning clutch splinesate shaft during removal. could rotate out of alignment. If misalignment (15) Place several clean shop towels on a bench. occurs, overdrive will have to be disassem-Then position unit on towels to absorb spilled fluid. bled in order to realign splines. (16) Position overdrive unit over drain pan and tilt (b) Align and carefully insert park rod into parkunit to drain residual fluid from case. Examine fluidfor clutch material or metal fragments. If fluid con- pawl. Rod will make click noise as it enters pawl.tains these items, overhaul will be necessary. Move rod slightly to check engagement.OVERDRIVE UNIT INSTALLATION (2-WHEEL CAUTION: It is possible for the park rod to displace into a cavity just above the pawl sprag during in-DRIVE) stallation. Make sure the rod is actually engaged in (1) Be sure Alignment Tool 6227-2 is still fully seated the pawl and ha not displaced into this case cavity.in splines of overdrive planetary gear and overrunning If the rod enters the cavity during installation, it willclutch. If misalignment occurs, overdrive will have to be become bent when the overdrive bolts are tight-disassembled in order to realign splines. (2) If original case gasket is in good condition, pro- ened. If this occurs, the rod will have to be replacedceed to step (6). If overdrive piston retainer was not because it is not repairable.removed during service and original case gasket is (c) Work overdrive unit forward on intermediatenot reusable, prepare new gasket as described in shaft until seated against transmission case. If unitsteps (3) through (5). (3) Cut out old case gasket around piston retainer is not fully seated, tighten overdrive bolts to drawwith razor knife. it up against transmission case. (4) Use old gasket as template and trim new gas- (12) Apply Mopar Lock N’ Seal or Loctite 242 toket to fit (Fig. 9). threads of overdrive attaching bolts. (5) Position new gasket over piston retainer and on (13) Install and tighten overdrive unit attachingtransmission case. Use petroleum jelly to hold gasket in bolts to 34 N⅐m (25 ft. lbs.).place if necessary. Do not use any type of sealer to (14) Connect transmission throttle valve and gearsecure gasket. Use petroleum jelly only. shift cables. (6) Install selective spacer on intermediate shaft, if (15) Install crossmember and rear mount.removed. Spacer goes in groove just rearward of (16) Connect all necessary electrical wires.shaft rear splines (Fig. 10). (17) Install and index speedometer adapter and (7) Install overdrive piston in retainer, if removed. pinion (Fig. 13). Refer to In-Vehicle Service sectionLubricate piston seals with Ru-Glyde, Door-Eze or for indexing procedure.petroleum jelly to ease installation. Be sure piston lo- (18) Align and connect propeller shaft. Tighten U-cating lugs are aligned in piston retainer. joint clamp bolts to 19 N⅐m (170 in. lbs.) torque. (8) Install thrust bearing in overdrive clutch hub. (19) Install exhaust system components.Use liberal quantity of petroleum jelly to hold bear- (20) Lower vehicle.ing in position. (21) Connect battery negative cable. (22) Check and adjust transmission shift andCAUTION: Be sure the shoulder on the inside diam-eter of the bearing is facing forward. throttle valve cables if necessary. (23) Check and adjust transmission fluid level. Use (9) Install thrust plate in overdrive piston hub Mopar ATF Plus, type 7176 fluid.(Fig. 12). Use liberal amount of petroleum jelly tohold thrust plate in position.
    • 21 - 98 42RE TRANSMISSION OVERHAUL ZJ 42RE TRANSMISSION OVERHAUL INDEX page pageFront Clutch Overhaul . . . . . . . . . . . . . . . . . . . . . 110 Rear Clutch Overhaul . . . . . . . . . . . . . . . . . . . . . 112Front Servo and Band Overhaul . . . . . . . . . . . . . 120 Rear Servo and Band Overhaul . . . . . . . . . . . . . . 120Oil Pump and Reaction Shaft Support Overhaul . . 106 Transmission Assembly and Adjustment . . . . . . . . 137Overhaul Service Information . . . . . . . . . . . . . . . . 104 Transmission Case Cleaning and Inspection . . . . 105Overrunning Clutch, Low-Reverse Drum and Overdrive Transmission Disassembly . . . . . . . . . . . . . . . . . . 98 Piston Retainer Inspection and Overhaul . . . . . . . 105 Valve Body Cleaning and Inspection . . . . . . . . . . 129Planetary Gear Train and Intermediate Shaft Valve Body Service and Adjustment . . . . . . . . . . . 121 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115TRANSMISSION DISASSEMBLY (1) Remove torque converter if not previously re-moved. (2) Clean transmission exterior with steam gun orwith solvent. Wear eye protection during cleaning oper-ations. (3) Remove shift and throttle levers from valvebody manual lever shaft. (4) Remove transmission speed sensor and O-ringseal from overdrive unit (Fig. 1). Fig. 2 Removing/Installing Overdrive Unit Attaching Bolts 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 and bolts for instal- Fig. 3 Overdrive Unit Removallation reference. (a) If overdrive unit does not require service, in- (7) Lift overdrive unit up and off transmission in- sert Alignment Tool 6227-2 in overrunning clutchtermediate shaft (Fig. 3). and planetary gear splines to maintain alignment
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 99 (Fig. 4). If clutch and gear splines rotate out of 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. Fig. 6 Oil Filter Removal/Installation Fig. 4 Overdrive Spline Alignment Tool Installation (8) Remove thrust bearing and thrust plate fromoverdrive piston (Fig. 5). Fig. 7 Overdrive Piston Removal 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 bodyscrews. Filter screws are longer and should be keptwith filter. (12) Remove overdrive piston from retainer (Fig.7). (13) Remove pump oil seal with Special ToolC-3981B (Fig. 8). Be sure to tighten tool threads com-pletely into seal before using puller bolt to withdraw Fig. 8 Oil Pump Seal Removalseal.
    • 21 - 100 42RE TRANSMISSION OVERHAUL ZJ (14) Remove park/neutral position switch (Fig. 9). Fig. 9 Park/Neutral Position Switch Removal/ Installation (15) Remove hex head bolts attaching valve bodyto transmission case (Fig. 10). A total of 10 bolts areused. Note different bolt lengths for assembly refer- Fig. 11 Valve Body Removalence. Fig. 12 Accumulator Piston And Springs (18) Remove front band lever shaft access plug (Fig. 13). Plug is accessible through converter hous- ing. Use 1/4 inch drive extension to remove plug as shown. Fig. 10 Valve Body Bolt Locations (16) Remove valve body assembly. Push valve bodyharness connector out of case. Then work park rodand valve body out of case (Fig. 11). Exercise careduring removal as governor pressure solenoidand transducer can both be damaged by roughhandling. Fig. 13 Removing/Installing Front Band Lever Shaft (17) Remove accumulator piston and inner and Access Plugouter springs (Fig. 11). (19) Loosen front band adjusting screw locknut 4-5 turns. Then tighten band adjusting screw until band
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 101is tight around front clutch retainer. This preventsfront/rear clutches from coming out with pump andpossibly damaging clutch or pump components. (20) Remove oil pump bolts. (21) Thread bolts of Slide Hammer Tools C-3752into threaded holes in pump body flange (Fig. 14). (22) Bump slide hammer weights outward to re-move pump and reaction shaft support assemblyfrom case (Fig. 14). Fig. 16 Removing Front Band Lever Shaft Fig. 14 Removing Oil Pump And Reaction Shaft Support Assembly (23) Loosen front band adjusting screw until bandis completely loose. Fig. 17 Removing/Installing Front Band Lever (24) Squeeze front band together and remove band (28) Remove front and rear clutch units as assem-strut (Fig. 15). bly. Grasp input shaft, hold clutch units together and remove them from case (Fig. 18). Fig. 15 Removing/Installing Front Band Strut (25) Remove front band lever shaft with pencilmagnet. Pin is accessible from converter housing sideof case (Fig. 16). (26) Remove front band lever (Fig. 17) (27) Slide front band rearward and onto drivingshell. Band will not be removed until after front/rearclutch removal. Fig. 18 Removing Front/Rear Clutch Assemblies
    • 21 - 102 42RE TRANSMISSION OVERHAUL ZJ (29) Lift front clutch off rear clutch (Fig. 19). Setclutch units aside for overhaul. Fig. 21 Removing Intermediate Shaft Thrust Plate Fig. 19 Separating Front/Rear Clutch Assemblies (30) Remove intermediate shaft thrust washerfrom front end of shaft or from rear clutch hub (Fig.20). (31) Remove output shaft thrust plate from inter-mediate shaft hub (Fig. 21). Fig. 22 Front Band Removal/Installation (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. (37) Remove rear band pivot and reaction pins (Fig. 26). Use parallel jaw snap ring pliers to remove pins. Insert and spread plier jaws in pin bore to gripFig. 20 Removing Intermediate Shaft Thrust Washer pin. Then twist and pull pins to remove them. (32) Slide front band off driving shell (Fig. 22) and (38) Remove rear band lever.remove band from case.
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 103 Fig. 23 Removing Planetary Geartrain And Fig. 25 Overdrive Piston Retainer Bolt Location Intermediate Shaft Assembly Fig. 26 Rear Band And Lever Pin Location Fig. 24 Removing Low-Reverse Drum Snap Ring (39) Remove low-reverse drum and rear band asassembly. Turn drum clockwise and pull outward toremove it from overrunning clutch (Fig. 27). (40) Remove bolts attaching overrunning clutchcam to case (Fig. 28). (41) Remove overrunning clutch cam and rollerclutch assembly as a unit (Fig. 29). Turn cam backand forth and tilt it inward to remove it from case. Fig. 27 Low-Reverse Drum And Rear Band Removal (42) Compress front servo rod guide about 1/8 inch with Valve Spring Compressor C-3422-B (Fig. 30). A
    • 21 - 104 42RE TRANSMISSION OVERHAUL ZJ Fig. 28 Overrunning Clutch Cam Bolt Locations Fig. 30 Compressing Front Servo Rod Guide Fig. 29 Overrunning Clutch Assembly RemovalC-clamp and Special Tool C-4470 can also be used tocompress rod guide. (43) Remove front servo rod guide snap ring. Ex-ercise caution when removing snap ring. Servobore can be scratched or nicked if care is notexercised. (44) Remove compressor tools and remove frontservo rod guide, spring and servo piston. (45) Compress rear servo spring retainer about1/16 inch with Valve Spring Compressor C-3422-B(Fig. 31). A C-clamp and Tool C-4470 or SP-5560 can Fig. 31 Compressing Rear Servo Springalso be used to compress spring retainer. (46) Remove rear servo spring retainer snap ring. celerated wear of other components. However, do notThen remove compressor tools and remove rear servo replace bushings as a matter of course. Replace bush-spring and piston. ings only when they are actually worn, or scored. (47) Inspect transmission and overdrive compo- Use recommended tools to replace bushings. Thenents. If major components such as the over- tools are sized and designed to remove, install, anddrive unit, front clutch, or oil pump require seat bushings correctly. The bushing replacementservice, refer to appropriate overhaul proce- tools are included in Bushing Tool Set C-3887-J, ordure. C-3887-B. Pre-sized service bushings are available for replace-OVERHAUL SERVICE INFORMATION ment purposes. Only the sun gear bushings are not Inspect the transmission bushings during overhaul. serviced. The sun gear is replaced as an assembly ifBushing condition is important as worn, scored bush- the bushings are damaged.ings contribute to low pressures, clutch slip and ac-
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 105 Heli-Coil inserts can be used to repair damaged,stripped or worn threads in aluminum parts. Theseinserts 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 onshafts, or valves, use extreme care to avoid roundingoff sharp edges. Sharp edges are vital as they pre-vent foreign matter from getting between the valveand valve bore. Do not reuse oil seals, gaskets, seal rings, orO-rings during overhaul. Replace these parts as amatter of course. Also do not reuse snap rings or E-clips that are bent or distorted. Replace these partsas well. Lubricate transmission parts with Mopar ATFPlus, Type 7176 transmission fluid during overhaul Fig. 32 Removing Overrunning Clutch Fromand assembly. Use Mopar Door Ease, or Ru-Glyde to Low-Reverse Drumprelubricate seals, O-rings, and thrust washers. Pe- CLEANING AND INSPECTIONtroleum jelly can also be used to lubricate and hold Clean the clutch rollers, springs and retainer,parts in place during reassembly. clutch cam, low-reverse drum and overdrive piston retainer in solvent. Air dry the rollers after cleaning.TRANSMISSION CASE CLEANING AND Inspect condition of each clutch part after cleaning.INSPECTION Replace the rollers and the retainer and spring as- Clean the case in a solvent tank. Flush the case sembly if the rollers, springs or spring retainer arebores and fluid passages thoroughly with solvent. worn or damaged. Replace the clutch cam if worn,Dry the case and all fluid passages with compressed cracked or damaged.air. Be sure all solvent is removed from the case and Inspect the overrunning clutch race and low-re-that all fluid passages are clear. verse drum. Replace the drum and race as an assem- Do not use shop towels or rags to dry the case bly if either part is worn, scored or damaged.(or any other transmission component) unless Examine the overdrive piston retainer carefully forthey are made from lint-free materials. Lint wear, cracks, scoring or other damage. Be sure thewill stick to case surfaces and transmission retainer hub is a snug fit in the case and low-reversecomponents and circulate throughout the drum. Replace the retainer if worn or damaged.transmission after assembly. A sufficient quan-tity of lint can block fluid passages and inter- OVERRUNNING CLUTCH ASSEMBLYfere with valve body operation. (1) Install clutch rollers in spring retainer (Fig. Inspect the case for cracks, porous spots, worn 33). Be sure springs are seated squarely against roll-bores, or damaged threads. Damaged threads can be ers.repaired with Helicoil thread inserts. However, thecase will have to be replaced if it exhibits any type ofdamage or wear. Lubricate the front band adjusting screw threadswith petroleum jelly and thread the screw part-wayinto the case. Be sure the screw turns freely.OVERRUNNING CLUTCH, LOW-REVERSE DRUMAND OVERDRIVE PISTON RETAINER INSPECTIONAND OVERHAUL If the overrunning clutch and cam came out withthe low-reverse drum, remove the cam and clutchfrom the drum as follows: Thread two clutch cambolts into the cam. Then lift the clutch and cam out Fig. 33 Installing Overrunning Clutch Rollers Inof the drum with the bolts (Fig. 32). Rotate the cam Retainerback and forth to ease removal if necessary.
    • 21 - 106 42RE TRANSMISSION OVERHAUL ZJ (2) Install roller and spring assembly in clutch cam OIL PUMP AND REACTION SHAFT SUPPORT(Fig. 34). OVERHAUL (3) Lubricate overrunning clutch rollers, springscam and race with transmission fluid. Verify compo- PUMP AND SUPPORT DISASSEMBLYnent installation before proceeding. Bolt holes in (1) Remove seal from around pump housing (Fig.clutch cam are countersunk on one side. Be sure this 36).side of cam will face rearward as shown (Fig. 34). Fig. 36 Removing Pump Housing Seal (2) Loosen bolts that attach pump body to support (Fig. 37). Fig. 34 Checking Overrunning Clutch Installation (4) Inspect bolt holes in overrunning clutch cam.Note that one hole is not threaded. Identify locationof non threaded hole with paint mark for assemblyreference (Fig. 35). Fig. 37 Loosening Pump Support Bolts (5) Set assembly aside for final installation after (3) Remove pump-to-support bolts and separateoverhaul is complete. support from pump housing (Fig. 38). Fig. 38 Separating Pump Housing From Reaction Shaft Support (4) Remove inner and outer gears from reaction shaft support (Fig. 39). Fig. 35 Marking Location Of Non-Threaded Hole In (5) If pump seal was not removed during transmis- Clutch Cam sion disassembly, remove seal with punch and ham- mer.
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 107 pumps has a new design drive lug. The new de- sign incorporates drive flats instead of the square lug used previously. The torque con- verter hub has also been redesigned to accept the new drive. If pump gear replacement is nec- essary, 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. Fig. 39 Pump Gear Removal Install the gears in the pump housing and measure (6) Remove front clutch thrust washer from sup- end clearance with a feeler gauge and straightedgeport hub (Fig. 40). Note position of chamfer on (Fig. 41). End clearance should be 0.010 - 0.06 mmwasher inside diameter for installation reference. (0.0004 - 0.0025 in.).Chamfer side faces pump.OIL PUMP AND REACTION SHAFT SUPPORTCLEANING AND INSPECTION Clean pump and reaction shaft support componentswith solvent and dry them with compressed air. Inspect the pump housing and support components.Replace the housing or support if the seal ringgrooves or machined surfaces are worn, scored, pit-ted, or damaged. Replace the pump gears if pitted, worn chipped, ordamaged. Inspect the thrust washer for wear or dam- Fig. 41 Measuring Pump Gear End Clearanceage. Replace the washer if necessary. Note that theinner gear used in 1993 and later 42RE oil Fig. 40 Oil Pump And Reaction Shaft Support Components
    • 21 - 108 42RE TRANSMISSION OVERHAUL ZJ Measure clearance between the outer gear and thepump body (Fig. 42). Clearance should be 0.08 - 0.19mm (0.0035 - 0.0075 in.). Measure gear tooth clearance with a feeler gauge.Align one tooth of the outer gear in inner gear andmeasure clearance (Fig. 43). Clearance should be0.08 - 0.19 mm (0.0035 - 0.0075 in.). Fig. 42 Measuring Pump Housing-To-Inner Gear Clearances Fig. 44 Removing Oil Pump Bushing Fig. 43 Measuring Pump Gear Tooth ClearanceREPLACING OIL PUMP BUSHING (1) Remove pump bushing with Tool HandleC-4171 and Bushing Remover SP-3551 (Fig. 44). (2) Install new pump bushing with Tool Handle Fig. 45 Staking Oil Pump BushingC-4171 and Bushing Installer SP-5117 (Fig. 44). (4) Lightly grip old bushing in vise or with pliersBushing should be flush with pump housing bore. and back remover tool out of bushing. (3) Stake new pump bushing in two places with (5) Assemble Bushing Installer Tools C-4171 andblunt punch (Fig. 45). Remove burrs from stake SP-5325 (Fig. 46).points with knife blade afterward. (6) Slide new bushing onto Installer Tool SP-5325.REPLACING REACTION SHAFT SUPPORT (7) Position reaction shaft support upright on aBUSHING clean smooth surface. (1) Assemble Bushing Remover Tools SP-1191, (8) Align bushing in bore. Then tap bushing into3633 and 5324 (Fig. 46). Do not clamp any part of place until Bushing Installer SP-5325 bottoms.reaction shaft or support in vise. (9) Clean reaction shaft support thoroughly after (2) Hold Cup Tool SP-3633 firmly against reaction installing bushing.shaft and thread remover SP-5324 into bushing as ASSEMBLING OIL PUMP AND REACTIONfar as possible by hand. Then thread remover tool 3-4 SHAFT SUPPORTadditional turns into bushing with a wrench. (1) Lubricate gear bore in pump housing with (3) Turn remover tool hex nut down against re- transmission fluid.mover cup to pull bushing from shaft. Clean all chips (2) Lubricate pump gears with transmission fluid.from shaft after bushing removal.
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 109 Fig. 46 Replacing Reaction Shaft Support Bushing Fig. 48 Pump Inner Gear Installation (3) Support pump housing on wood blocks (Fig. bricate seal rings with transmission fluid or petro-47). leum jelly after installation. Squeeze each ring until (4) Install outer gear in pump housing (Fig. 47). ring ends are securely hooked together.Gear can be installed either way (it is not a one-wayfit). CAUTION: The reaction shaft support seal rings will break if overspread, or twisted. If new rings are be- ing installed, spread them only enough for installa- tion. 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.Fig. 47 Supporting Pump And Installing Outer Gear (5) Install pump inner gear (Fig. 48). Fig. 49 Hub Seal Ring PositionCAUTION: The pump inner gear is a one-way fit. (8) Install reaction shaft support on pump housingThe bore on one side of the gear inside diameter is (Fig. 50).chamfered. Be sure the chamfered side faces for- (9) Align reaction support on pump housing. Useward (to front of pump). alignment marks made at disassembly. Or, rotate support until bolt holes in support and pump housing (6) Install new thrust washer on hub of reaction are all aligned (holes are offset for one-way fit).shaft support. Lubricate washer with transmission (10) Install all bolts that attach support to pumpfluid or petroleum jelly. housing. Then tighten bolts finger tight. (11) Tighten support-to-pump bolts to requiredCAUTION: The thrust washer is a one-way fit. The torque as follows:washer inside diameter is chamfered on one side. (a) Reverse pump assembly and install it inBe sure the washer is installed with the chamfered transmission case. Position pump so bolts are fac-side facing forward. ing out and are accessible. (b) Secure pump assembly in case with 2 or 3 (7) If reaction shaft seal rings are being replaced,install new seal rings on support hub (Fig. 49). Lu- bolts, or with pilot studs.
    • 21 - 110 42RE TRANSMISSION OVERHAUL ZJ Fig. 50 Assembling Reaction Shaft Support And Fig. 51 Pump Oil Seal Installation Pump Housing FRONT CLUTCH OVERHAUL (c) Tighten support-to-pump bolts to 20 N⅐m (15 ft. lbs.). FRONT CLUTCH DISASSEMBLY (d) Remove pump assembly from transmission (1) Remove waved snap ring and remove pressure case. plate, clutch plates and clutch discs (Fig. 52). (12) Install new oil seal in pump with Special Tool (2) Compress clutch piston spring with CompressorC-4193 and Tool Handle C-4171 (Fig. 51). Be sure Tool C-3575-A (Fig. 53). Be sure legs of tool areseal lip faces inward. seated squarely on spring retainer before compress- (13) Install new seal ring around pump housing. ing spring.Be sure seal is properly seated in groove. (3) Remove retainer snap ring and remove com- (14) Lubricate lip of pump oil seal with petroleum pressor tool.jelly. Lubricate pump seal with Ru-Glyde or petro- (4) Remove spring retainer and clutch spring. Noteleum jelly. 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. Fig. 52 Front Clutch Components
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 111 Fig. 54 Front Clutch Piston Retainer Check Ball Location Fig. 53 Compressing Front Clutch Piston Spring (6) Remove seals from clutch piston and clutch re-tainer hub. Discard both seals as they are not reusable.FRONT CLUTCH INSPECTION Clean the front clutch components in solvent and drythem with compressed air only. Do not use rags or shoptowels to dry any of the clutch parts. Lint from suchmaterials will adhere to the component surfaces andcould restrict or block fluid passages after assembly. Replace the clutch discs if warped, worn, scored,burned or charred, or if the facing is flaking off. Re-place the steel plates if heavily scored, warped, orbroken. Be sure the driving lugs on the plates are in Fig. 55 Retainer Bushing Locationsgood condition. The lugs must not be bent, cracked or (3) Lubricate lips of piston and retainer seals withdamaged in any way. liberal quantity of Mopar Door Ease, or with Ru- Replace the clutch spring and spring retainer if ei- Glyde. Then lubricate retainer hub, bore and pistonther is distorted, warped or broken. with transmission fluid. Check the lug grooves in the clutch retainer. The (4) Install clutch piston in retainer (Fig. 56). Usesteel plates should slide freely in the slots. Replace twisting motion to seat piston in bottom of retainer.the retainer if the grooves are worn or damaged. Do not attempt to push the piston straight in. Check action of the check ball in the retainer (Fig. This could fold the seals over causing leakage54). The ball must move freely and not stick. and clutch slip. Inspect the clutch retainer bushings carefully (5) Position spring in clutch piston (Fig. 57).(Fig. 55). The retainer bushings are not service-able. It will be necessary to replace the retainer (6) Position spring retainer on top of piston springif either bushing is scored, or worn. (Fig. 58). Make sure retainer is properly in- Inspect the piston and retainer seal surfaces for stalled. Small raised tabs should be facing up-nicks or scratches. Minor scratches can be removed ward. Semicircular lugs on underside ofwith crocus cloth. However, replace the piston and/or retainer are for positioning retainer in spring.retainer if the seal surfaces are seriously scored. (7) Compress piston spring and retainer with Com- pressor Tool C-3575-A (Fig. 53). Then install newFRONT CLUTCH ASSEMBLY snap ring to secure spring retainer and spring. (1) Soak clutch discs in transmission fluid while (8) Install clutch plates and discs (Fig. 52). Installassembling other clutch parts. steel plate then disc until all plates and discs are in- (2) Install new seals on piston and in hub of re- stalled. Four discs are required.tainer. Be sure lip of each seal faces interior of clutch (9) Install pressure plate and waved snap ringretainer. (Fig. 52).
    • 21 - 112 42RE TRANSMISSION OVERHAUL ZJ Fig. 56 Front Clutch Piston Installation Fig. 59 Measuring Front Clutch Pack Clearance (4) Remove clutch piston. Grasp piston and rotate piston up and out of retainer. Fig. 57 Clutch Spring Installation (5) Remove and discard piston seals. (6) Remove input shaft snap ring (Fig. 61). (7) Press input shaft out of retainer 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 clutch 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, Fig. 58 Correct Spring Retainer Installed Position burned/charred, the lugs are damaged, or if the fac- (10) Check clutch plate clearance (Fig. 59). Clear- ing is flaking off. Replace the top and bottom pres-ance should be 1.70 to 3.40 mm (0.067 to 0.134 in.). sure plates if scored, warped, or cracked. Be sure theIf clearance is incorrect, clutch discs, pressure plates driving lugs on the pressure and clutch plates areand snap ring may have to be changed. also in good condition. The lugs must not be bent, cracked or damaged in any way.REAR CLUTCH OVERHAULREAR CLUTCH DISASSEMBLY (1) Remove plastic thrust washer from forwardside of clutch retainer. (2) Remove selective clutch pack snap ring (Fig.60). (3) Remove top pressure plate, clutch discs, steelplates, bottom pressure plate and wave spring (Fig.60).
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 113 Fig. 60 Rear Clutch Components Fig. 62 Removing Input Shaft From Rear Clutch Retainer Fig. 61 Removing/Installing Input Shaft Snap Ring Inspect the piston and retainer seal surfaces for Replace the piston spring and wave spring if either nicks or scratches. Minor scratches can be removedpart is distorted, warped or broken. with crocus cloth. However, replace the piston and/or Check the lug grooves in the clutch retainer. The retainer if the seal surfaces are seriously scored.clutch and pressure plates should slide freely in the Check condition of the fiber thrust washer andslots. Replace the retainer if the grooves are worn or metal output shaft thrust washer. Replace eitherdamaged. Also check action of the check ball in the washer if worn or damaged.piston. The check ball must move freely and not Check condition of the seal rings on the input shaftstick. and clutch retainer hub. Replace the seal rings only Replace the retainer bushing if worn, scored, ordoubt exists about bushing condition.
    • 21 - 114 42RE TRANSMISSION OVERHAUL ZJif obviously damaged. The input shaft front seal ringis teflon with chamfered ends. The rear ring is metalwith interlocking ends. Check the input shaft for wear, or damage. Replacethe 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 huband 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. (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. Fig. 64 Input Shaft Seal Ring Identification Fig. 63 Installing Rear Clutch Retainer And Input Shaft Seal Rings (3) Lubricate splined end of input shaft and clutchretainer with transmission fluid. Then press inputshaft into retainer (Fig. 65). (4) Install input shaft retaining ring (Fig. 61). Fig. 65 Pressing Input Shaft Into Rear Clutch (5) Install new seals on clutch piston. Be sure lip Retainerof each seal faces interior of clutch retainer. (8) Install piston spring in retainer and on top of (6) Lubricate lip of piston seals with liberal quan- piston (Fig. 56). Concave side of spring faces up astity of Mopar Door Ease, or with Ru-Glyde. Then lu- shown.bricate retainer hub and bore with transmission (9) Install wave spring in retainer (Fig. 66). Befluid. (7) Install clutch piston in retainer. Use twisting sure spring is completely seated in retainer groove.motion to seat piston in bottom of retainer. Do not (10) Install bottom pressure plate (Fig. 60). Ridgedattempt to push the piston straight in. This side of plate faces downward (toward piston) and flatcould fold the seals over causing leakage and side toward clutch pack.clutch slip.
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 115 (16) Set rear clutch aside for installation during fi- nal assembly. Fig. 66 Piston And Wave Spring Position (11) Install first clutch disc in retainer on top ofbottom pressure plate. Then install a clutch plate fol- Fig. 68 Installing Rear Clutch Thrust Washerlowed by a clutch disc until entire clutch pack is in- PLANETARY GEAR TRAIN AND INTERMEDIATEstalled. Four clutch discs and three steel plates are SHAFT OVERHAULrequired. (12) Install top pressure plate (Fig. 60). GEARTRAIN DISASSEMBLY (FIG. 69) (13) Install selective snap ring (Fig. 60). Be sure (1) Remove snap ring, tabbed thrust washer andsnap ring is fully seated in retainer groove. thrust plate from front of output shaft. (14) Measure clutch pack clearance (Fig. 67). (2) Remove front annulus gear and support assem-Clearance should be 0.64 to 1.14 mm (0.025 to 0.045 bly.in.). If clearance is incorrect, adjust clearance with (3) Remove front planetary front thrust washer.select fit snap ring. (4) Remove front planetary gear. (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 plane- tary gear. (9) Remove rear planetary gear from rear annulus gear and remove annulus gear from intermediate shaft. (10) Remove snap rings 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. Re- place the gear if damaged or if the bushings are scored or worn. The bushings are not serviceable. Re- place 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 Fig. 67 Checking Rear Clutch Pack Clearance damaged. (15) Coat rear clutch thrust washer with petro- Inspect the geartrain spacers, thrust plates, snapleum jelly and install washer over input shaft and rings, and thrust washers. Replace any part that isinto clutch retainer (Fig. 68). Use enough petroleum worn or damaged. Do not attempt to reuse thesejelly to hold washer in place. parts.
    • 21 - 116 42RE TRANSMISSION OVERHAUL ZJ Fig. 69 Transmission Planetary Gear Train Inspect the intermediate shaft carefully. Pay partic-ular attention to the machined bushing/bearing sur-faces on the shaft. Replace the intermediate shaft if any machinedsurfaces are scored, pitted, or damaged in any way.Also replace the shaft if the splines are damaged, orexhibits cracks at any location. Be sure the selectspacer groove on the shaft is in good condition. Trialfit the spacer if necessary.PLANETARY GEARTRAIN ASSEMBLY (1) Lubricate intermediate shaft and planetarycomponents with transmission fluid. Use petroleumjelly to lubricate and hold thrust washers and platesin position. (2) Assemble rear annulus gear and support if dis-assembled. Be sure support snap ring is seated and Fig. 70 Assembling Rear Annulus And Planetarythat shoulder side of support faces rearward. Gear (3) Install rear thrust washer on rear planetary (6) Install front thrust washer on rear planetarygear (Fig. 70). Use enough petroleum jelly to hold gear (Fig. 72). Use enough petroleum jelly to holdwasher in place. Also be sure washer tabs are prop- washer on gear.erly engaged in gear slots. (7) Install spacer on sun gear (Fig. 73). (4) Install rear annulus over and onto rear plane- (8) Install thrust plate over sun gear and on top oftary gear (Fig. 70). spacer (Fig. 74). Note that thrust plates are inter- (5) Install assembled rear planetary and annulus changeable. Use either plate on sun gear and rear ofgear on intermediate shaft (Fig. 71). Verify that as- driving shell.sembly is fully seated on shaft. (9) Insert sun gear into driving shell (Fig. 75).
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 117 Fig. 74 Installing Spacer And Thrust Plate On Sun Fig. 71 Installing Assembled Rear Annulus And Gear Planetary Gear On Intermediate Shaft Fig. 75 Installing Sun Gear And Rear Thrust Plate InFig. 72 Installing Rear Planetary Front Thrust Washer Driving Shell Fig. 73 Installing Sun Gear Spacer Fig. 76 Supporting Sun Gear On Wood Block (10) Hold sun gear in position and install rearthrust plate. Plate goes over sun gear at rear of driv- and install sun gear lock ring. Keep wood blocking shell (Fig. 75). handy as it will also be used for geartrain end play (11) Position wood block on bench and support sun check.gear on block (Fig. 76). This makes it easier to align
    • 21 - 118 42RE TRANSMISSION OVERHAUL ZJ (12) Align rear thrust plate on driving shell andinstall sun gear lock ring. Be sure ring is fully seatedin sun gear ring groove (Fig. 77). Fig. 79 Installing Rear Thrust Washer On Front Planetary Gear Fig. 77 Installing Sun Gear Lock Ring (13) Install assembled driving shell and sun gearon intermediate shaft (Fig. 78). Fig. 80 Installing Thrust Plate On Front Annulus SupportFig. 78 Installing Assembled Sun Gear And Driving Shell On Intermediate Shaft (14) Install rear thrust washer on front planetarygear (Fig. 79). Use enough petroleum jelly to holdwasher on gear and be sure washer tabs are all prop-erly seated. (15) Assemble front annulus gear and support ifnecessary. (16) Position thrust plate on front annulus gearsupport (Fig. 80). Use liberal quantity of petroleumjelly to hold plate in place. (17) Install front planetary gear on intermediateshaft and in driving shell (Fig. 81). (18) Install front thrust washer on front planetary Fig. 81 Installing Front Planetary And Annulusgear (Fig. 81). Use enough petroleum jelly to hold Gearswasher in place on gear and be sure washer tabs areseated.
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 119 (19) Assemble front annulus gear and support. Besure support snap ring is seated. (20) Install front annulus thrust washer (Fig. 82).Align flat on washer with flat on planetary hub. Alsobe sure washer tab is facing forward. Fig. 84 Installing Planetary Selective Snap Ring (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 have to be replaced. Snap ring is available in three different thicknesses for ad- Fig. 82 Installing Front Annulus Thrust Washer justment purposes. (21) Install front annulus snap ring (Fig. 83). Usesnap ring pliers to avoid distorting ring during in-stallation. Also be sure ring is fully seated. Fig. 83 Installing Front Annulus Snap Ring (22) Install planetary selective snap ring with snapring pliers (Fig. 84). Be sure ring is fully seated. Fig. 85 Checking Planetary Geartrain End Play (23) Turn planetary geartrain assembly over sodriving shell is facing workbench. Then supportgeartrain on wood block positioned under forwardend of output shaft. This is necessary so geartraincomponents will move forward for accurate end playcheck. (24) Check planetary geartrain end play withfeeler gauge (Fig. 85). Gauge goes between shoulderon intermediate shaft and end of rear annulus sup-port.
    • 21 - 120 42RE TRANSMISSION OVERHAUL ZJFRONT SERVO AND BAND OVERHAUL REAR SERVO AND BAND OVERHAULFRONT SERVO DISASSEMBLY (FIG. 86) REAR SERVO PISTON DISASSEMBLY (1) Remove small snap ring from servo piston. (1) Remove seal from servo piston. Note which way (2) Remove piston, rod, springs and guide. seal lip faces for assembly reference. (3) Remove and discard servo piston rings and O- (2) Compress cushion spring in vise only enough toring. allow piston plug snap ring removal (Fig. 87). Use wood block between vise jaws and end of piston plugFRONT BAND AND SERVO INSPECTION to keep plug aligned and in position. Clean the servo components with solvent and dry (3) Remove snap ring from end of piston plug (Fig.them with compressed air. 87). Inspect the servo components. Replace the springs (4) Open vise and remove wood block, piston plug,if collapsed, distorted or broken. Replace the guide, cushion spring and servo piston.rod and piston if cracked, bent, or worn. Discard theservo snap ring if distorted or warped. Replace the front band if distorted, the lining isburned or flaking off, or excessively worn. Check the servo piston bore for wear. Replace thepiston and rod as an assembly if either part is wornor damaged. Replace any servo component if doubt exists aboutits condition. Do not reuse suspect parts. 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 dis- torted, the lining is burned or flaking off, or the lin- ing is excessively worn. Check the band pivot and reaction pins. Minor pin scoring can be cleaned up with crocus cloth. However, replace the pins if worn, severely scored, or cracked. Replace the pin O-rings. Inspect the servo components. Replace the servo and cushion springs if collapsed, distorted or broken. Replace the plug or piston if cracked, bent, or worn. Discard the servo snap ring and spring retainer if Fig. 86 Front Servo Components distorted or warped.ASSEMBLING FRONT SERVO PISTON If doubt exists about the condition of any servo component, replace it. Do not reuse suspect parts. (1) Lubricate seal rings and O-rings with petro-leum jelly. Lubricate other servo parts with transmis- ASSEMBLING REAR SERVO PISTONsion fluid. (1) Assemble piston plug, cushion spring and pis- (2) Install new O-ring on servo piston rod. ton (Fig. 88). (3) Install new seal on piston rod guide and install (2) Compress cushion spring in vise and install pis-new seal rings on piston. ton plug snap ring (Fig. 87). (4) Assemble rod, piston, servo springs and snap (3) Install new seal on piston. Be sure seal lip isring (Fig. 86). toward servo bore (Fig. 89). (4) Lubricate piston seal with petroleum jelly. Lu- bricate other servo parts with transmission fluid.
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 121 Fig. 90 Governor Pressure Solenoid And Sensor Wire Locations Fig. 88 Rear Servo Components Fig. 89 Installing Rear Servo Piston SealVALVE BODY SERVICE AND ADJUSTMENTVALVE BODY MAIN COMPONENTDISASSEMBLYCAUTION: Do not clamp any valve body component Fig. 91 Governor Body And Retainer Plate Attachingin a vise. This practice can damage the component Screw Removal/Installationresulting in unsatisfactory operation after assembly (4) Disconnect wires from governor pressure sen-and installation. Do not use pliers to remove any of sor, if not done previously (Fig. 93).the valves, plugs or springs and do not force any of (5) Remove governor pressure sensor from gover-the components out or into place. The valves and nor body. Sensor is retained in body with M-shapedvalve body housings will be damaged if force is spring clip (Fig. 93). Remove clip with small pointedused. Tag or mark the valve body springs for refer- tool and slide sensor out of body.ence as they are removed. Do not allow them to be- (6) Remove governor pressure solenoid by pullingcome intermixed. it straight out of bore in governor body (Fig. 94). Re- (1) Disconnect wires from governor pressure sensor move and discard solenoid O-rings if worn, cut, orand solenoid (Fig. 90). torn. (2) Remove screws attaching governor body and re- (7) Remove small shoulder bolt that secures sole-tainer plate to transfer plate (Fig. 91). noid harness case connector to 3-4 accumulator hous- (3) Remove retainer plate, governor body and gas- ing (Fig. 95). Retainket from transfer plate (Fig. 92).
    • 21 - 122 42RE TRANSMISSION OVERHAUL ZJ Fig. 94 Governor Pressure Solenoid Removal Fig. 92 Governor Body, Retainer Plate And Gasket Removal Fig. 95 Removing/Installing Solenoid Harness Case Connector Shoulder Bolt Fig. 93 Governor Pressure Sensor Removal shoulder bolt. Either tape it to harness or thread itback into accumulator housing after connector re-moval. (8) Unhook overdrive/converter solenoid harnessfrom 3-4 accumulator cover plate (Fig. 96). (9) Turn valve body over and remove screws that Fig. 96 Unhooking Solenoid Harness From Accumulator Cover Plateattach overdrive/converter solenoid assembly to valvebody (Fig. 97). (10) Remove solenoid and harness assembly from valve body (Fig. 98).
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 123 Fig. 97 Removing Solenoid Assembly Screws Fig. 100 Boost Valve Components (13) Secure detent ball and spring with Retainer Tool 6583 (Fig. 101). Fig. 101 Securing Detent Ball And Spring (14) Remove E-clip and washer that retains throt- tle lever shaft in manual lever (Fig. 102). Fig. 98 Solenoid Assembly Removal (11) Remove boost valve cover (Fig. 99). (12) Remove boost valve retainer, valve spring andboost valve (Fig. 100). Fig. 99 Boost Valve Cover Location Fig. 102 Throttle Lever E-Clip And Washer Removal
    • 21 - 124 42RE TRANSMISSION OVERHAUL ZJ (15) Remove manual lever and throttle lever (Fig.103). Rotate and lift manual lever off valve body andthrottle lever shaft. Then slide throttle lever out ofvalve body. Fig. 105 Park Rod Removal Fig. 103 Manual And Throttle Lever Removal (16) Position pencil magnet next to detent housingto catch detent ball and spring. Then carefully re-move Retainer Tool 6583 and remove detent ball andspring (Fig. 104). Fig. 106 Adjusting Screw Bracket Fastener Removal/Installation Fig. 104 Detent Ball And Spring Removal (17) Remove park rod E-clip and separate rod frommanual lever (Fig. 105). (18) Remove screws attaching pressure adjustingscrew bracket to valve body and transfer plate (Fig.106). Hold bracket firmly against spring tensionwhile removing last screw. (19) Remove adjusting screw bracket, line pressureadjusting screw, pressure regulator valve spring andswitch valve spring (Fig. 107). Do not removethrottle pressure adjusting screw from bracketand do not disturb setting of either adjusting Fig. 107 Adjusting Screw Bracket And Spring Removalscrew during removal.
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 125 (20) Loosen left-side 3-4 accumulator housing at-taching screw about 2-3 threads. Then remove centerand right-side housing attaching screws (Fig. 108). Fig. 108 Accumulator Housing Screw Locations (21) Carefully rotate 3-4 accumulator housing up-ward and remove 3-4 shift valve spring and converter Fig. 110 3-4 Accumulator Housing, Valve Springsclutch valve plug and spring (Fig. 109). And Plug Removal Fig. 109 Removing 3-4 Shift And Converter Clutch Valve Springs And Plug (22) Remove left-side screw and remove 3-4 accu-mulator housing from valve body (Fig. 110). (23) Remove pressure regulator valve spring fromlower housing (Fig. 111). Fig. 111 Lower Housing Valve Spring Locations (24) Bend back tabs on boost valve tube brace (Fig. (26) Turn valve body over so lower housing is fac-112). ing upward (Fig. 114). In this position, the two check (25) Remove boost valve connecting tube (Fig. 113). balls in upper housing will remain in place and notDisengage tube from upper housing port first. Then fall out when lower housing and separator plate arerock opposite end of tube back and forth to work it removed.out of lower housing. (27) Remove screws attaching valve body lowerCAUTION: Do not use tools to loosen or pry the housing to upper housing and transfer plate (Fig.connecting tube out of the valve body housings. 114). Note position of boost valve tube brace forLoosen and remove the tube by hand only. assembly reference.
    • 21 - 126 42RE TRANSMISSION OVERHAUL ZJFig. 112 Boost Valve Tube Brace (Double Tab Style) Fig. 115 Removing Transfer Plate From Upper Housing Fig. 113 Boost Valve Tube Removal (28) Remove lower housing and overdrive separa-tor plate from transfer plate (Fig. 114). Fig. 116 Brace Plate Removal Fig. 114 Lower Housing Removal (29) Remove transfer plate from upper housing(Fig. 115). (30) Turn transfer plate over so upper housing sep-arator plate is facing upward (Fig. 116). (31) Remove brace plate from lower housing sepa-rator plate and transfer plate (Fig. 116). (32) Remove upper housing separator plate from Fig. 117 Upper Housing Separator Plate Removaltransfer plate (Fig. 117). Note position of filter in steel on some early production models andseparator plate for assembly reference. plastic on later production models. (33) Remove rear clutch and rear servo check ballsfrom transfer plate. Note check ball location for as-sembly reference (Fig. 118). Check balls will be
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 127 Fig. 118 Rear Clutch And Rear Servo Check Ball LocationsVALVE BODY UPPER HOUSINGDISASSEMBLY (1) Note location of check balls in valve body upperhousing (Fig. 119). Then remove the one large diam- Fig. 119 Check Ball Locations In Upper Housingeter and the six smaller diameter check balls. Checkballs will be steel on some early productionmodels and plastic on later production models. (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, shuttlevalve, secondary spring, and spring guides (Fig. 121). (5) Remove boost valve retainer, spring and valveif not previously removed. (6) Turn upper housing over and remove switchvalve, regulator valve and spring, and manual valve(Fig. 122). (7) Remove kickdown detent, kickdown valve, andthrottle valve and spring (Fig. 122). (8) Remove throttle plug and 1-2 and 2-3 governor Fig. 120 Shuttle Valve E-Clip And Secondary Springplugs (Fig. 122). Also remove shuttle valve primary Locationspring if not removed in prior step.
    • 21 - 128 42RE TRANSMISSION OVERHAUL ZJ Fig. 121 Shuttle And Boost Valve Components Fig. 122 Upper Housing Control Valve Locations
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 129 Fig. 123 Upper Housing Shift Valve And Pressure Plug Locations (9) Turn upper housing around and remove limit 3-4 ACCUMULATOR HOUSING DISASSEMBLYvalve and shift valve covers (Fig. 123). (FIG. 125) (10) Remove limit valve housing. Then remove re- (1) Remove end plate from housing.tainer, spring, limit valve, and 2-3 throttle plug from (2) Remove piston spring.limit valve housing (Fig. 123). (3) Remove piston. Remove and discard piston (11) Remove 1-2 shift control valve and spring (Fig. seals.123). (12) Remove 1-2 shift valve and spring (Fig. 123). VALVE BODY CLEANING AND INSPECTION (13) Remove 2-3 shift valve and spring from valve Clean the valve housings, valves, plugs, springs,body (Fig. 123). and separator plates with a standard parts cleaning (14) Remove pressure plug cover (Fig. 123). solution only. Do not use gasoline, kerosene, or any (15) Remove line pressure plug, sleeve, throttle type of caustic solution.pressure plug and spring (Fig. 123). Do not immerse any of the electrical components in cleaning solution. Clean the governor solenoid andVALVE BODY LOWER HOUSING sensor and the dual solenoid and harness assemblyDISASSEMBLY (FIG. 124) by wiping them off with dry shop towels only. (1) Remove timing valve cover. Dry the parts with compressed air. Make sure all (2) Remove 3-4 timing valve and spring. passages are clean and free from obstructions. Do (3) Remove 3-4 quick fill valve, spring and plug. not use rags or shop towels to dry or wipe off (4) Remove 3-4 shift valve and spring. valve body components. Lint from these materi- (5) Remove converter clutch valve, spring and als will adhere to the valve body components.plug. Lint will interfere with valve operation and (6) Remove converter clutch timing valve, retainer may clog filters and fluid passages.and valve spring. 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
    • 21 - 130 42RE TRANSMISSION OVERHAUL ZJ Fig. 124 Lower Housing Shift Valves And Springs CAUTION: Do not turn the small screw at the end of the solenoid valve for any reason. Turning the screw in either direction will ruin solenoid calibra- tion and result in solenoid failure. In addition, the filter on the solenoid valve is NOT serviceable. Do not try to remove the filter as this will damage the valve housing. Fig. 125 3-4 Accumulator Housing Componentsblocked by dirt or debris. Replace the valve and/or Fig. 126 Governor Pressure Solenoid Valve O-Ringsensor only when DRB II scan tool diagnosis indi- And Vent Locationcates this is necessary. Or, if either part has sus-tained physical damage (dented, deformed, broken, Inspect the throttle and manual valve levers andetc.). shafts (Fig. 128). Do not attempt to straighten a bent
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 131 Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Re- place the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Check the two separator plates for distortion or 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 andFig. 127 Governor Pressure Sensor O-Ring Location transfer plate check balls as well. The check ballsshaft or correct a loose lever. Replace these compo- and ball seats must not be worn or damaged.nents if worn, bent, loose or damaged in any way. Trial fit each valve and plug in its bore to check Inspect all of the valve body mating surfaces for freedom of operation. When clean and dry, the valvesscratches, nicks, burrs, or distortion. Use a straight- and plugs should drop freely into the bores.edge to check surface flatness. Minor scratches may Valve body bores do not change dimensionally withbe removed with crocus cloth using only very light use. If the valve body functioned correctly when new,pressure. it will continue to operate properly after cleaning and Minor distortion of a valve body mating surface inspection. It should not be necessary to replace amay be corrected by smoothing the surface with a valve body assembly unless it is damaged in han-sheet of crocus cloth. Position the crocus cloth on a dling.surface plate, sheet of plate glass or equally flat sur- The only serviceable valve body components areface. If distortion is severe or any surfaces are listed below. The remaining valve body componentsheavily scored, the valve body will have to be re- are serviced only as part of a complete valve body as-placed. sembly. Serviceable parts are: • dual solenoid and harness assemblyCAUTION: Many of the valves and plugs, such as • solenoid gasketthe throttle valve, shuttle valve plug, 1-2 shift valve • solenoid case connector O-rings and shoulder boltand 1-2 governor plug, are made of coated alumi- • switch valve and springnum. Aluminum components are identified by the • pressure adjusting screw and bracket assemblydark color of the special coating applied to the sur-face (or by testing with a magnet). Do not sand alu- • throttle leverminum valves or plugs under any circumstances. • manual lever and shaft sealThis practice could damage the special coating • throttle lever shaft seal, washer, and E-clipcausing the valves/plugs to stick and bind. • fluid filter and screws • detent ball and spring Inspect the valves and plugs for scratches, burrs, • valve body screwsnicks, or scores. Minor surface scratches on steel • governor pressure solenoidvalves and plugs can be removed with crocus cloth • governor pressure sensor and retaining clipbut do not round off the edges of the valve or • park lock rod and E-clipplug lands. Maintaining sharpness of these edges isvitally important. The edges prevent foreign matterfrom lodging between the valves and plugs and thebore.
    • 21 - 132 42RE TRANSMISSION OVERHAULFig. 128 Upper Housing Valves, Plug, Springs And Brackets ZJ
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 133VALVE BODY REASSEMBLY (3) Align and position upper housing separator plate on transfer plate (Fig. 116).CAUTION: Do not force valves or plugs into place (4) Install brace plate (Fig. 116). Tighten brace at-during reassembly. If the valve body bores, valves taching screws to 4 N⅐m (35 in. lbs.) torque.and plugs are free of distortion or burrs, the valve (5) Install remaining separator plate attachingbody components should all slide into place easily. screws. Tighten screws to 4 N⅐m (35 in. lbs.) torque.In addition, do not overtighten the transfer plateand valve body screws during reassembly. Over- Assembling Upper And Lower Housingstightening can distort the housings resulting in (1) Position upper housing so internal passagesvalve sticking, cross leakage and unsatisfactory op- and check ball seats are facing upward. Then installeration. Tighten valve body screws to recom- check balls in housing (Fig. 119). Seven check ballsmended torque only. are used. The single large check ball is approxi- mately 8.7 mm (11/32 in.) diameter. The remaining 6 check balls are approximately 6.3 mm (1/4 in.) in di-Lower Housing Assembly (Fig. 124) ameter. Some early production valve bodies will (1) Lubricate valves, springs, and the housing have steel check balls while later models willvalve and plug bores with clean transmission fluid. have the new plastic check balls. (2) Install 3-4 timing valve spring and valve in (2) Position assembled transfer plate and upperlower housing. housing separator plate on upper housing (Fig. 130). (3) Install 3-4 quick fill valve in lower housing. Be sure filter screen is seated in proper housing re- (4) Install 3-4 quick fill valve spring and plug in cess.housing. (5) Install timing valve end plate. Tighten endplate screws to 4 N⅐m (35 in. lbs.) torque. (6) Install 3-4 shift valve and spring. (7) Install converter clutch valve, spring and plug. (8) Install converter clutch timing valve andspring.3-4 Accumulator Assembly (Fig. 125) (1) Lubricate accumulator piston, seals and hous-ing 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 Fig. 130 Installing Transfer Plate On Upper Housingtransfer plate (Fig. 118). Some early production (3) Position lower housing separator plate onvalve bodies will have steel check balls while transfer plate (Fig. 131).later models will have the new plastic check (4) Install lower housing on assembled transferballs. plate and upper housing (Fig. 132). (2) Install filter screen in upper housing separator (5) Install and start valve body screws by hand.plate (Fig. 129). Then tighten screws evenly to 4 N⅐m (35 in. lbs.) torque. Start at center and work out to sides when tightening screws (Fig. 132). Upper Housing Valve And Plug Installation (Figs. 122, 123, 124) (1) Lubricate valves, plugs, springs with clean transmission fluid. (2) Assemble regulator valve line pressure plug, sleeve, throttle plug and spring. Insert assembly in upper housing and install cover plate. Tighten cover plate screws to 4 N⅐m (35 in. lbs.) torque. (3) Install 1-2 and 2-3 shift valves and springs. Fig. 129 Separator Plate Filter Screen Installation (4) Install 1-2 shift control valve and spring.
    • 21 - 134 42RE TRANSMISSION OVERHAUL ZJ (15) Install switch valve. Boost Valve Tube And Brace Installation (1) Position valve body assembly so lower housing is facing upward (Fig. 113). (2) Lubricate tube ends and housing ports with transmission fluid or petroleum jelly. (3) Start tube in lower housing port first. Then swing tube downward and work opposite end of tube into upper housing port (Fig. 113). (4) Insert and seat each end of tube in housings. (5) Slide tube brace under tube and into alignment with valve body screw holes (Fig. 133). (6) Install and finger tighten three screws that se- cure tube brace to valve body housings (Fig. 133). (7) Bend tube brace tabs up and against tube toFig. 131 Lower Housing Separator Plate Installation hold it in position (Fig. 134). (8) Tighten all valve body housing screws to 4 N⅐m (35 in. lbs.) torque after tube and brace are installed. Tighten screws in diagonal pattern starting at center and working outward.Fig. 132 Installing Lower Housing On Transfer Plate And Upper Housing (5) Install shift valve cover plate. (6) Install shuttle valve as follows: (a) Insert plastic guides in shuttle valve second- Fig. 133 Boost Valve Tube And Brace Installation ary spring and install spring on end of valve. (b) Hold shuttle valve in place. (c) Compress secondary spring and install E-clip in groove at end of shuttle valve. (d) Verify that spring and E-clip are properly seated before proceeding. (7) Install shuttle valve cover plate. Tighten coverplate screws to 4 N⅐m (35 in. lbs.) torque. (8) Install 1-2 and 2-3 valve governor plugs invalve body. (9) Install shuttle valve primary spring and throt-tle plug. (10) Align and install governor plug cover. Tightencover screws to 4 N⅐m (35 in. lbs.) torque. (11) Install manual valve. (12) Install throttle valve and spring. (13) Install kickdown valve and detent. Fig. 134 Securing Boost Valve Tube With Brace (14) Install pressure regulator valve. Tabs
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 1353-4 Accumulator Installation (6) Attach solenoid case connector to 3-4 accumula- (1) Position converter clutch valve and 3-4 shift tor with shoulder-type screw. Connector has small lo-valve springs in housing (Fig. 135). cating tang that fits in dimple at top of accumulator (2) Loosely attach accumulator housing with right- housing (Fig. 95). Seat tang in dimple before tighten-side screw (Fig. 135). Install only one screw at this ing connector screw.time as accumulator must be free to pivot upward for (7) Install solenoid assembly and gasket. Tightenease of installation. solenoid attaching screws to 8 N⅐m (72 in. lbs.) (3) Position plug on end of converter clutch valve torque.spring. Then compress and hold springs and plug in (8) Verify that solenoid wire harness is properlyplace with fingers of one hand. routed (Figs. 95 and 96). Solenoid harness must (4) Swing accumulator housing upward over valve be clear of manual lever and park rod and notsprings and plug. be pinched between accumulator housing and (5) Hold accumulator housing firmly in place and cover.install remaining two attaching screws. Be suresprings and clutch valve plug are properly seated Valve Body Final Assembly And Adjustment(Fig. 136). (1) Insert manual lever detent spring in upper housing. (2) Position line pressure adjusting screw in ad- justing 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 bot- tom screw last. Verify that valve springs and bracket are properly aligned. Then tighten all three bracket screws to 4 N⅐m (35 in. lbs.) torque. (6) Install throttle lever in upper housing. Then in- stall manual lever over throttle lever and start man- ual lever into housing. (7) Position detent ball on end of spring. Then hold detent ball and spring in detent housing with Re- tainer Tool 6583 (Fig. 101). Fig. 135 Installing Converter Clutch And 3-4 Shift (8) Align manual lever with detent ball and man- Valve Springs ual valve. Hold throttle lever upward. Then press down on manual lever until fully seated. Remove de- tent 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. 137). (12) Install boost valve, valve spring, retainer and cover plate. Tighten cover plate screws to 4 N⅐m (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 ad- Fig. 136 Seating 3-4 Accumulator On Lower justment screw settings were not disturbed, continue Housing with overhaul or reassembly. However, if adjustment
    • 21 - 136 42RE TRANSMISSION OVERHAUL ZJscrew settings were moved or changed, readjust as VALVE BODY CONTROL PRESSUREdescribed in Valve Body Control Pressure Adjustment ADJUSTMENTSprocedure. 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. 138). Distance should be 33.4 mm (1-5/16 inch). If adjustment is required, turn the adjusting screw in, or out, to obtain required distance setting. The 33.4 mm (1-5/16 inch) setting is an ap- proximate setting. Because of manufacturing Fig. 137 Manual And Throttle Lever Alignment tolerances, it may be necessary to vary fromGOVERNOR BODY, SENSOR AND SOLENOID this dimension to obtain desired pressure.INSTALLATION One complete turn of the adjusting screw changes line pressure approximately 1-2/3 psi (9 kPa). Turn-CAUTION: Do not turn the small screw at the end of ing the adjusting screw counterclockwise increasesthe governor pressure solenoid valve for any rea- pressure while turning the screw clockwise decreasesson (Fig. 126). Turning the screw in either direction pressure.will ruin solenoid calibration and result in solenoidfailure. In addition, the filter on the solenoid valve isNOT serviceable. Do not try to remove the filter asthis will damage the solenoid valve housing. (1) Turn valve body assembly over so accumulatorside of transfer plate is facing down. (2) Install new O-rings on governor pressure sole-noid and sensor (Figs. 126 and 127). (3) Lubricate solenoid and sensor O-rings withclean transmission fluid. (4) Install governor pressure sensor in governorbody. Then secure sensor with M-shaped retainingclip (Fig. 93). (5) Install governor pressure solenoid in governorbody (Fig. 94). Push solenoid in until it snaps intoplace in body. Fig. 138 Line Pressure Adjustment (6) Position governor body gasket on transfer plate Throttle Pressure Adjustment(Fig. 92). Insert Gauge C-3763 between the throttle lever (7) Install retainer plate on governor body and cam and the kickdown valve stem (Fig. 139).around solenoid (Fig. 90). Be sure solenoid connector Push the gauge tool inward to compress the kick-is positioned in retainer cutout. down valve against the spring and bottom the throt- (8) Align screw holes in governor body and transfer tle valve.plate. Then install and tighten governor body screws Maintain pressure against kickdown valve spring.to 4 N⅐m (35 in. lbs.) torque. Turn throttle lever stop screw until the screw head (9) Connect harness wires to governor pressure so- touches throttle lever tang and the throttle lever camlenoid and governor pressure sensor (Fig. 90). touches gauge tool. The kickdown valve spring must be fully com- pressed and the kickdown valve completely bottomed to obtain correct adjustment.
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 137 TRANSMISSION ASSEMBLY PROCEDURE (1) Install rear servo piston, spring and retainer (Fig. 140). Install spring on top of servo piston and install retainer on top of spring. Fig. 139 Throttle Pressure AdjustmentTRANSMISSION ASSEMBLY AND ADJUSTMENTAssembly Tips Do not allow dirt, grease, or foreign material to en- Fig. 140 Rear Servo Componentster the case or transmission components during as-sembly. Keep the transmission case and components (2) Install front servo piston assembly, servo springclean. Also make sure the tools and workbench area and rod guide (Fig. 141).used for assembly operations are equally clean. Shop towels used for wiping off tools and handsmust be made from lint free material. Lint will stickto transmission parts and could interfere with valveoperation, or even restrict fluid passages. Lubricate the transmission components with Mopartransmission fluid during reassembly. Use MoparDoor Ease, or Ru-Glyde on seals and O-rings to easeinstallation. Petroleum jelly can also be used to hold thrustwashers, thrust plates and gaskets in position duringassembly. However, do not use chassis grease, bear-ing grease, white grease, or similar lubricants on anytransmission part. These types of lubricants caneventually block or restrict fluid passages and inter-fere with valve operation. Use petroleum jelly only. Do not force parts into place. The transmission Fig. 141 Front Servo Componentscomponents and sub-assemblies are easily installedby hand when properly aligned. (3) Compress front/rear servo springs with Valve If a part seems extremely difficult to install, it is Spring Compressor C-3422-B and install each servoeither misaligned or incorrectly assembled. Also ver- snap ring (Fig. 142).ify that thrust washers, thrust plates and seal rings (4) Examine bolt holes in overrunning clutch cam.are correctly positioned before assembly. These parts Note that one hole is not threaded (Fig. 143). Thiscan interfere with proper assembly if mispositioned hole must align with blank area in clutch cam bolt(or ‘‘left out’’ by accident). circle (Fig. 144). Mark hole location on clutch cam The planetary geartrain, front/rear clutch assem- and blank area in case with grease pencil, paintblies and oil pump are all much easier to install stripe, or scribe mark for assembly reference.when the transmission case is upright or as close to (5) Mark location of non-threaded hole in clutchthis position as possible. Either tilt the case upward cam and blank area in bolt circle with grease pencil.with wood blocks, or cut a hole in the bench large (6) Align and install overrunning clutch and camenough for the output shaft. Then lower the shaft in case (Fig. 145). Be sure cam is correctly in-through the hole and support the transmission case stalled. Bolt holes in cam are slightly counter-directly on the bench.
    • 21 - 138 42RE TRANSMISSION OVERHAUL ZJ Fig. 144 Location Of Blank Area In Clutch Cam Bolt Circle Fig. 142 Compressing Front/Rear Servo Springs Fig. 145 Overrunning Clutch Installation Fig. 143 Location Of Non-Threaded Hole In Clutch Camsunk on one side. Be sure this side of cam facesrearward (toward piston retainer). (7) Verify that non-threaded hole in clutch cam isproperly aligned. Check alignment by threading abolt into each bolt hole. Adjust clutch cam position ifnecessary. (8) Install and tighten overrunning clutch cambolts to 17 N⅐m (13 ft. lbs.) torque. Note that clutchcam bolts are shorter than piston retainer bolts. (9) Lubricate clutch cam rollers with transmissionfluid. (10) Install rear band reaction pin (Fig. 146). Besure pin is fully seated in case. Fig. 146 Installing Rear Band Reaction Pin (11) Install rear band in case (Fig. 147). Be sure (a) Lubricate overrunning clutch race (on drumtwin lugs on band are seated against reaction pin. hub) with transmission fluid. (12) Install low-reverse drum and check overrun- (b) Guide drum through rear band.ning clutch operation as follows:
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 139 Fig. 147 Rear Band Installation Fig. 149 Installing/Aligning Case Gasket (c) Tilt drum slightly and start race (on drum (14) Position overdrive piston retainer on transmis- hub) into overrunning clutch rollers. sion case and align bolt holes in retainer, gasket and (d) Press drum rearward and turn it in clockwise case (Fig. 150). Then install and tighten retainer direction until drum seats in overrunning clutch bolts to 17 N⅐m (13 ft. lbs.) torque. (Fig. 148). (e) Turn drum back and forth. Drum should ro- tate freely in clockwise direction and lock in counterclockwise direction (as viewed from front of case). Fig. 148 Installing Low-Reverse Drum Fig. 150 Aligning Overdrive Piston Retainer (13) Install new gasket at rear of transmissioncase. Use petroleum jelly to hold gasket in place. Be (15) Install snap ring that secures low-reversesure to align governor feed holes in gasket with feed drum to hub of piston retainer (Fig. 151).passages in case (Fig. 149). Also install gasket before (16) Install rear band lever and pivot pin (Fig.overdrive piston retainer. Center hole in gasket is 152). Align lever with pin bores in case and pushsmaller than retainer and cannot be installed over pivot pin into place.retainer. (17) Install planetary geartrain assembly (Fig. 153)
    • 21 - 140 42RE TRANSMISSION OVERHAUL ZJ Fig. 153 Installing Planetary Geartrain Fig. 151 Installing Low-Reverse Drum Retaining Snap Ring Fig. 154 Installing Intermediate Shaft Thrust PlateFig. 152 Rear Band Lever And Pivot Pin Installation (18) Install thrust plate on intermediate shaft hub(Fig. 154). Use petroleum jelly to hold thrust plate inplace. (19) Check seal ring on rear clutch retainer hub(Fig. 49) and seal rings on input shaft (Fig. 155). Ver-ify that diagonal-cut ends of teflon seal rings areproperly joined and ends of metal ring are correctlyhooked together. Also verify that shaft seal rings areinstalled in sequence shown. (20) Check rear clutch thrust washer (Fig. 156).Use additional petroleum jelly to hold washer inplace if necessary. (21) Align clutch discs in front clutch and installfront clutch on rear clutch (Fig. 157). Rotate frontclutch retainer back and forth until completelyseated on rear clutch. Fig. 155 Input Shaft Seal Ring Location
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 141 Fig. 156 Installing Rear Clutch Thrust Washer Fig. 158 Installing Intermediate Shaft Thrust Washer Fig. 157 Assembling Front And Rear Clutch Units (22) Coat intermediate shaft thrust washer withpetroleum jelly. Then install washer in rear clutchhub (Fig. 158). Use enough petroleum jelly to holdwasher in place. Be sure grooved side of washerfaces rearward (toward output shaft) as shown. Fig. 159 Aligning Rear Clutch Disc LugsAlso note that washer only fits one way in (26) Carefully work assembled clutches back andclutch hub. Note thickness of this washer. It is a se- forth to engage and seat rear clutch discs on frontlect fit part and is used to control transmission end annulus gear. Also be sure front clutch drive lugs areplay. fully engaged in slots of driving shell after installa- (23) Align drive teeth on rear clutch discs with tion.small screwdriver (Fig. 159). This makes installation (27) Slide front band over front clutch retaineron front planetary easier. (24) Raise front end of transmission upward as far (Fig. 161).as possible and support case with wood blocks. Front/ (28) Insert front band lever pivot shaft part wayrear clutch and oil pump assemblies are easier to in- into case (Fig. 161).stall if transmission is as close to upright position as (29) Install front band lever, strut and adjustingpossible. screw (Fig. 162). (25) Install front and rear clutch units as assembly (30) Push front band lever shaft completely into(Fig. 160). Align rear clutch with front annulus gear place. Then tighten band adjusting screw until bandand install assembly in driving shell. Be sure out- just grips clutch retainer. Verify that front/rearput shaft thrust washer and thrust plate are clutches are still seated before continuing.not displaced during installation.
    • 21 - 142 42RE TRANSMISSION OVERHAUL ZJ Fig. 162 Front Band Linkage Installation Fig. 160 Installing Front/Rear Clutch Assemblies Fig. 163 Reaction Shaft Support Seal Rings And Front Clutch Thrust Washer Position Fig. 161 Installing Front Band And Reaction Pin (31) Coat band reaction pin access plug with sealerand install plug in converter housing. (32) Check seal rings on reaction shaft supporthub. Verify that seal rings are hooked together andthat front clutch thrust washer is properly positioned(Fig. 163). Use extra petroleum jelly to hold thrustwasher in place if necessary.CAUTION: The thrust washer bore ID is chamferedon one side. Make sure this side of the washer isfacing toward the front of the transmission. (33) Thread two Pilot Stud Tools C-3288-B intobolt holes in oil pump flange (Fig. 164). Fig. 164 Installing Pilot Studs And Oil Pump Gasket (34) Align and install oil pump gasket (Fig. 164).
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 143 (35) Lubricate oil pump body seal with Ru-Glyde,or petroleum jelly. Lubricate pump shaft seal lip withpetroleum jelly. (36) Install oil pump (Fig. 165). Align and positionpump on pilot studs. Slide pump down studs andwork it into front clutch hub and case by hand. Theninstall 2 or 3 pump bolts to hold pump in place. (37) Remove pilot stud tools and install remainingoil pump bolts. Tighten bolts alternately in diagonalpattern to 20 N⅐m (15 ft. lbs.). Fig. 166 Overdrive Piston Alignment Fig. 165 Installing Oil Pump Assembly In Case (38) Install new seals on overdrive piston. Then lu-bricate seals with Mopar Door Ease, or Ru-Glyde. (39) Install overdrive piston in retainer. Align lo-cating lugs on piston in locating bores in re-tainer (Fig. 166). Use thin plastic strip or feelergauge to help guide piston outer seal into retainer. (40) Install spacer on intermediate shaft, if notpreviously installed. (41) Install overdrive piston thrust plate (Fig. 167).Use liberal quantity of petroleum jelly to hold thrustplate in position on piston. (42) Install overdrive piston thrust bearing in di-rect clutch hub (Fig. 168). Use liberal quantity of pe-troleum jelly to hold thrust bearing in place. Notethat one side of bearing has dark coated sur- Fig. 167 Installing Overdrive Piston Thrust Plateface. This surface faces overdrive piston. Also Overdrive unit may have to be disassembled inbe sure raised shoulder on inside diameter of order to realign splines.bearing faces forward as well. (45) Carefully withdraw alignment tool from over- (43) Apply small amount of petroleum jelly to pilot drive unit.hub of intermediate shaft. (46) Lubricate intermediate shaft splines and (44) Verify alignment of splines in overdrive unitplanetary gear and overrunning clutch. Be sure bushing surfaces with transmission fluid or petro-Alignment Tool 6227-2 is still fully seated (Fig. 169). leum jelly.If planetary gear and overrunning clutch (47) Install overdrive unit. Note that intermediatesplines become misaligned, overdrive unit can- shaft is snug fit in overdrive planetary gear andnot be fully installed on intermediate shaft. overrunning clutch. If overdrive unit will not seat
    • 21 - 144 42RE TRANSMISSION OVERHAUL ZJ play. If end play turns out to be incorrect, remove oil pump, and clutches. Then install thinner/thicker thrust washer as necessary.Fig. 168 Installing Overdrive Piston Thrust Bearing Fig. 170 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 in- stalled 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 make click noise as it enters pawl. Move rod slightly to check engagement. CAUTION: It is possible for the park rod to displaceFig. 169 Checking Alignment Of Overdrive Planetary into a cavity just above the pawl sprag during in- Gear And Overrunning Clutch Splines stallation. Make sure the rod is actually engaged ingear and clutch splines may be misaligned. the pawl and has not displaced into the cavity. If the (48) Apply 1-2 drops of Mopar thread adhesive (or rod enters the cavity during installation, it will be-Loctite 242) to overdrive unit attaching bolts. Then come bent when the overdrive bolts are tightened.install and tighten bolts to 34 N⅐ (25 ft. lbs.) torque. If this occurs, the rod will have to be removed andBe sure wire harness clips are placed on appro- replaced.priate overdrive bolts beforehand. (b) Align and seat valve body on case. Be sure (49) Measure and if necessary, correct input shaft manual lever shaft and overdrive connector areend play as follows (Fig. 170): fully seated in case. Also be sure valve body wiring (a) Be sure overdrive unit is installed on trans- is not pinched or kinked. mission. End play cannot be properly checked (c) Install and start all valve body attaching with overdrive unit off transmission. bolts by hand. Then tighten bolts evenly, in a diag- (b) Attach dial indicator to converter housing. onal pattern to 12 N⅐m (105 in. lbs.) torque. Do not (c) Position indicator plunger against input shaft overtighten valve body bolts. This could re- and zero indicator. sult in distortion and cross leakage after in- (d) Move input shaft in and out and record read- stallation.. ing. End play should be 0.56 - 2.31 mm (0.022 - (54) Install new filter on valve body. Tighten filter 0.091 in.). Proceed to step (e) if end play is not screws to 4 N⅐m (35 in. lbs.). within specified limits. (55) Adjust front and rear bands as follows: (e) Intermediate shaft thrust washer (in hub of (a) Loosen band adjusting screw locknuts. rear clutch retainer) controls end play. Washer is a (b) Tighten each band adjusting screw to 5 N⅐m select fit part and can be changed to adjust end (72 in. lbs.) with torque wrench.
    • ZJ 42RE TRANSMISSION OVERHAUL 21 - 145 (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. 171). Then install and tighten switch to 34 N⅐m(25 ft. lbs.). Fig. 172 Installing Manual Lever Shaft Seal (62) Install torque converter. Use C-clamp or metal strap to hold converter in place for installation. (63) Install transmission speed sensor in overdrive case (Fig. 1).Fig. 171 Park/Neutral Position Switch Seal Position (64) Mount transmission on jack for installation in (57) Install magnet in oil pan. Magnet goes on vehicle.small protrusion at corner of pan. (65) Apply dielectric grease to terminal pins of so- (58) Position new oil pan gasket on case and in- lenoid case connector and neutral switch.stall oil pan. Tighten pan bolts to 17 N⅐m (13 ft. lbs.). (59) Install new valve body manual shaft seal in CAUTION: The transmission cooler and lines mustcase (Fig. 172). Lubricate seal lip and manual shaft be reverse flushed if overhaul corrected a malfunc-with petroleum jelly. Start seal over shaft and into tion that generated sludge, metal particles, orcase. Seat seal with 15/16 inch, deep well socket. clutch friction material. The torque converter should (60) Install throttle valve and shift selector levers also be replaced if contaminated by the same mal-on valve body manual lever shaft. function. Debris and residue not flushed from the (61) Cap or cover transmission openings (cooler cooler and lines will flow back into the transmissionline fittings, filler tube bore, etc.) to prevent dirt en- and converter. The result could be a repeat failuretry. and shop comeback.
    • 21 - 146 42RE OVERDRIVE UNIT OVERHAUL ZJ 42RE OVERDRIVE UNIT OVERHAUL INDEX page pageOverdrive Component Cleaning and Inspection . . 153 Overdrive Unit Disassembly . . . . . . . . . . . . . . . . . 146Overdrive Unit Assembly and Adjustment . . . . . . . 155OVERDRIVE UNIT DISASSEMBLYOVERDRIVE REMOVAL (1) Remove transmission speed sensor and O-ringseal from overdrive case (Fig. 1). Fig. 2 Overdrive Unit Attaching Bolt Removal Fig. 1 Transmission Speed Sensor Removal/ Installation (2) Place transmission in upright position (Fig. 2). (3) Remove bolts attaching overdrive unit to trans-mission case (Fig. 2). Note position of wire harnessclips for installation reference. (4) Lift overdrive unit up and off transmission caseand intermediate shaft (Fig. 3). Fig. 3 Overdrive Unit Removal/Installation
    • ZJ 42RE OVERDRIVE UNIT OVERHAUL 21 - 147 (5) Remove overdrive piston thrust bearing (Fig.4). Fig. 6 Intermediate Shaft Spacer Location Fig. 4 Overdrive Piston Thrust Bearing Removal/ InstallationOVERDRIVE PISTON REMOVAL (1) Remove overdrive piston thrust plate (Fig. 5).Retain thrust plate. It is a select fit part and maypossibly be reused. Fig. 7 Overdrive Piston Removal Fig. 5 Overdrive Piston Thrust Plate Removal/ Installation (2) Remove intermediate shaft spacer (Fig. 6). Re-tain spacer. It is a select fit part and may possibly bereused. (3) Remove overdrive piston from retainer (Fig. 7).OVERDRIVE CLUTCH PACK REMOVAL (1) Remove overdrive clutch pack wire retainingring (Fig. 8). Fig. 8 Removing Overdrive Clutch Pack Retaining Ring
    • 21 - 148 42RE OVERDRIVE UNIT OVERHAUL ZJ (2) Remove overdrive clutch pack (Fig. 9). (2) Remove overdrive clutch reaction snap ring (Fig. 12). Note that snap ring is located in same groove as wave spring. Fig. 9 Overdrive Clutch Pack Removal (3) Note position of clutch pack components for as- Fig. 12 Overdrive Clutch Reaction Snap Ringsembly reference (Fig. 10). Thick reaction plate goes Removal/Installationto front as shown. (3) Remove Torx head screws that attach access cover and gasket to overdrive case (Fig. 13). A T25 size Torx head bit is required. (4) Remove access cover and gasket (Fig. 14). Fig. 13 Access Cover Screw Removal/Installation Fig. 10 Overdrive Clutch Component PositionOVERDRIVE GEARTRAIN REMOVAL (1) Remove overdrive clutch wave spring (Fig. 11). Fig. 14 Access Cover And Gasket Removal/ Installation Fig. 11 Overdrive Clutch Wave Spring Removal/ Installation
    • ZJ 42RE OVERDRIVE UNIT OVERHAUL 21 - 149 (5) Expand output shaft bearing snap ring with ex-panding-type snap ring pliers. Then push outputshaft forward to release shaft bearing from locatingring (Fig. 15). Fig. 17 Rear Bearing Snap Ring Removal/ Installation Fig. 15 Releasing Bearing From Locating Ring (6) Lift gear case up and off geartrain assembly(Fig. 16). Fig. 18 Rear Bearing Removal 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. RE- LEASE CLUTCH SPRING TENSION SLOWLY AND COMPLETELY TO AVOID PERSONAL INJURY. Fig. 16 Removing Gear Case From Geartrain Assembly (1) Mount geartrain assembly in shop press (Fig. (7) Remove snap ring that retains rear bearing on 19).output shaft (Fig. 17). (2) Position Compressor Tool 6227-1 on clutch hub (8) Remove rear bearing from output shaft (Fig. (Fig. 19). Support output shaft flange with steel18). press plates as shown and center assembly under press ram.DIRECT CLUTCH, HUB AND SPRING (3) Use Special Tool C-3995-A (or similar size tool)REMOVAL at top of Tool 6227-1 to help distribute load and pro-WARNING: THE NEXT STEP IN DISASSEMBLY IN- vide needed extra press length (Fig. 19).VOLVES COMPRESSING THE DIRECT CLUTCH (4) Apply press pressure slowly. Compress hub andSPRING. IT IS EXTREMELY IMPORTANT THAT spring far enough to expose clutch hub retaining ringPROPER EQUIPMENT BE USED TO COMPRESS and relieve spring pressure on clutch pack snap ringTHE SPRING AS SPRING FORCE IS APPROXI- (Fig. 19).MATELY 830 POUNDS. USE SPRING COMPRESSOR (5) Remove direct clutch pack snap ring (Fig. 20).TOOL 6227-1 AND A HYDRAULIC SHOP PRESS
    • 21 - 150 42RE OVERDRIVE UNIT OVERHAUL ZJ Fig. 21 Direct Clutch Hub Retaining Ring Removal clutch pack from hub (Fig. 22). Fig. 19 Geartrain Mounted In Shop Press (6) Remove direct clutch hub retaining ring (Fig.21). Fig. 22 Direct Clutch Pack Removal GEARTRAIN DISASSEMBLY (1) Remove direct clutch hub and spring (Fig. 23). (2) Remove sun gear and spring plate. Then re- move planetary thrust bearing and planetary gear (Fig. 24). Fig. 20 Direct Clutch Pack Snap Ring Removal (3) Remove overrunning clutch assembly with ex- panding type snap ring pliers (Fig. 25). Insert pliers (7) Release press load slowly and completely(Fig. 22). (8) Remove Special Tool 6227-1. Then remove
    • ZJ 42RE OVERDRIVE UNIT OVERHAUL 21 - 151 (4) Remove thrust bearing from overrunning clutch hub (Fig. 26). (5) Remove overrunning clutch from hub (Fig. 26). Fig. 23 Direct Clutch Hub And Spring Removal Fig. 26 Overrunning Clutch Components Fig. 24 Removing Sun Gear, Thrust Bearing And (6) Mark position of annulus gear and direct clutch Planetary Gear drum for assembly alignment reference (Fig. 27). Useinto clutch hub. Expand pliers to grip hub splines small center punch or scriber to make alignmentand remove clutch with counterclockwise, twisting marks.motion. Fig. 27 Marking Direct Clutch Drum And Annulus Fig. 25 Overrunning Clutch Assembly Removal/ Gear For Assembly Alignment Installation
    • 21 - 152 42RE OVERDRIVE UNIT OVERHAUL ZJ (7) Remove direct clutch drum rear retaining ring(Fig. 28). Fig. 30 Marking Annulus Gear And Output Shaft For Assembly AlignmentFig. 28 Clutch Drum Inner Retaining Ring Removal (8) Remove direct clutch drum outer retaining ring(Fig. 29). Fig. 31 Annulus Gear Snap Ring RemovalFig. 29 Clutch Drum Outer Retaining Ring Removal (9) Mark annulus gear and output shaft for assem-bly alignment reference (Fig. 30). Use punch orscriber to mark gear and shaft. (10) Remove snap ring that secures annulus gearon output shaft (Fig. 31). Use two screwdrivers to un-seat 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 offshaft.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. Fig. 32 Annulus Gear Removal (3) Remove reaction plug snap ring and remove re-action plug. (4) Remove output shaft seal. Use punch or toolsimilar to Seal Remover C-3981.
    • ZJ 42RE OVERDRIVE UNIT OVERHAUL 21 - 153OVERDRIVE COMPONENT CLEANING AND to reduce severe scoring on any components withINSPECTION abrasive materials. Replace severely scored compo- Clean the geartrain (Fig. 33) and case components nents; do not try to salvage them.(Fig. 34) with solvent. Dry all parts except the bear- Check condition of the park lock components andings with compressed air. Allow bearings to air dry. the overdrive gear case (Fig. 34). Do not use shop towels for wiping parts dry unless Replace the case if cracked, scored, or damaged.the towels are made from a lint-free material. A suf- Replace the park lock pawl, plug, or spring if worn orficient quantity of lint (from shop towels, cloths, rags, damaged. Be sure the knob at the end of the parketc.) could plug the transmission filter and fluid pas- lock rod is in good condition. Replace the rod if thesages. knob is worn or the rod itself is bent or distorted. Do Discard the old case gasket and seals. Do not at- not attempt to straighten the rod.tempt to salvage these parts. They are not reusable. Check the bushings in the overdrive case. ReplaceReplace any of the overdrive unit snap rings if dis- the bushings if severely scored or worn. Also replacetorted or damaged. the case seal if loose, distorted, or damaged. Minor nicks or scratches on components can besmoothed with crocus cloth. However, do not attempt
    • 21 - 154 42RE OVERDRIVE UNIT OVERHAUL ZJ Fig. 33 Overdrive Geartrain Components
    • ZJ 42RE OVERDRIVE UNIT OVERHAUL 21 - 155 Examine the overdrive and direct clutch discs and nor nicks or scratches can be polished down with cro- cus 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 intermediate shaft pilot bush- ing. The large bushing is the overrunning clutch hub bushing. 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 replacement 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 pur- pose installer kit such as the Snap-On A257 bushing driver set. Fig. 34 Overdrive Gear Case And Park Lock Componentsplates (Fig. 32). Replace the discs if the facing isworn, severely scored, or burned and flaking off. Re-place the clutch plates if worn, heavily scored, orcracked. Check the lugs on the clutch plates for wear.The plates should slide freely in the drum. Replacethe plates or drum if binding occurs. Check condition of the annulus gear, direct clutchhub, clutch drum and clutch spring (Fig. 32). Replacethe gear, hub and drum if worn or damaged. Replace Fig. 35 Output Shaft Bushing Locationthe spring if collapsed, distorted, or cracked. Be surethe splines and lugs on the gear, drum and hub are OVERDRIVE UNIT ASSEMBLY AND ADJUSTMENTin good condition. The clutch plates and discs should GEARTRAIN AND DIRECT CLUTCHslide freely in these components. ASSEMBLY Inspect the thrust bearings and spring plate (Fig. (1) Soak direct clutch and overdrive clutch discs in33). Replace the plate if worn or scored. Replace the Mopar ATF Plus transmission fluid. Allow discs tobearings if rough, noisy, brinnelled, or worn. soak for 10-20 minutes. Inspect the planetary gear assembly and the sun (2) Install new pilot bushing and clutch hub bush-gear and bushings (Fig. 34). If either the sun gear or ing in output shaft if necessary (Fig. 34). Lubricatethe bushings are damaged, replace the gear and new (or old) bushings with petroleum jelly, or trans-bushings as an assembly. The gear and bushings are mission fluid.not serviced separately. (3) Install annulus gear on output shaft, if re- The planetary carrier and pinions must be in good moved. Then install annulus gear retaining snap ringcondition. Also be sure the pinion pins are secure andin good condition. Replace the carrier if worn or dam- (Fig. 36).aged. (4) Align and install clutch drum on annulus gear Inspect the overrunning clutch and race. The race (Fig. 37). Be sure drum is engaged in annulus gearsurface should be smooth and free of scores. Replace lugs.the overrunning clutch assembly or the race if either (5) Install clutch drum outer retaining ring (Fig.assembly is worn or damaged in any way. 37). Check the machined surfaces on the output shaft. (6) Slide clutch drum forward and install inner re-These surfaces should be clean and smooth. Very mi- taining ring (Fig. 38).
    • 21 - 156 42RE OVERDRIVE UNIT OVERHAUL ZJ (7) Install rear bearing and snap ring on output shaft (Fig. 39). Be sure locating ring groove in bear- ing is toward rear. Fig. 39 Rear Bearing And Snap Ring Installation Fig. 36 Annulus Gear Installation (8) Install overrunning clutch 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 bearing in place for installation. Bear- ing fits one way only. Be sure bearing is seated squarely against hub. Reinstall bearing if it does not seat squarely. Fig. 37 Clutch Drum And Outer Retaining Ring Installation Fig. 40 Assembling Overrunning Clutch And Hub (10) Install overrunning clutch in output shaft (Fig. 42). Insert snap ring pliers in hub splines. Ex- pand pliers to grip hub. Then install assembly with counterclockwise, twisting motion. (11) Install planetary gear in annulus gear (Fig. 43). Be sure planetary pinions are fully seated in annulus gear before proceeding. Fig. 38 Clutch Drum Inner Retaining Ring Installation
    • ZJ 42RE OVERDRIVE UNIT OVERHAUL 21 - 157 Fig. 41 Overrunning Clutch Thrust Bearing Fig. 43 Planetary Gear Installation Installation Fig. 44 Sun Gear And Spring Plate Assembly (14) Install planetary thrust bearing on sun gear (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. Fig. 42 Overrunning Clutch Installation (12) Install direct clutch spring plate on sun gear.Shoulder side of plate should face outward and to-ward front. Then secure plate to sun gear with snapring (Fig. 44). (13) Coat planetary thrust bearing and bearingcontact surface of spring plate with generous amountof petroleum jelly. This will help hold bearing inplace during installation. Fig. 45 Planetary Thrust Bearing Installation
    • 21 - 158 42RE OVERDRIVE UNIT OVERHAUL ZJ (15) Install assembled sun gear, spring plate andthrust bearing (Fig. 46). Be sure sun gear and thrustbearing are fully seated before proceeding. Fig. 46 Sun Gear Installation (16) Mount assembled output shaft, annulus gear,and clutch drum in shop press. Direct clutch spring, Fig. 48 Direct Clutch Spring Installationhub and clutch pack are easier to install with assem-bly mounted in press. (a) Assemble clutch pack components (Fig. 49). (17) Align splines in hubs of planetary gear and (b) Install direct clutch reaction plate on clutchoverrunning clutch with Alignment tool 6227-2 (Fig. hub first. Note that one side of reaction plate47). Insert tool through sun gear and into splines of is counterbored. Be sure this side faces rear-both hubs. Be sure alignment tool is fully seated be- ward. Splines at rear of hub are raisedfore proceeding. slightly. Counterbore in plate fits over raised splines. Plate should be flush with this end of hub (Fig. 50). (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 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 RE- QUIRED. RELEASE CLUTCH SPRING TENSION Fig. 47 Alignment Tool Installation SLOWLY AND COMPLETELY TO AVOID PERSONAL (18) Install direct clutch spring (Fig. 48). Be sure INJURY.spring is properly seated on spring plate. (19) Assemble and install direct clutch pack on (21) Carefully remove Alignment Tool 6227-2 fromhub as follows: clutch and hub splines. Withdraw tool slowly to avoid
    • ZJ 42RE OVERDRIVE UNIT OVERHAUL 21 - 159 Fig. 49 Direct Clutch Pack Components Fig. 51 Correct Position Of Direct Clutch Pressure Plate (22) Position Compressor Tool 6227-1 on clutch hub (Fig. 53). (23) Position Tool C-3995-A or similar type tool on top of Tool 6227-1 (Fig. 19). Fig. 50 Correct Position Of Direct Clutch Reaction (24) Compress clutch hub and spring just enough Plate to place tension on hub and hold it in place.spline misalignment. Tool must be removed at this (25) Slide direct clutch pack upwards on hub (Fig.point to provide room for compressor tool movement. 53). Then set clutch pack on edge of clutch hub and compressor tool as shown.
    • 21 - 160 42RE OVERDRIVE UNIT OVERHAUL ZJ Fig. 54 Direct Clutch Pack Snap Ring Installation Fig. 52 Direct Clutch Pack And Clutch Hub Installation (26) Slowly compress clutch hub and spring (Fig.53). Compress spring and hub only enough to exposering grooves for clutch pack snap ring and clutch hubretaining ring. (27) Realign clutch pack on hub and seat clutchdiscs and plates in clutch drum (Fig. 53). Fig. 55 Clutch Hub Retaining Ring Installation (2) Install pawl shaft retaining bolt. Tighten bolt to 27 N⅐m (20 ft. lbs.) 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 installing snap ring. (4) Install reaction plug snap ring (Fig. 57). Com- Fig. 53 Seating Clutch Pack In Drum press snap ring only enough for installation; do (28) Install direct clutch pack snap ring (Fig. 54). not distort it.Be very sure snap ring is fully seated in clutchdrum ring groove. (29) Install clutch hub retaining ring (Fig. 55). Bevery sure retaining ring is fully seated in sungear ring groove. (30) Slowly release press ram, remove compressortools and remove geartrain assembly.GEAR CASE ASSEMBLY AND INSTALLATION (1) Position park pawl and spring in case and in-stall park pawl shaft (Fig. 34). Verify that end ofspring with 90° bend is hooked to pawl and straightend of spring is seated against case. Fig. 56 Reaction Plug Locating Pin And Snap Ring
    • ZJ 42RE OVERDRIVE UNIT OVERHAUL 21 - 161 Fig. 57 Reaction Plug And Snap Ring Installation Fig. 59 Correct Rear Bearing Locating Ring Position (5) Install new seal in gear case (Fig. 58). On 4x4gear case, use Tool Handle C-4171 and Installer 5062(or similar size tool) to seat seal in case. On 4 x 2gear case, use same tool handle and suitable size in-staller to seat seal in case. Fig. 60 Overdrive Gear Case Installation Fig. 58 Rear Seal Installation (In 4x4 Gear Case) (6) Verify that tab ends of rear bearing locatingring extend into access hole in gear case (Fig. 59). (7) Support geartrain on Tool 6227-1 (Fig. 60). Besure tool is securely seated in clutch hub. (8) Install overdrive gear case on geartrain (Fig.60). (9) Expand front bearing locating ring with snapring pliers (Fig. 61). Then slide case downward untillocating ring locks in bearing groove and releasesnap ring. (10) Install locating ring access cover and gasket in Fig. 61 Seating Locating Ring In Rear Bearingoverdrive unit case (Fig. 62). (2) Install wave spring on top of reaction ring (Fig. 64). Reaction ring and wave ring both fit inOVERDRIVE CLUTCH INSTALLATION same ring groove. Use screwdriver to seat each (1) Install overdrive clutch reaction ring first. Re- ring securely in groove.action ring is flat with notched ends (Fig. 63).
    • 21 - 162 42RE OVERDRIVE UNIT OVERHAUL ZJ Fig. 62 Locating Ring Access Cover And Gasket Fig. 64 Overdrive Clutch Wave Spring Installation Installation (6) Verify clutch pack. 3 clutch discs, 2 steel plates, 1 reaction plate and 1 pressure plate are required. (7) Install clutch pack pressure plate. Note that pressure plate is thickest plate in clutch pack. (8) Install clutch pack wire-type retaining ring (Fig. 66). SHAFT END PLAY ADJUSTMENT (1) Place overdrive unit in vertical position. Mount it on blocks, or in workbench with appropriate size mounting hole cut into it. Be sure unit is facing up- ward for access to direct clutch hub. Also be sure out- put shaft is not loaded and internal components areFig. 63 Overdrive Clutch Reaction Ring Installation moved rearward for accurate measurement. (3) Assemble overdrive clutch pack (Fig. 65). (2) Determine correct thickness intermediate (4) Install overdrive clutch reaction plate first. shaft spacer as follows:Note that reaction plate is thinner than pres- (a) Insert Special Tool 6312 through sun gear,sure plate. planetary gear and into pilot bushing in output (5) Install first clutch disc followed by first clutch shaft. Be sure tool bottoms against planetaryplate. Then install remaining clutch discs and plates shoulder.in same order. Fig. 65 Overdrive Clutch Components
    • ZJ 42RE OVERDRIVE UNIT OVERHAUL 21 - 163 Fig. 68 Intermediate Shaft End Play Spacer Selection (4) Leave Alignment Tool 6227-2 in place. Tool will keep planetary and clutch hub splines in alignment Fig. 66 Overdrive Clutch Pack Retaining Ring until overdrive unit is ready for installation on trans- Installation mission. (b) Position Gauge Tool 6311 across face of over- (5) Transmission speed sensor can be installed at drive case (Fig. 67). Then position Dial Caliper this time if desired. However, it is recommended that C-4962 over gauge tool. sensor not be installed until after overdrive unit is (c) Extend sliding scale of dial caliper downward secured to transmission. through gauge tool slot until scale contacts end of Gauge Alignment Tool 6312. Lock scale in place. Remove dial caliper tool and note distance mea- sured (Fig. 67). (d) Select proper thickness end play spacer from spacer chart based on distance measured (Fig. 68). (e) Remove Gauge Alignment Tool 6312. Fig. 69 Overdrive Piston Thrust Plate Measurement Fig. 67 Shaft End Play Measurement (3) Determine correct thickness overdrive pistonthrust 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). (b) Measure distance to clutch hub thrust bear- ing seat at four points 90° apart. Then average measurements by adding them and dividing by 4. (c) Select and install required thrust plate from Fig. 70 Overdrive Piston Thrust Plate Selection information in thrust plate chart (Fig. 70).
    • 21 - 164 46RH AUTOMATIC TRANSMISSION ZJ 46RH AUTOMATIC TRANSMISSION CONTENTS page page46RH IN-VEHICLE SERVICE . . . . . . . . . . . . . . 204 46RH TRANSMISSION OVERHAUL . . . . . . . . . 22346RH OVERDRIVE UNIT OVERHAUL . . . . . . . 270 GENERAL INFORMATION . . . . . . . . . . . . . . . . 16446RH TRANSMISSION DIAGNOSIS . . . . . . . . 170 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 370 GENERAL INFORMATION INDEX page pageBoost Valve . . . . . . . . . . . . . . . . . .... . . . . . . . 168 Overdrive Off Switch . . . . . . . . . . . . . . . . . . . . . . 167Converter Clutch Control . . . . . . . . .... . . . . . . . 168 Quick Fill Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 168Converter Drainback Valve . . . . . . .... . . . . . . . 168 Recommended Fluid . . . . . . . . . . . . . . . . . . . . . . 166Fourth Gear Overdrive Components ... . . . . . . . 166 Torque Converter . . . . . . . . . . . . . . . . . . . . . . . . 164Fourth Gear Shift Sequence . . . . . .... . . . . . . . 168 Transmission Changes and PartsGear Ratios . . . . . . . . . . . . . . . . . .... . . . . . . . 164 Interchangeability . . . . . . . . . . . . . . . . . . . . . . . 169Gearshift Mechanism . . . . . . . . . . .... . . . . . . . 166 Transmission Description . . . . . . . . . . . . . . . . . . . 164Hydraulic Control System . . . . . . . .... . . . . . . . 167 Transmission Identification . . . . . . . . . . . . . . . . . . 166TRANSMISSION DESCRIPTION and pump, stator and overrunning clutch, turbine The Chrysler 46RH automatic transmission is a and a modulated converter clutch mechanism.4-speed, fully automatic units with an overdrive fourth The converter clutch mechanism consists of agear range. The 46RH is used with 5.2L (V8) engines. clutch piston, clutch springs and the clutch disc ma- The 46RH is a dual unit design. The assembly consists terial (Fig. 4). The clutch provides optimum torqueof a three speed automatic transmission with an over- transfer and economy when applied.drive unit attached at the rear (Fig. 1). The overdrive The clutch disc is attached to the converter frontunit provides a fourth gear overdrive ratio of 0.69 to 1. cover. The clutch piston and clutch springs are at- The 46RH valve body has an additional housing. This tached to the turbine hub. The springs dampen en-housing contains the extra valving and electrical sole- gine firing impulses and loads during the initialnoids that provide overdrive fourth gear range. phase of converter clutch engagement. The governor and park lock assemblies are located in- Clutch engagement is controlled by the converterside the overdrive unit in 46RH transmissions. The over- clutch valve. The valve is located in the transmissiondrive unit must be removed and disassembled for service valve body. Clutch engagement occurs in drive range ataccess to the park lock and governor components. speeds above approximately 48-56 km/h (30-35 mph). First through third gear ranges are provided by theclutches, bands, overrunning clutch and planetary GEAR RATIOSgear sets in the transmission unit. Fourth gear range 46RH forward gear ratios are:is provided by the overdrive unit which contains an • First gear = 2.45:1overdrive clutch, direct clutch, planetary gear set and • Second gear = 1.45:1overrunning clutch. The overdrive clutch is applied in fourth gear only. • Third gear = 1.00:1The direct clutch is applied in all ranges except • Fourth gear = 0.69:1.fourth gear.TORQUE CONVERTER A three element torque converter is used for all ap-plications. The converter consists of the front cover
    • ZJ 46RH AUTOMATIC TRANSMISSIONFig. 1 46RH Transmission And Overdrive Unit 21 - 165
    • 21 - 166 46RH AUTOMATIC TRANSMISSION ZJRECOMMENDED FLUID ated by fluid pressure supplied through pressure The recommended and preferred fluid for 46RH tubes. The tubes are permanently attached to thetransmissions is Mopar ATF Plus, type 7176. governor support. Mopar Dexron II is not really recommended and Governor pressure and overdrive clutch pressureshould only be used when ATF Plus is not avilable. taps are provided in the transmission case for pres- sure testing purposes.TRANSMISSION IDENTIFICATION The overdrive unit contains a direct clutch, an The transmission part/identification numbers and overdrive clutch and an overrunning clutch. Fourth gear range is provided by an additional planetarycodes are stamped on the left side of the case just gear set in the overdrive unit.above the oil pan gasket surface (Fig. 2). The direct clutch is applied by spring pressure. A The first letter/number group is the assembly part high load spring rated at approximately 830 poundsnumber. The next number group the transmission (5520 kPa), holds the clutch in engagement. The sunbuild date. The last number group is the transmis- gear, direct clutch sliding hub and drum are con-sion serial number. Refer to this information when nected to the annulus gear for direct drive. For coast-ordering replacement parts. ing or reverse gear, power flows only through the direct clutch. A timing valve disengages the torque converter clutch prior to a 4-3 downshift. The clutch solenoid, engagement valve, and timing valve are actuated in fourth gear range. The 46RH valve body is similar to the standard three speed valve body. However, additional compo- nents are used to provide fourth gear overdrive range (Fig. 3). The additional valve body components in- clude: • a separate housing for the overdrive valves and plugs • an overdrive solenoid • a converter clutch solenoid • a 3-4 shift valve • a 3-4 timing valve Fig. 2 Transmission Identification Code Location • a 3-4 accumulator • a 3-4 quick fill valveFOURTH GEAR OVERDRIVE COMPONENTS • an overdrive separator plate Components in the transmission section of 46RH • a boost valvetransmissions are similar to those in Chrysler The separate housing for the 3-4 shift valves is at-3-speed automatic transmissions. Main component tached to the lower part of the valve body assembly.differences concern the valve body and the partswhich connect the overdrive unit to the transmission. GEARSHIFT MECHANISM 46RH models have three transmission shafts. An The gear shift mechanism provides six rangesintermediate shaft is used between the input and which are:output shafts as a connecting device between the • park (P)transmission and overdrive unit. The output shaft is • reverse (R)in the overdrive unit. The intermediate shaft is sup- • neutral (N)ported by the overdrive piston retainer and piloted in • drive (D)the output shaft (Fig. 1). • manual second (2) • manual low (1) The overdrive piston and retainer are located at Manual low (1) range provides first gear only.the rear of the transmission case. The retainer serves Overrun braking is also provided in this range. Man-as both the rear support and pressure chamber for ual second (2) range provides first and second gearthe overdrive piston. The intermediate shaft is only.splined to the planetary assembly and overrunning Drive range provides first, second third and over-clutch (Fig. 1). drive fourth gear ranges. The shift into overdrive The governor components and speedometer drive fourth gear range occurs only after the transmissionare located on the overdrive output shaft. Two bear- has completed the shift into D third gear range. Noings support the output shaft. The governor is oper- further movement of the shift mechansism is re- quired to complete the 3-4 shift.
    • ZJ 46RH AUTOMATIC TRANSMISSION 21 - 167 by throttle pressure which is dependent on the de- gree of throttle opening. The regulator valve is lo- cated in the valve body. The throttle valve determines line pressure and shift speed. Governor pressure increases in propor- tion to vehicle speed. The throttle valve controls up- shift and downshift speeds by regulating pressure according to throttle position. Shift Valve Flow Control The manual valve is operated by the gearshift link- age and provides the operating range selected by the driver. The 1-2 shift valve provides 1-2 or 2-1 shifts and the 2-3 shift valve provides 2-3 or 3-2 shifts. The kickdown valve provides forced 3-2 or 3-1 downshifts depending on vehicle speed. Downshifts occur when the throttle is opened beyond downshift detent position. Detent is reached just before wide open throttle position. The 2-3 valve throttle pressure plug provides 3-2 Fig. 3 46RH Valve Body downshifts at varying throttle openings depending on The fourth gear upshift occurs automatically when vehicle speed.the overdrive control switch is in the ON position. The 1-2 shift control valve transmits 1-2 shift pres- sure to the accumulator piston. This controls kick-OVERDRIVE OFF SWITCH down band capacity on 1-2 upshifts and 3-2 The overdrive Off switch is located in the instru- downshifts.ment panel. The switch is a momentary contact de- The 3-4 shift valve, quick fill valve, timing valvevice that signals the TCM to toggle current status of and accumulator are only actuated when the over-the overdrive function. At key-on, overdrive operation drive solenoid is energized.is allowed. The solenoid contains a check ball that controls a Pressing the switch once causes the overdrive Off vent port to the 3-4 valve. The check ball either di-mode to be entered and the overdrive Off switch verts line pressure away from or directly to, the 3-4lamp to be illuminated. Pressing the switch a second valve. Energizing the solenoid causes the check balltime causes normal overdrive operation to be re- to close the vent port allowing line pressure to actstored and the overdrive lamp to be turned off. upon the 3-4 valve. The normal position for the control switch is the The limit valve determines maximum speed atON position. The switch must be in this position to which a 3-2 part throttle kickdown can be made. Onenergize the solenoid and allow a fourth gear upshift. transmissions without a limit valve, maximum speed The control switch has an indicator light. The light for a 3-2 kickdown is at detent position.illuminates when the overdrive switch is turned to The 2-3 shuttle valve has two functions. First isthe OFF position, or when illuminated by the trans- fast front band release and smooth engagement dur-mission control module. ing lift-foot 2-3 upshifts. The second is to regulate The control switch indicator light is also used to front clutch and band application during 3-2 down-signal fault flash codes for diagnostic purposes. shifts. The 3-4 timing valve is moved by line pressureHYDRAULIC CONTROL SYSTEM coming through the 3-4 shift valve. The timing valve The 46RH hydraulic control system provides fully holds the 2-3 shift valve in an upshift position. Theautomatic operation. The system performs five basic purpose is to prevent the 2-3 valve from up or down-functions which are: pressure supply, pressure regu- shifting before the 3-4 valves.lation, flow control, clutch/band application, and lu- The 3-4 accumulator is mounted on the overdrivebrication. housing. It performs the same function as the 2-3 ac- cumulator. It is used to smooth engagement duringPRESSURE REGULATION the 3-4 shift. The pressure regulator valve maintains line pres-sure. The amount of pressure developed is controlled
    • 21 - 168 46RH AUTOMATIC TRANSMISSION ZJBOOST VALVE from draining from the converter into the cooler and The boost valve provides increased fluid apply pres- lines when the vehicle is shut down for lengthy peri-sure for converter clutch and overdrive clutch en- ods.gagement. Production valves have a hose nipple at one end, The boost valve is connected to the overdrive clutch while the opposite end is threaded for a flare fitting.circuit via a tube connected between the valve body Some early valves have hose nipples at both ends. Allupper and lower housings. The valve is connected to valves have an arrow mark (or similar mark) to in-the converter clutch circuit via the regulator valve, dicate direction of flow through the valve.switch valve and 3-4 valves. Hydraulic circuitry for the boost valve is shown in FOURTH GEAR SHIFT SEQUENCEthe hydraulic flow diagrams. The diagrams are lo- The overdrive clutch is applied in fourth gear only.cated at the end of the transmission diagnosis and The direct clutch is applied in all ranges excepttest section. fourth gear. During converter clutch engagement in fourth gear, Fourth gear overdrive range is electronically con-the valve supplies full line pressure directly to the trolled and hydraulically activated. Various sensor in-clutch. The increased pressure available at the clutch puts are supplied to the powertrain control module toprovides smooth shifting and positive engagement. operate the overdrive solenoid on the valve body. The The 3-4 upshift causes the boost valve to increase solenoid contains a check ball that opens and closes aline pressure to the overdrive clutch. Pressure also vent port in the 3-4 shift valve feed passage.increases with throttle opening. This ensures positive The overdrive solenoid (and check ball) are not en-clutch engagement during periods of high throttle ergized in first, second, third or reverse gear. Theopening acceleration. vent port remains open diverting line pressure from the 2-3 shift valve away from the 3-4 shift valve.QUICK FILL VALVE The overdrive switch must be in the On position to The 3-4 quick fill valve provides faster engagement transmit signals to the solenoid. A 3-4 upshift occursof the overdrive clutch during 3-4 upshifts. The valve only when the overdrive solenoid is energized by antemporarily bypasses the clutch piston feed orifice at electrical signal from the powertrain control modulethe start of a 3-4 upshift. This exposes a larger pas- (PCM).sage into the piston retainer resulting in a much The solenoid is energized upon receiving a signalfaster clutch fill and apply sequence. from the PCM. This causes the check ball to close the The quick fill valve does not bypass the regular vent port. Closing the vent port allows line pressureclutch feed orifice throughout the 3-4 upshift. In- from the 2-3 shift valve to act directly upon the 3-4stead, once a predetermined pressure develops within valves.the clutch, the valve closes the bypass. Clutch fill is Line pressure acting on the 3-4 shift valve over-then completed through the regular feed orifice. comes valve spring tension moving the valve to the upshift position. This action exposes the feed pas-CONVERTER CLUTCH CONTROL sages to the 3-4 timing valve, 3-4 quick fill valve, 3-4 The converter clutch valve applies the converter accumulator and ultimately to the overdrive piston.clutch when supplied with line pressure through the Line pressure through the timing valve moves theconverter clutch solenoid. The solenoid is mounted on overdrive piston into contact with the overdrivethe valve body and energized by an electrical signal clutch.from the powertrain control module. Electronic con- The overdrive clutch is engaged and the directtrol of converter clutch operation includes clutch re- clutch is disengaged to complete the 3-4 upshift. Thelease at closed throttle during warmup and during boost valve provides increased fluid apply pressure topart throttle acceleration. The boost valve provides the overdrive clutch during the 3-4 upshift and dur-additional apply pressure for converter clutch appli- ing fourth gear acceleration.cation. The overdrive piston engages the overdrive clutch The switch valve directs fluid apply pressure to the by pressing directly against the clutch pressure plate.converter clutch in one position and releases it in the The direct clutch is disengaged once spring load is re-opposite position. It also directs oil to the cooling and lieved. The direct clutch is released just before thelube circuits. The switch valve regulates oil pressure overdrive clutch is applied.to the torque converter by limiting maximum oil The 3-4 accumulator cushions overdrive clutch en-pressure to 130 psi. gagement to smooth the transition into fourth gear. The accumulator is charged at the same time as ap-CONVERTER DRAINBACK VALVE ply pressure acts against the overdrive piston. The drainback valve is located in the transmission Converter clutch engagement in overdrive fourthcooler outlet (pressure) line. The valve prevents fluid gear is controlled by sensor inputs to the powertrain
    • ZJ 46RH AUTOMATIC TRANSMISSION 21 - 169control module. Inputs to the control module that de- The governor weight assembly now consists of thetermine clutch engagement are: inner and outer weights, a smaller weight spring,• coolant temperature (verifies temperature mini- and a new intermediate weight. A spacer has beenmum of 60° F) added to the weight bore in the governor body to help• engine speed secure the new weight assembly.• vehicle speed The low-reverse drum has a spotface in the hub for• throttle position a double tab thrust washer. The drum and new• manifold vacuum (MAP sensor) thrust washer are used on all 46RH transmissions. Plastic check balls are now used in some valve bod-TRANSMISSION CHANGES AND PARTS ies. The new check balls entered production as a run-INTERCHANGEABILITY ning change. The plastic and steel check balls are not 1995 transmissions are similar to previous models interchangeable.but only in appearance. Current transmissions are A converter drainback check valve has been addeddimensionally different and have different hydraulic to the fluid cooler system. The one-way valve is lo-circuitry. Do not interchange parts. cated in the transmission outlet (pressure) line. The Tranmission changes affect the governor weight as- valve prevents fluid drainback when the vehicle issembly, low-reverse drum, front annulus, boost valve parked for lengthy periods.tube retainer, fluid cooling system, and valve check The boost valve tube retainer has been lengthenedballs. A check ball has been added to the rear servo cir- and an extra tab added to better secure the tube.cuit. The check ball is located in the transfer plate.
    • 21 - 170 46RH TRANSMISSION DIAGNOSIS ZJ 46RH TRANSMISSION DIAGNOSIS INDEX page pageAir Testing Transmission Clutch and Band Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Fluid Contamination . . . . . . . . . . . . . . . . . . . . . . 171Analyzing the Road Test . . . . . . . . . . . . . . . . . . . 172 General Information . . . . . . . . . . . . . . . . . . . . . . . 170Causes of Burned Fluid . . . . . . . . . . . . . . . . . . . . 171 Hydraulic Pressure Test . . . . . . . . . . . . . . . . . . . . 172Checking Fluid Level and Condition . . . . . . . . . . . 170 Overdrive Electrical Controls . . . . . . . . . . . . . . . . 171Converter Housing Fluid Leak Diagnosis . . . . . . . 176 Preliminary Diagnosis . . . . . . . . . . . . . . . . . . . . . 170Converter Stall Test . . . . . . . . . . . . . . . . . . . . . . . 175 Road Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172Diagnosis Charts . . . . . . . . . . . . . . . . . . . . . . . . . 179 Stall Test Analysis . . . . . . . . . . . . . . . . . . . . . . . . 175Effects of Incorrect Fluid Level . . . . . . . . . . . . . . . 171 Transmission Control Cable Adjustments . . . . . . . 172GENERAL INFORMATION VEHICLE IS DISABLED Begin diagnosis by checking the easily accessible (1) Check fluid level and condition.items such as fluid level, fluid condition and throttle (2) Check for broken, disconnected shift linkage.cable/shift linkage adjustments. A road test will de- (3) Check for cracked, leaking cooler lines, or loose,termine if further diagnosis is necessary. missing pressure port plugs. Procedures outlined in this section should be per- (4) Raise vehicle, start engine, shift transmissionformed in the following sequence to realize the most into gear and note following:accurate results: (a) If propeller shaft turns but wheels do not, (1) preliminary diagnosis problem is with differential or axle shafts. (2) fluid Level and condition (b) If propeller shafts does not turn and trans- (3) leak checks (if fluid level is low) mission is noisy, stop engine. Remove oil pan, and (4) throttle and shift linkage adjustment check for debris. If pan is clear, remove transmis- (5) overdrive control switch test sion and check for damaged drive plate, converter, (6) road test oil pump, input shaft, planetary gear, clutches. (7) stall test (c) If propeller shaft does not turn and transmis- (8) hydraulic pressure test sion is not noisy, perform hydraulic pressure test to (9) air pressure tests determine if problem is hydraulic or mechanical. (10) analyze test results (11) refer to diagnosis charts CHECKING FLUID LEVEL AND CONDITIONPRELIMINARY DIAGNOSIS (1) Place vehicle on level surface. This is important Two basic procedures are required. One procedure for an accurate reading.for vehicles that are driveable and an alternate pro- (2) Do not check level until fluid is at normal op-cedure for disabled vehicles (will not back up or move erating temperature of approximately 82°C (180°F).forward). This is necessary to avoid false readings which could produce under or over fill condition,VEHICLE IS DRIVEABLE (3) Fully apply parking brakes. (1) Check fluid level and condition. (4) Start and run engine at curb idle speed. Then (2) Check throttle cable and gearshift linkage ad- shift transmission through all gear ranges and backjustments if complaint was based on delayed, erratic, to Neutral.or harsh shifts. (5) Clean top of filler tube and dipstick to keep dirt (3) Road test vehicle and note how transmission out of tube.engages, upshifts, downshifts. (6) Remove dipstick and check fluid level as fol- (4) Perform stall test if complaint is based on slug- lows:gish acceleration or if abnormal throttle opening is (a) Dipstick has three fluid level indicatingneeded to maintain normal speeds with a properly marks which are a MIN dot mark, an OK marktuned engine. and a MAX fill arrow mark: (5) Perform hydraulic pressure test if shift prob- (b) Correct level is to MAX arrow nark on dip-lems were noted during road test. stick. This is correct maximum hot fluid level. Ac- (6) Perform air pressure test to check clutch-band ceptable level is between OK mark and max arrowoperation if hydraulic pressure test is inconclusive. mark on dipstick.
    • ZJ 46RH TRANSMISSION DIAGNOSIS 21 - 171 (c) If level is at, or below MIN level dot on dip- FLUID CONTAMINATION stick, add only enough fluid to restore correct level. Fluid contamination is generally a result of: Mopar ATF Plus, type 7176 is the recommended • adding incorrect fluid and preferred fluid. • failure to clean dipstick and fill tube when check- ing levelCAUTION: Do not overfill the tranmission. Overfill- • engine coolant entering fluiding may cause leakage out the pump vent which • internal failure that generates debriscan be mistaken for a pump seal leak. In addition, • overheat that generates sludge (fluid breakdown)overfilling will also cause fluid aeration and foam- • failure to reverse flush cooler and lines after re-ing as the excess fluid is picked up and churned by pairthe gear train. This will significantly reduce fluid • failure to replace contaminated converter duringlife. repair (7) Check and note fluid condition as follows: The use of non-recommended fluids can result in (a) Fluid should be dark to light red in color and transmission failure. The usual results are erratic free of particles and sludge. shifts, slippage, abnormal wear and eventual failure (b) If fluid is orange, brown, or smells slightly due to fluid breakdown and sludge formation. Avoid burned, flow test and reverse flush cooler and lines. this condition by using recommended fluids only. Then change fluid and filter and road test again to The dipstick cap and fill tube should be wiped confirm proper operation. clean before checking fluid level. Dirt, grease and (c) If fluid is black, dark brown, turned to sludge, other foreign material on the cap and tube could fall contains extensive amount of metal or friction ma- into the tube if not removed beforehand. Take the terial particles, transmission will need overhaul. time to wipe the cap and tube clean before withdraw- Main and auxiliary coolers and cooler lines will ing the dipstick. have to be flow tested and reverse flushed as well. Engine coolant in the transmission fluid is gener- ally caused by a cooler malfunction. The only remedyEFFECTS OF INCORRECT FLUID LEVEL is to replace the radiator as the cooler in the radiator A low fluid level allows the pump to take in air is not a serviceable part. If coolant has circulatedalong with the fluid. Air in the fluid will cause fluid through the transmission for some time, an overhaulpressures to be low and develop slower than normal. may also be necessary; especially if shift problems If the transmission is overfilled, the gears churn had developed.the fluid into foam, aerating the fluid and causing The transmission cooler and lines should be reversethe same conditions that occur with a low level. Ineither case, air bubbles cause fluid overheating, oxi- flushed whenever a malfunction generates sludgedation and varnish buildup which interferes with and/or debris. The torque converter should also be re-valve, clutch and servo operation. placed at the same time. Foaming also causes fluid expansion which can re- Failure to flush the cooler and lines will result insult in fluid overflow from the transmission vent or re-contamination and a shop comeback. Flushing ap-fill tube. Fluid overflow can easily be mistaken for a plies to auxiliary coolers as well. The torque con-leak if inspection is not careful. verter and drainback valve should also be replaced whenever a failure generates sludge and debris. ThisCAUSES OF BURNED FLUID is necessary because converter flushing procedures Burned, discolored fluid is a result of overheating will not remove all of the contaminants.which has two primary causes. The first cause is a result of restricted fluid flow OVERDRIVE ELECTRICAL CONTROLSthrough the main and/or auxiliary cooler. This condi- The electrical controls governing the shift intotion is usually the result of a faulty or improperly in- fourth gear consist of the control switch on the in-stalled drainback valve, a damaged main cooler, or strument panel and the overdrive solenoid on thesevere restrictions in the coolers and lines caused by valve body. The control switch is in circuit with thedebris. solenoid and must be in the On position to energize The second primary cause is heavy duty operation the solenoid. The transmission must also havewith a vehicle not properly equipped for this type of reached third gear range before the shift to fourthoperation. Trailer towing or similar high load opera- gear will occur.tion will overheat the transmission fluid if the vehi- The control switch, valve body solenoid, case con-cle is improperly equipped. Such vehicles should have nectors and related wiring can all be tested with a 12an auxiliary transmission fluid cooler, a heavy duty volt test lamp or a volt/ohmmeter. Check continuitycooling system, and the engine/axle ratio combination of each component when diagnosis indicates this isneeded to handle heavy loads. necessary.
    • 21 - 172 46RH TRANSMISSION DIAGNOSIS ZJ Switch and solenoid continuity should be checked For example: If slippage occurs in first gear in Dwhenever the transmission fails to shift into fourth and 2 range but not in 1 range, the transmissiongear range. overrunning clutch is faulty. Similarly, if slippage oc- curs in any two forward gears, the rear clutch is slip-TRANSMISSION CONTROL CABLE ADJUSTMENTS ping. Transmission throttle valve cable adjustment is ex- Applying the same method of analysis, note thattremely important to proper operation. This adjust- the front and rear clutches are applied simulta-ment positions the throttle valve which controls shift neously only in D range third and fourth gear. If thespeed, quality and part throttle downshift sensitivity. transmission slips in third gear, either the front If cable setting is too short, early shifts and slip- clutch or the rear clutch is slipping.page between shifts may occur. If the setting is too If the transmission slips in fourth gear but not inlong, shifts may be delayed and part throttle down- third gear, the overdrive clutch is slipping. By select-shifts may be very sensitive. Refer to the In Vehicle ing another gear which does not use these clutches,Service section for adjustment procedure. the slipping unit can be determined. For example, if Shift cable adjustment is important because it po- the transmission also slips in Reverse, the frontsitions the valve body manual valve. Incorrect adjust- clutch is slipping. If the transmission does not slip inment will cause creeping in Neutral, premature Reverse, the rear clutch is slipping.clutch wear, delayed engagement in any gear, or a If slippage occurs during the 3-4 shift or only inno-start in Park or Neutral position. fourth gear, the overdrive clutch is slipping. Simi- Proper operation of the park/neutral position larly, if the direct clutch were to fail, the transmis-switch will provide a quick check of cable adjust- sion would lose both reverse gear and overrunment. Refer to the In-Vehicle Service section for link- braking in 2 position (manual second gear). If theage adjustment procedure. transmission slips in any other two forward gears, the transmission rear clutch is probably slipping.ROAD TESTING If the transmission will not shift to fourth gear, the Before road testing, be sure the fluid level and all control switch, overdrive solenoid or related wiringlinkage adjustments have been checked and adjusted may also be the problem cause.if necessary. Observe engine performance during the This process of elimination can be used to identifyroad test. A poorly tuned engine will not allow an ac- a slipping unit and check operation. Proper use ofcurate analysis of transmission operation. the Clutch and Band Application Chart is the key. Operate the transmission in all gear ranges. Check Although road test analysis will help determine thefor shift variations and engine flare, which indicates slipping unit, the actual cause of a malfunction usu-slippage. Note if shifts are harsh, spongy, delayed, ally cannot be determined until hydraulic and airearly, or if part throttle downshifts are sensitive. pressure tests are performed. Practically any condi- Slippage indicated by engine flare, usually means tion can be caused by leaking hydraulic circuits orclutch, band or overrunning clutch problems. If the sticking valves.condition is advanced, an overhaul may be necessary Unless a malfunction is obvious, such as noto restore normal operation. drive in D range first gear, do not disassemble A slipping clutch or band can often be determined the transmission. Perform the hydraulic andby comparing which internal units are applied in the air pressure tests to help pinpoint the problemvarious gear ranges. The Clutch and Band Applica- cause.tion chart (Fig. 4) provides a basis for analyzing roadtest results. HYDRAULIC PRESSURE TEST Hydraulic test pressures range from a low of oneANALYZING THE ROAD TEST psi (6.895 kPa) governor pressure, to 300 psi (2068 Refer to the Clutch and Band Application chart kPa) at the rear servo pressure port in reverse.(Fig. 1) and note which elements are in use in the An accurate tachometer and two test gauges are re-various gear ranges. quired for the pressure test. Test Gauge C-3292 has a Note that the rear clutch is applied in all forward 100 psi range and is used at the accumulator, gover-ranges (D, 2, 1). The transmission overrunning clutch nor, and front servo pressure ports. Test Gaugeis applied in first gear (D, 2 and 1 ranges) only. The C-3293 has a 300 psi range and is used at the rearrear band is applied in 1 and R range only. servo port and overdrive test ports where pressures Note that the overdrive clutch is applied only in are higher. In cases where two test gauges are re-fourth gear and the overdrive direct clutch and over- quired, the 300 psi gauge can be used at any of therunning clutch are applied in all ranges except fourth other test ports.gear.
    • ZJ 46RH TRANSMISSION DIAGNOSIS 21 - 173 Fig. 4 Clutch And Band Application ChartPressure Test Port Locations There are pressure test ports at the accumulator,front servo, and rear servo. Governor and overdriveclutch pressure test ports are located at the left andright rear sides of the case (Fig. 5). Line pressure is checked at the accumulator porton the right side of the case. The front servo pressureport is at the right side of the case just behind thefiller tube opening. The rear servo and governor pressure ports are atthe right rear of the transmission case. The overdriveclutch pressure port is at the left rear of the case(Fig. 5).HYDRAULIC PRESSURE TEST PROCEDURETest One—Transmission In 1 Range This test checks pump output, pressure regu-lation, and condition of the rear clutch andservo circuit. Test Gauges C-3292 and C-3293-SPare required for this test. Gauge C-3292 has a100 psi range. Gauge C-3293-SP has a 300 psirange. (1) Connect tachometer to engine. Position tachom-eter so it can be observed from driver seat if helperwill be operating engine. Raise vehicle on hoist thatwill allow rear wheels to rotate freely. (2) Connect 100 psi Gauge C-3292 to accumulator Fig. 5 Pressure Test Port Locationsport. Then connect 300 psi Gauge C-3293-SP to rear (5) Move transmission shift lever fully forward intoservo port (Fig. 5). (3) Disconnect throttle and gearshift cables from 1 range.levers on transmission valve body manual shaft. (4) Have helper start and run engine at 1000 rpm.
    • 21 - 174 46RH TRANSMISSION DIAGNOSIS ZJ (6) Gradually move transmission throttle lever in place at accumulator port.from full forward to full rearward position and note (2) Move 300 psi Gauge C-3293-SP back to rearpressures on both gauges: servo port. (a) Line pressure at accumulator port should be (3) Have helper start and run engine at 1600 rpm 54-60 psi (372-414 kPa) with throttle lever forward for test. and gradually increase to 90-96 psi (621-662 kPa) (4) Move transmission shift lever four detents rear- as throttle lever is moved rearward. ward from full forward position. This is Reverse (b) Rear servo pressure should be same as line range. pressure within 3 psi (20.68 kPa). (5) Move transmission throttle lever fully forward then fully rearward and note reading at GaugeTest Two—Transmission In 2 Range C-3293-SP. This test checks pump output, line pressure (6) Pressure should be 145 - 175 psi (1000-1207and pressure regulation. Use 100 psi Test Gauge kPa) with throttle lever forward and increase to 230 -C-3292 for this test. (1) Leave vehicle in place on hoist and leave Test 280 psi (1586-1931 kPa) as lever is gradually movedGauge C-3292 connected to accumulator port for this rearward.test. Test Five—Governor Pressure (2) Have helper start and run engine at 1000 rpm. (3) Move transmission shift lever one detent rear- This test checks governor operation by mea-ward from full forward position. This is 2 range. suring governor pressure response to changes (4) Move transmission throttle lever from full for- in vehicle speed. It is usually not necessary toward to full rearward position and read pressure on check governor operation unless shift speedsgauge: are incorrect or if the transmission will not (5) Line pressure should be 54-60 psi (372-414 downshift. The test should be performed on akPa) with throttle lever forward and gradually in- hoist that will allow the rear wheels to rotatecrease to 90-96 psi (621-662 kPa) as lever is moved freely.rearward. (1) Move 100 psi Test Gauge C-3292 to governor pressure port (Fig. 5).Test Three—Transmission In D Range Third Gear (2) Move transmission shift lever two detents rear- This test checks pressure regulation and con- ward from full forward position. This is D range.dition of the clutch circuits. Use both pressure (3) Have helper start and run engine at curb idleTest Gauges C-3292 and C-3293-SP for this test. speed. Then firmly apply service brakes so wheels (1) Turn OD switch off. will not rotate. (2) Leave vehicle on hoist and also leave Gauge (4) Note governor pressure:C-3292 in place at accumulator port. (a) Governor pressure should be no more than 10 (3) Move Gauge C-3293-SP over to front servo port kPa (1-1/2 psi) at curb idle speed and wheels notfor this test. rotating. (4) Have helper start and run engine at 1600 rpm (b) If pressure exceeds 10 kPa (1-1/2 psi)3 psi, afor this test. governor fault exists. Valve, or weight is sticking, (5) Move transmission shift lever two detents rear-ward from full forward position. This is D range. E-clip has come off shaft, or leak exists at tubes. (6) Read pressures on both gauges as transmission (5) Release brakes, slowly increase engine speed,throttle lever is gradually moved from full forward to and observe speedometer and pressure test gauge.full rearward position: Governor pressure should increase in proportion to (a) Line pressure at accumulator in D range vehicle speed, or approximately 6.89 kPa (1 psi) for third gear, should be 54-60 psi (372-414 kPa) with every 1 mph. throttle lever forward and increase as lever is (6) Pressure rise should be smooth and drop back moved rearward. to no more than 10 kPa (1-1/2 psi) after engine re- (b) Front servo pressure in D range third gear, turns to curb idle speed and brakes are applied to should be within 3 psi (21 kPa) of line pressure up prevent wheel rotation. to kickdown point. (7) Compare results of pressure test with analysis chart (Fig. 6).Test Four—Transmission In Reverse This test checks pump output, pressure regu- Test Six—Transmission In Overdrive Fourth Gearlation and the front clutch and rear servo cir- This test checks line pressure at the over-cuits. Use 300 psi Test Gauge C-3293-SP for this drive clutch in fourth gear range. Use 300 psitest. Test Gauge C-3292 for this test. The test should (1) Leave vehicle on hoist and leave gauge C3292 be performed on the road or on a chassis dyno.
    • ZJ 46RH TRANSMISSION DIAGNOSIS 21 - 175 (1) Remove tachometer. It will not be used for this Speed Specifications chart and Stall Speed Diagnosistest. guides. (2) Move 300 psi Gauge to overdrive clutch pres-sure test port. Then remove other gauge and reinstall WARNING: NEVER ALLOW ANYONE TO STAND DI-test port plug. RECTLY IN LINE WITH THE VEHICLE FRONT OR (3) Lower vehicle. REAR DURING A STALL TEST. ALWAYS BLOCK (4) Turn OD switch on. THE WHEELS AND APPLY THE SERVICE AND (5) Secure test gauge so it can be viewed from driv- PARKING BRAKES DURING THE TEST.ers seat. (6) Start engine and shift into D range. (7) Increase vehicle speed gradually until 3-4 shift STALL TEST PROCEDUREoccurs and note gauge pressure. (1) Connect tachometer to engine. Position tachom- (8) Pressure should be 469-496 kPa (68-72 psi) eter so it can be viewed from driver seat.with closed throttle and increase to 620-827 kPa (90- (2) Check transmission fluid level. Add fluid if nec-120 psi) at 1/2 to 3/4 throttle. Note that pressure can essary.increase to around 896 kPa (130 psi) at full throttle. (3) Start and run engine until transmission fluid (9) Return to shop or move vehicle off chassis reaches normal operating temperature.dyno. (4) Block front wheels. (5) Fully apply service and parking brakes. (6) Stall speeds should be in 1750-2300 rpm range. Perform stall test as described in next. (7) Open throttle completely and record maximum engine rpm registered on tachometer. It will take from 4-10 seconds to reach max rpm. However, once max rpm has been achieved, do not hold wide open throttle for more than 4-5 seconds. CAUTION: Stalling the converter causes a rapid in- crease in fluid temperature. To avoid fluid overheat- ing, hold wide open throttle for no more than 4-5 seconds after reaching peak rpm. In addition, if en- gine exceeds 2300 rpm, release accelerator pedal immediately as transmission clutch slippage is oc- curring. (8) If a second stall test is required, cool fluid down as follows before proceeding: Shift into Neutral, and run engine at 1000 rpm with transmission for 20-30 seconds to cool fluid. (9) Refer to Stall Test Analysis. STALL TEST ANALYSIS Stall Speed Too High Stall speeds over 2300 rpm indicates transmission clutch slippage. Stall Speed Too Low Low stall speeds with a properly tuned engine in- Fig. 6 Pressure Test Analysis Chart dicate a torque converter overrunning clutch prob-CONVERTER STALL TEST lem. The condition should be confirmed by road Stall testing involves determining maximum engine testing prior to converter replacement.rpm obtainable at full throttle with the rear wheels Stall speeds 250-350 rpm below normal indicateslocked and the transmission in D range. This test the converter overrunning clutch is slipping. The ve-checks the holding ability of the the converter over- hicle will also exhibit poor acceleration but operaterunning clutch and both of the transmission clutches. normally once highway cruise speeds are reached.When stall testing is completed, refer to the Stall Torque converter replacement will be necessary.
    • 21 - 176 46RH TRANSMISSION DIAGNOSIS ZJStall Speed Normal But Acceleration Is Sluggish (Fig. 7). Piston movement can be felt and a soft thud If stall speeds are normal (1800-2300 rpm) but ab- heard as the clutch applies.normal throttle opening is required for acceleration,or to maintain cruise speeds, the converter overrun- FRONT SERVO AIR TESTning clutch is seized. The torque converter will have Apply air pressure to the front servo apply passage.to be replaced. The servo rod should extend and cause the band to tighten around the drum. Spring tension should re-CONVERTER NOISE DURING TEST lease the servo when air pressure is removed. A whining noise caused by fluid flow is normal dur-ing a stall test. However, loud metallic noises indi- REAR SERVO AIR TESTcate a damaged converter. To confirm that noise is Apply air pressure to the rear servo apply passage.originating from the converter, operate the vehicle at The servo rod should extend and cause the band tolight throttle in Drive and Neutral on a hoist and lis- tighten around the drum. Spring tension should re-ten for noise coming from the converter housing. lease the servo when air pressure is removed.AIR TESTING TRANSMISSION CLUTCH AND BAND CONVERTER HOUSING FLUID LEAK DIAGNOSIS When diagnosing converter housing fluid leaks, twoOPERATION items must be established before repair. First, it Air pressure testing can be used to check transmis- must be verified that a leak condition actually exists.sion front/rear clutch and band operation with the And second, the true source of the leak must be de-transmission either in the vehicle, or on the work termined.bench as a final check after overhaul. Some suspected converter housing fluid leaks may Air pressure testing requires that the oil pan and not be leaks at all. They may only be the result ofvalve body be removed from the transmission. The residual fluid in the converter housing, or excessservo and clutch apply passages are shown in Figure fluid spilled during factory fill or refill after repair.7. Converter housing leaks have several potential sources. Through careful observation, a leak source can be identified before removing the transmission for repair. Pump seal leaks tend to move along the drive hub and onto the rear of the converter. Pump O-ring or pump body leaks follow the same path as a seal leak (Fig. 8). 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. 8). Pump seal or gasket leaks usually travel down the inside of the converter housing. Front band lever pin plug leaks are generally de- posited on the housing and not on the converter. Fig. 7 Air Pressure Test PassagesFRONT CLUTCH AIR TEST Place one or two fingers on the clutch housing andapply air pressure through front clutch apply passage(Fig. 8). Piston movement can be felt and a soft thudheard as the clutch applies.REAR CLUTCH AIR TEST Place one or two fingers on the clutch housing andapply air pressure through rear clutch apply passage Fig. 8 Converter Housing Leak Paths
    • ZJ 46RH TRANSMISSION DIAGNOSIS 21 - 177LEAK DIAGNOSIS PROCEDURE (1) Raise rear of vehicle and allow accumulatedfluid to drain out of converter housing. (2) Check and adjust transmission fluid level. (3) Raise vehicle. Remove converter housing dustcover and wipe as much fluid as possible from con-verter housing. (4) Fabricate test probe (Fig. 9). Attach probe toconverter housing with a dust shield bolt. (5) Have a helper run engine at 2500 rpm (withtransmission in Neutral) for two minutes; then stopengine. (6) Inspect test probe and converter housing. Ifleak is evident, note color of fluid: (a) If fluid is red/pink, leak is from transmission part. Proceed with diagnosis. (b) If fluid is brown or green, oil leak is from en- gine. Refer to engine leak diagnosis procedures in Fig. 10 Pump Area Inspection Points Group 9. (7) Determine where transmission fluid is leakingfrom: (a) If probe upper surface is wet with trans- mission fluid, converter or seal are at fault. Fluid across probe upper surface indicates converter or seal leak. (b) If transmission fluid is leaking under probe, it is coming from pump housing area (Fig. 8). (8) Fluid leaking under probe could be from: pumpseal and/or bushing, pump vent, front band levershaft access plug, pump bolts, or porous spots inpump body or transmission case (Fig. 8). (9) If porous spots in transmission case or pump Fig. 11 Converter Leak Points (Typical)body are suspected leak source, pressurize transmis- LEAK TESTING WITH AIR PRESSUREsion as described in Leak Testing With Air Pressure. This test involves closing off all openings and pres- surizing the transmission to 8 psi with hand oper- ated Air Pump 7700. 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 re- Fig. 9 Leak Test Probe moved, a shipping plug can be used to close off this opening.TORQUE CONVERTER LEAK POINTS The torque converter hub opening in the pump and Possible sources of converter leaks are: (a) leaks at the pump vent require special tools to close them off.the weld joint around the outside diameter weld (Fig. The converter hub seal cap is made from thin wall9) and (b) leaks at the converter hub weld (Fig. 11). tube and a 3.17 mm (1/8 in.) thick disc (Figs. 12 and 13). A retaining strap is needed to secure the seal cup for testing (Fig. 14). The strap attaching hole po-
    • 21 - 178 46RH TRANSMISSION DIAGNOSIS ZJsitions are approximate only. Measure hole positionon the converter housing before drilling. The pump vent plug is made from 6.35 mm (1/4 in.)rod and 4.76 mm (3/16 in.) plate (Fig. 14). The fabricated tools can all be made from mildsteel or aluminum stock. Fig. 14 Pump Vent Plug CAUTION: The recommended test pressure is 8 psi. Fig. 12 Converter Hub Seal Cup The maximum allowable test pressure is 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 comple- tion and make necessary repairs as described in Leak Correction procedure. Fig. 13 Seal Cup Retaining StrapAIR PRESSURE LEAK TEST PROCEDURE (1) Install vent plug, converter hub seal cup andcup retaining strap (Fig. 15).CAUTION: Be sure the surfaces of the hub seal cupare smooth and free of nicks, scratches, or burrs.Surface irregularities on the cup will damage thepump seal if not removed. Sand and/polish the cupwith 400 grit sandpaper or crocus cloth to smooththe surface if necessary. (2) Close off remaining transmission openings withrubber plugs, or stoppers or similar devices. Do not Fig. 15 Vent Plug And Hub Seal Cup Installationclose off rear cooler line fitting. Hand operated CONVERTER HOUSING AREA LEAKair pump will be attached to this fitting. CORRECTION (3) Attach Air Pump 7700 to rear cooler line fit- (1) Remove converter.ting. Connect a length of copper tube to fitting. Then (2) Tighten front band adjusting screw until bandattach pump hose to tube with hose clamp (Fig. 16). is tight around front clutch retainer. This prevents (4) Apply a thick soapy water solution to suspected front/rear clutches from coming out when oil pump isleak areas. removed.
    • ZJ 46RH TRANSMISSION DIAGNOSIS 21 - 179 (6) Loosen kickdown lever pin access plug three turns. Apply Permatex No. 2 or equivalent to plug threads and tighten plug to 17 N⅐m (150 in-lbs) torque. (7) Adjust front band. (8) Lubricate pump seal and converter hub with transmission fluid or petroleum jelly and install con- verter. (9) Install transmission and converter housing dust shield. (10) Lower vehicle. DIAGNOSIS CHARTS Fig. 16 Typical Method of Pressurizing The diagnosis charts provide additional reference Transmission when diagnosing a transmission fault. The charts (3) Remove oil pump and remove pump seal. In- provide general information on a variety of transmis-spect pump housing drainback and vent holes for ob- sion, overdrive and converter fault conditions.structions. Clear holes with solvent and wire. The hydraulic flow charts outline fluid flow and hy- (4) Inspect pump bushing and converter hub. If draulic circuitry. Circuit flow is provided for all gearbushing is scored, replace it. If converter hub is ranges. Approximate working pressures are also sup-scored, either polish it with crocus cloth or replace plied for each gear range.converter if scoring is severe. (5) Install new pump seal, O-ring, gasket, bushing.Replace oil pump if cracked, porous or damaged inany way.
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    • ZJ 46RH TRANSMISSION DIAGNOSIS 21 - 183 TRANSMISSION DIAGNOSIS
    • 21 - 184 46RH TRANSMISSION DIAGNOSIS ZJ TRANSMISSION DIAGNOSIS
    • ZJ 46RH TRANSMISSION DIAGNOSIS 21 - 185 TRANSMISSION DIAGNOSIS
    • 21 - 186 46RH TRANSMISSION DIAGNOSIS ZJ TRANSMISSION DIAGNOSIS
    • ZJ 46RH TRANSMISSION DIAGNOSIS 21 - 187 TRANSMISSION DIAGNOSIS
    • 21 - 188 46RH TRANSMISSION DIAGNOSIS ZJ OVERDRIVE DIAGNOSIS
    • ZJ 46RH TRANSMISSION DIAGNOSIS 21 - 189 OVERDRIVE DIAGNOSIS
    • 21 - 190 46RH TRANSMISSION DIAGNOSIS ZJ OVERDRIVE DIAGNOSIS
    • ZJ 46RH TRANSMISSION DIAGNOSIS 21 - 191 TORQUE CONVERTER DIAGNOSIS
    • 21 - 192 46RH TRANSMISSION DIAGNOSIS ZJ TORQUE CONVERTER DIAGNOSIS
    • ZJ 46RH TRANSMISSION DIAGNOSIS 21 - 193 TORQUE CONVERTER DIAGNOSIS
    • 21 - 194 46RH TRANSMISSION DIAGNOSIS ZJ HYDRAULIC FLOW IN PARK
    • ZJ 46RH TRANSMISSION DIAGNOSIS 21 - 195HYDRAULIC FLOW IN NEUTRAL
    • 21 - 196 46RH TRANSMISSION DIAGNOSIS ZJHYDRAULIC FLOW IN REVERSE
    • ZJ 46RH TRANSMISSION DIAGNOSIS 21 - 197HYDRAULIC FLOW IN D FIRST GEAR
    • 21 - 198 46RH TRANSMISSION DIAGNOSIS ZJHYDRAULIC FLOW IN D SECOND GEAR
    • ZJ 46RH TRANSMISSION DIAGNOSIS 21 - 199HYDRAULIC FLOW IN D THIRD GEAR
    • HYDRAULIC FLOW IN D FOURTH GEAR (CONVERTER CLUTCH NOT APPLIED) 21 - 200 46RH TRANSMISSION DIAGNOSIS ZJ
    • HYDRAULIC FLOW IN D FOURTH GEAR (CONVERTER CLUTCH APPLIED) ZJ 46RH TRANSMISSION DIAGNOSIS 21 - 201
    • HYDRAULIC FLOW IN MANUAL FIRST GEAR (1) 21 - 202 46RH TRANSMISSION DIAGNOSIS ZJ
    • HYDRAULIC FLOW IN MANUAL SECOND GEAR (2) ZJ 46RH TRANSMISSION DIAGNOSIS 21 - 203
    • 21 - 204 46RH IN-VEHICLE SERVICE ZJ 46RH IN-VEHICLE SERVICE INDEX page pageAluminum Thread Repair . . . . . . ....... . . . . . . 215 Recommended Fluid . . . . . . . . . . . . . . . . . . . . . . 204Converter Drainback Check Valve Service . . . . . . 213 Refilling After Overhaul or Fluid/Filter Change . . . 205Fluid and Filter Replacement . . . ....... . . . . . . 205 Slip Yoke Seal Replacement—2-Wheel DriveFluid Level Check . . . . . . . . . . . ....... . . . . . . 204 Models . . . . . . . . . . . . . . . . . . . . . . . . . . .... 209Front Band Adjustment . . . . . . . ....... . . . . . . 207 Speedometer Service . . . . . . . . . . . . . . . . . .... 208Gearshift Cable Adjustment . . . . ....... . . . . . . 206 Transmission Cooler Flow Testing . . . . . . . . .... 213Governor and Park Lock Service ....... . . . . . . 204 Transmission Cooler Line and Fitting Service .... 211Oil Pump Seal . . . . . . . . . . . . . ....... . . . . . . 204 Transmission Cooler Replacement . . . . . . . . .... 214Park Interlock Cable Adjustment ....... . . . . . . 207 Transmission Cooler Reverse Flushing . . . . .... 214Park/Neutral Position Switch . . . ....... . . . . . . 209 Transmission Throttle Valve Cable Adjustment ... 205Rear Band Adjustment . . . . . . . ....... . . . . . . 207 Valve Body Service . . . . . . . . . . . . . . . . . . . .... 210GOVERNOR AND PARK LOCK SERVICE (4) Apply parking brakes. The governor and park lock components are located (5) Shift transmission momentarily into all gearwithin the overdrive unit and cannot be serviced in ranges. Then shift transmission back to Neutral.the vehicle. The overdrive unit must be removed and (6) Clean top of filler tube and dipstick to keep dirtdisassembled for access to the governor and park lock from entering tube.components. (7) Remove dipstick and check fluid level as fol- Refer to the sections dealing with overdrive re- lows:moval, installation and disassembly for repair proce- (a) Dipstick has three fluid level indicator levelsdures. (Fig. 1) which are a MIN dot, an OK crosshatch area, and a MAX fill arrow.OIL PUMP SEAL (b) Correct maximum level is to MAX arrow The transmission and torque converter must be re- mark. Correct acceptable level is to OK mark inmoved for access to the oil pump seal. Oil pump seal crosshatch area. Incorrect level is at or below MINreplacement procedures are described in the Trans- dot.mission/Converter Removal And Installation section. (c) If fluid is low, add only enough Mopar ATF Plus to restore correct level. Do not overfill.RECOMMENDED FLUID The recommended and preferred fluid for 46RH CAUTION: Do not overfill the tranmission. Overfill-transmissions is Mopar ATF Plus, type 7176. ing may cause leakage out the pump vent which Mopar Dexron II is not really recommended and can be mistaken for a pump seal leak. Overfillingshould only be used when ATF Plus is not available. will also cause fluid aeration and foaming as the ex- cess fluid is picked up and churned by the gearFLUID LEVEL CHECK train. This will significantly reduce fluid life. Transmission fluid level should be checked monthlyunder normal operation. If the vehicle is used fortrailer towing or similar heavy load hauling, checkfluid level and condition weekly. Fluid level is checked with the engine running atcurb idle speed, the transmission in Neutral, parkingbrakes applied, and the transmission fluid at normaloperating temperature.FLUID LEVEL CHECK PROCEDURE (1) Transmission fluid must be at normal operatingtemperature for accurate fluid level check. Drive ve- Fig. 1 Fluid Level Marks On Dipstickhicle if necessary to bring fluid temperature up tonormal 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.
    • ZJ 46RH IN-VEHICLE SERVICE 21 - 205FLUID AND FILTER REPLACEMENT (3) Apply parking brakes. (4) Start and run engine at normal curb idle speed.NORMAL CHANGE INTERVAL (5) Apply service brakes, shift transmission The fluid and filter should be changed (and the through all gear ranges then back to Neutral butbands adjusted) at recommended maintenance inter- leave engine running at curb idle speed.vals, or whenever the transmission has been disas- (6) Remove funnel, insert dipstick and check fluidsembled for any reason. level. Add only enough fluid to bring level to ADD Refer to the Driveline section in Group O, Lubrica- mark on dipstick. Do not overfill.tion and Maintenance for recommended change inter- (7) Drive vehicle until transmission fluid is at nor-vals. Refer to the fluid/filter replacement and band mal operating temperature. Then recheck fluid leveladjustment procedures in this section. as described in next step. (8) Leave engine running at curb idle speed, shiftSEVERE USAGE CHANGE INTERVAL Under severe usage, the fluid and filter should be into Neutral, and check fluid level again. This time,changed and the bands adjusted at 12,000 mile (19 add only enough fluid to bring level up to Full mark000 Km) intervals. but do not overfill. Severe usage is defined as: (9) When fluid level is correct, shut engine off, re- (a) More than half of vehicle operation occurs in lease park brake, remove funnel, and reseat dipstick heavy city traffic during hot weather (above 90° F). in fill tube. (b) Vehicle is used for taxi, police, limousine, or similar commercial operation. TRANSMISSION THROTTLE VALVE CABLE (c) Vehicle is used for trailer towing or heavy ADJUSTMENT load hauling. The transmission throttle valve is operated by a When the factory fluid is drained, refill the trans- cam on the throttle lever. The throttle lever is oper-mission with Mopar ATF Plus, type 7176 fluid. ated by an adjustable cable (Fig. 2). The cable is at- tached to an arm mounted on the throttle lever shaft.FLUID/FILTER REPLACEMENT PROCEDURE A lock button at the engine-end of the cable is pro- (1) Raise vehicle. vided for cable adjustment. (2) Remove oil pan and drain fluid. A correctly adjusted throttle valve cable will cause (3) Clean oil pan and pan magnet. Then clean re-maining gasket material from gasket surface of the throttle lever on the transmission to move simul-transmission case. taneously with the throttle body lever from the idle (4) Remove fluid filter screws and remove filter. position. Proper adjustment will allow simultaneous (5) Position new filter on valve body and install fil- movement without causing the transmission throttleter screws. Tighten screws to 4 N⅐m (35 in. lbs.) lever to either move ahead of, or lag behind the levertorque. on the throttle body. (6) Adjust rear band at this time if required. (7) Position new gasket on oil pan and install pan CHECKING THROTTLE VALVE CABLEon transmission. Tighten pan bolts to 150 in. lbs. (17 ADJUSTMENTN⅐m) torque. (1) Turn ignition key to OFF position. (8) Adjust front band at this time if required. (2) Remove air cleaner. (9) Lower vehicle and refill transmission with Mo- (3) Verify that lever on throttle body is at curb idlepar ATF Plus, type 7176 fluid. Refer to Refilling After position. Then verify that transmission throttle leverOverhaul Or Fluid/Filter Change. (Fig. 3) is also at idle (fully forward) position. (4) Slide cable off attachment stud on throttle bodyREFILLING AFTER OVERHAUL OR FLUID/FILTER lever (Fig. 4).CHANGE (5) Compare position of cable end to attachment The most effective way to avoid overfilling after a stud on throttle body lever (Fig. 4):fluid change or overhaul is as follows: (a) Cable end and attachment stud should be (1) Remove dipstick and insert clean funnel in aligned (or centered on one another) to within 1transmission fill tube. mm (0.039 in.) in either direction. (2) Add following initial quantity of Mopar ATF (b) If cable end and attachment stud are mis-Plus to transmission: aligned (off center), cable will have to be adjusted (a) If fluid/filter change was performed, add 3 as described in Throttle Valve Cable Adjustment pints (1-1/2 quarts) of ATF Plus to transmission. procedure. (b) If transmission was completely overhauled (6) Reconnect cable end to attachment stud. Then and torque converter was replaced or drained, add with aid of a helper, observe movement of transmis- 12 pints (6 quarts) of ATF Plus to transmission. sion throttle lever and lever on throttle body.
    • 21 - 206 46RH IN-VEHICLE SERVICE ZJ (a) If both levers move simultaneously from idle to half-throttle and back to idle position, adjust- ment is correct. (b) 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 posi- tion, cable adjustment will be necessary.THROTTLE VALVE CABLE ADJUSTMENTPROCEDURE (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 pullcable off. (4) Verify that transmission throttle lever is in Fig. 3 Throttle Cable Attachment At Transmissionfully closed position. Then be sure lever on throttlebody 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 in.) to release cable in adjuster head. (6) Center cable end on attachment stud to within1 mm (0.039 in.) and release lock button. (7) Check cable adjustment. Be sure transmissionthrottle lever and lever on throttle body move simul-taneously as described in cable adjustment checkingprocedure. Fig. 4 Throttle Valve Cable Adjustment (3) Release cable adjuster clamp (at transmission end of cable) to unlock cable (Fig. 5). (4) Unsnap cable from cable bracket (Fig. 5). Fig. 2 Throttle Cable Attachment At Engine (5) Check transmission shift lever position by mov- ing it all the way rearward into Park detent.GEARSHIFT CABLE ADJUSTMENT (6) Verify positive engagement of park lock by at- Check adjustment by starting the engine in Park tempting to rotate propeller shaft. Shaft will not ro-and Neutral. Adjustment is OK if the engine starts tate when park lock is engaged.only in these positions. Adjustment is incorrect if the (7) Snap cable into cable bracket on transmission.engine starts in one but not both positions. If the en- (8) Lock shift cable by pressing cable adjustergine starts in any position other than Park or Neu- clamp down until it snaps into place.tral, or if the engine will not start at all, the park/ (9) Check engine starting. Engine should start onlyneutral position switch may be faulty. in Park and Neutral.Gearshift Adjustment Procedure (10) Lower vehicle. (1) Shift transmission into Park. (2) Raise vehicle.
    • ZJ 46RH IN-VEHICLE SERVICE 21 - 207 Fig. 5 Shift Cable Attachment At Transmission Fig. 6 Shift And Park Interlock Cables ADJUSTMENT PROCEDUREPARK INTERLOCK CABLE ADJUSTMENT (1) Raise vehicle. (1) Shift transmission into Park. (2) Loosen band adjusting screw locknut. Then (2) Turn ignition switch to Accessory position. back locknut off 4-5 turns.CAUTION: Be sure the ignition switch is in the Ac- (3) Be sure adjusting screw turns freely in case.cessory position for cable adjustment. The cable Lubricate screw threads with Mopar spray lube, LPSand lever mechanism will not adjust correctly if the all purpose spray lube, or equivalent quality product.switch lock cylinder is in Park position. (4) Tighten band adjusting screw to 8 N⅐m (72 in. lbs.) torque with inch pound Torque Wrench (3) Remove shift lever bezel and console screws. C-3380-A, a 3-in. extension and 5/16 socket (Fig. 7).Raise bezel and console for access to cable. (4) Pull cable lock button up to release cable (Fig. CAUTION: If Adapter C-3705 is needed to reach the6). adjusting screw (Fig. 8), tighten the screw to only 5 (5) Pull cable forward. Then release cable and N⅐m (47-50 in. lbs.) torque.press cable lock button down until it snaps in place. (6) Check cable adjustment as follows: (5) Back off band adjusting screw 2-7/8 turns. (a) Place shift lever in Park. (6) Hold adjuster screw in position and tighten (b) Check shift handle release button and igni- locknut to 41 N⅐m (30 ft. lbs.) torque. tion lock cylinder operation. Release button should (7) Lower vehicle. be in released (out) position and ignition lock cylin- der should rotate freely from Off to Lock. REAR BAND ADJUSTMENT (c) Next, place shift lever in D or R position and The transmission oil pan must be removed for ac- check ignition lock cylinder operation again. Cylin- cess to the rear band adjusting screw. der should not rotate from Off to Lock position. (1) Raise vehicle. (d) Check shift lever operation. Shifting out of (2) Remove transmission oil pan and drain fluid. Park position should only be possible when ignition (3) Loosen band adjusting screw locknut 5-6 turns. lock cylinder is in Off, Run, or Start positions. Shift (4) Tighten adjusting screw to 8 N⅐m (72 in. lbs.) lever should be locked-in when lock cylinder is in torque (Fig. 9). Use inch-pound Torque Wrench Accessory and Lock positions. C-3380-A for adjustment. (5) Back off band adjusting screw two turns.FRONT BAND ADJUSTMENT (6) Hold adjusting screw in place and tighten lock- The front band adjusting screw is located on the nut to 34 N⅐m (25 ft. lbs.) torque.driver side of the transmission case above the man-ual valve and throttle valve levers.
    • 21 - 208 46RH IN-VEHICLE SERVICE ZJ Fig. 9 Rear Band Adjustment Screw Location (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. Fig. 7 Front Band Adjustment (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 INDEXING (1) Thoroughly clean adapter flange and adapter mounting surface in housing. Surfaces must be clean for proper adapter alignment and speedometer oper- ation. (2) Install new O-rings on speed sensor and speed- ometer adapter if necessary (Fig. 10). Fig. 8 Band Adjustment Adapter Tool Usage (3) Lubricate sensor and adapter O-rings with (7) Clean oil pan, pan magnet and gasket surface transmission fluid.of case. Also inspect and replace fluid filter if neces- (4) Install vehicle speed sensor in speedometersary. adapter. Tighten sensor attaching screw to 2-3 N⅐m (8) Position new gasket on oil pan and install pan (15-27 in. lbs.) torque.on transmission. Tighten pan bolts to 17 N⅐m (150 in. (5) Install speedometer pinion in adapter.lbs.) torque. (6) Count number of teeth on speedometer pinion. (9) Lower vehicle and refill the transmission with Do this before installing assembly in housing. ThenMopar ATF Plus, type 7176 fluid. lubricate pinion teeth with transmission fluid. (7) Note index numbers on adapter body (Fig. 11).SPEEDOMETER SERVICE These numbers will correspond to number of teeth on Rear axle gear ratio and tire size determine speed- pinion.ometer pinion requirements. If the pinion must be re- (8) Install speedometer assembly in housing.placed, refer to the parts catalogue information for (9) Rotate adapter until required range numbersthe correct part. are at 6 o-clock position. Be sure range index num- bers correspond to number of teeth on pinion gear.SPEEDOMETER ASSEMBLY REMOVAL (10) Install speedometer adapter clamp and retain- (1) Raise vehicle. ing screw. Tighten clamp screw to 10-12 N⅐m (90-110 (2) Disconnect wires from vehicle speed sensor. in. lbs.) torque. (3) Remove adapter clamp and screw (Fig. 10). (11) Connect wires to vehicle speed sensor. (4) Remove speed sensor and speedometer adapteras assembly.
    • ZJ 46RH IN-VEHICLE SERVICE 21 - 209 Fig. 10 Speedometer Components (12) Lower vehicle and top off transmission fluid mission case. Continuity should exist only whenlevel if necessary. transmission is in Park or Neutral. (3) Shift transmission into reverse and test conti- nuity at switch outer terminals. (a) Continuity should exist only when transmis- sion is in Reverse. (b) Continuity should not exist between outer terminals and case. PARK/NEUTRAL POSITION SWITCH REPLACEMENT (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 cen- tered in switch opening in case (Fig. 12). (4) Install new seal on switch and install switch inFig. 11 Location Of Index Numbers On Speedometer case. Tighten switch to 34 N⅐m (25 ft. lbs.) torque. Adapter (5) Connect switch wires, lower vehicle and top offPARK/NEUTRAL POSITION SWITCH transmission fluid level. The center terminal of the switch is the starter cir-cuit terminal. It provides the ground for the starter SLIP YOKE SEAL REPLACEMENT—2-WHEELsolenoid circuit through the selector lever in Park DRIVE MODELSand Neutral positions only. The outer terminals on (1) Raise vehicle.the switch are for the backup lamp circuit. (2) Mark propeller shaft U-joints for alignment ref- erence. Then disconnect and remove shaft.SWITCH TEST (3) Remove old seal from overdrive housing with (1) Verify that gearshift linkage is correctly ad- Remover Tool C-3985-B (Fig. 13), or hammer andjusted before testing. Switch will not operate prop- punch.erly if linkage adjustment is incorrect. (4) Position new seal in housing opening. Then tap (2) To test switch, remove wiring connector. Then seal into place with Installer Tool C-3995-A ortest continuity between center terminal and trans- C-3972-A (Fig. 14).
    • 21 - 210 46RH IN-VEHICLE SERVICE ZJ 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 valve body service procedures in the Transmis- sion 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 and screws • solenoid assembly, connecter seal and shoulder Fig. 12 Park/Neutral Position Switch Contacts screw (5) Smooth surface of propeller shaft slip yoke with • switch valve and spring400 grit paper if necessary. Clean yoke surface with • pressure adjusting screw bracketsolvent and wipe clean with shop cloth. • fluid temperature thermister (6) Lubricate slip yoke and new seal with liberal The remaining valve body components are servicedquantity of Mopar multi mileage grease or petroleum only as part of a complete valve body assembly.jelly. (7) Carefully guide propeller shaft slip yoke VALVE BODY REMOVALthrough seal, into housing and onto output shaft (1) Shift transmission into Neutral.splines. (2) Raise vehicle. (8) Align and connect propeller shaft U-joint to (3) Remove gearshift and throttle levers from shaftaxle yoke. Tighten clamp strap bolts to 19 N⅐m (170 of valve body manual lever.in. lbs.) torque. (4) Disconnect and remove neutral switch. (9) Lower vehicle. (5) Disconnect valve body overdrive and converter clutch solenoid wires at case connector (Fig. 15). Fig. 13 Removing Slip Yoke Seal Fig. 15 Transmission Wire Harness Identification (6) Position drain pan under transmission oil pan. (7) Remove transmission oil pan and gasket. (8) Remove fluid filter from valve body. (9) Push valve body solenoid wire connector out of case. Fig. 14 Installing Slip Yoke Seal (10) Remove valve body attaching bolts.
    • ZJ 46RH IN-VEHICLE SERVICE 21 - 211 (11) Lower valve body slightly and remove accumu- (8) Lubricate seal rings on solenoid case connectorlator piston and accumulator inner and outer with petroleum jelly.springs. (9) Position accumulator piston outer spring on (12) Push manual lever shaft and solenoid case valve body.connector out of transmission case. Lower valve body, (10) Raise valve body and work end of park lockrotate it away from case, pull park rod out of sprag rod into and through sprag. Use screwdriver to alignand remove valve body (Fig. 16). sprag if necessary. (11) Align accumulator springs, manual lever shaft and solenoid case connector. Then seat valve body on case and install one or two bolts to hold valve body in place. (12) Tighten valve body bolts alternately and evenly to 11 N⅐m (100 in. lbs.) torque. (13) Install new fluid filter on valve body. Tighten filter screws to 4 N⅐m (35 in. lbs.) torque. (14) Install new manual lever shaft seal in case if necessary. Use 15/16 deep well socket to seat seal (Fig. 18). Fig. 16 46RH Valve BodyVALVE BODY INSTALLATION (1) Verify that park/neutral position switch hasNOT been installed in case. Valve body cannot be in-stalled if switch is in place. (2) Check condition of seals on valve body solenoidcase connector. Replace seals if cut or worn. (3) Check condition of manual lever shaft seal (incase). Remove seal if lip is cut, or worn. However donot install new seal at this time. Fig. 18 Installing Manual Lever Shaft Seal (4) Check condition of seals on accumulator piston(Fig. 17). Install new piston seals if necessary. (15) Install and connect neutral switch in case. (16) Install throttle and gearshift levers on valve body manual lever shaft. (17) Check and adjust front and rear bands if nec- essary. (18) Connect valve body overdrive and converter clutch solenoid wires to case connector. (19) Install oil pan and new gasket. Tighten pan bolts to 17 N⅐m (13 ft. lbs.) torque. (20) Lower vehicle and fill transmission with Mo- par ATF Plus, type 7176 fluid. (21) Check and adjust gearshift and throttle valve cables if necessary. Fig. 17 Accumulator Piston And Springs (5) Install inner spring in accumulator piston. TRANSMISSION COOLER LINE AND FITTINGThen install piston and spring in bore. Petroleum SERVICEjelly can be used to hold piston in bore. The transmission cooler lines are attached with (6) Place valve body manual lever in low (1 posi- quick connect fittings. Two types of fitting will betion) so ball on park lock rod can be installed in used.sprag. Some early production models will have the type 2 (7) Lubricate shaft of manual lever with petroleum fitting used in prior years. This fitting requires a re-jelly. This will ease inserting shaft through seal (in lease tool to disconnect the cooler line from the fit-case). ting (Fig. 19).
    • 21 - 212 46RH IN-VEHICLE SERVICE ZJ Later production models will have a new style fit-ting that does not require any type of release tool.This fitting has a plastic insert with built-in releasetabs (Fig. 20).Cooler Line And Fitting Service The cooler lines and fittings are NOT serviceable.Damaged fittings or cooler lines are to be replaced asassemblies. Fittings swedged into cooler line hoses (Fig. 21) areserviced only as part of the entire cooler line. Fig. 21 Cooler Line Fitting Placement Fig. 19 Disconnecting Cooler Line With Release Tool (Type 2 fitting) Fig. 20 New Style Fitting With Release Tabs On Insert Fig. 22 Disconnecting New Style Fitting FromDISCONNECTING COOLER LINES WITH NEW Cooler LineSTYLE FITTING The new style fitting does not require any kind ofrelease tool. The fittings have built-in release tabs.The tabs only require finger pressure to compressthem and release the cooler line (Fig. 22). Note that the fitting insert remains on the coolerline after release (Fig. 22). It is not necessary toremove the insert from the cooler line unlessthe insert is damaged. If the fitting insert is damaged, simply spread therelease tabs far enough to release the insert andslide it off the cooler line (Fig. 23).DISCONNECTING COOLER LINES WITH TYPE Fig. 23 Removing Fitting Insert From Cooler Line2 FITTING Mopar spray type carburetor or brake cleaner. Plastic (1) If fitting and cooler line are encrusted with release tool will not fit into retainer clip if fitting isdirt, mud, or grease, clean fitting and cooler line with full of foreign material.
    • ZJ 46RH IN-VEHICLE SERVICE 21 - 213 Fig. 24 Transmission Auxiliary Cooler Mounting (2) Slide small plastic release tool into fitting until lower tank. The valve prevents fluid drainback whentool bottoms against cooler line flange (Fig. 19). the vehicle is parked for lengthy periods. The valve (3) Push and turn release tool to spread retainer check ball is spring loaded and has an opening pres-clip and pull cooler line out of fitting (Fig. 19). sure of approximately 2 psi. (4) Cover open ends of cooler lines and fittings to The valve is serviced as an assembly; it is not re-prevent dirt entry. pairable. Do not clean the valve if restricted, or con- (5) Inspect condition of fitting. Replace transmis- taminated by sludge, or debris. If the valve fails, or ifsion fitting as an assembly if fitting body or retainer a transmission malfunction occurs that generatesclip is damaged. Replace cooler line as assembly, if sludge and/or clutch particles and metal shavings,fitting swedged into cooler line hose, is damaged. the valve must be replaced. The valve must be removed whenever the coolerCONNECTING COOLER LINES (ALL TYPES) and lines are reverse flushed. The valve can be flow (1) If transmission or radiator fittings require re- tested when necessary. The procedure is exactly theplacement, apply Mopar Lock N’ Seal, or Loctite 242to fitting threads before installation. same as for flow testing a cooler. (2) Wipe off cooler line and fitting with clean, dry If the valve is restricted, installed backwards, or incloth. the wrong line, it will cause an overheat condition (3) Insert cooler line into fitting. Then push line and possible transmission failure.inward until retainer clip secures line. A snap orclick sound will be heard when the retainer clip seats CAUTION: The drainback valve is a one-way valve.behind the cooler line flange. As such, it must be properly oriented in terms of (4) Pull outward on cooler lines to verify they flow direction. In addition, the valve must only beare properly secured. installed in the pressure line. Otherwise flow will be blocked causing overheat and eventual transmis-CAUTION: It is extremely important that cooler line sion failure.seating be checked as described in step (4). If thelines are not fully secured, normal fluid pressurecould unseat the lines resulting in fluid loss and TRANSMISSION COOLER FLOW TESTINGtransmission damage. The transmission main and auxiliary coolers, plus the drainback valve, should be flow tested whenever fluid overheating is noted.CONVERTER DRAINBACK CHECK VALVE SERVICE Restricted flow caused by contamination, or a The converter drainback check valve is located in cooler malfunction, reduces lubrication fluid flowthe cooler outlet (pressure) line near the radiator throughout the transmission. This can result in fluid
    • 21 - 214 46RH IN-VEHICLE SERVICE ZJoverheating, fluid breakdown, bushing wear, shiftproblems and component failure. Normal color of transmission fluid varies frombright red, to light pink. Fluid overheating is indi-cated when fluid color ranges from orange-brown toblack, and the fluid smells burned, or containssludge.CAUTION: If a transmission malfunction contami-nates the fluid with clutch disc and metal particles,the cooler and lines must be reverse flushed thor-oughly. Flushing will prevent sludge and particlesfrom flowing back into the transmission and con-verter after repair. Cooler flow is tested by measuring the amount offluid pumped through the cooler in a specified timeby the transmission oil pump. The same flow testprocedure is used for the drainback valve, maincooler, and auxiliary cooler.Cooler And Drainback Valve Flow Test Procedure (1) Test flow through drainback valve as follows: (a) Add extra quart of ATF Plus to transmission. (b) Disconnect pressure line at radiator fitting, or at drainback valve and position hose or valve end in one quart test container. Fig. 25 Transmission Cooler Line Identification (c) Shift transmission into neutral, run engine at idle speed for 20 seconds, and note flow from valve. (2) Position drain pan under cooler pressure line to Use stopwatch to check test time. catch material flushed through cooler and lines. (d) Replace drainback valve if flow is less than (3) Reverse flush cooler using hand operated suc- one quart in 20 seconds, is intermittent, or does tion gun filled with mineral spirits. Insert gun nozzle not flow at all. (or hose) into cooler return line. Then force mineral (e) Connect pressure hose to radiator fitting and spirits into line and through cooler. proceed to cooler flow test. (4) Continue reverse flushing until fluid exiting (2) Test flow through main cooler as follows: cooler pressure line is clear and free from debris. Re- (a) Disconnect cooler return (rear) line at trans- place cooler if fluid cannot be pumped through mission and place it in one quart test container. it. (b) Add extra quart of fluid to transmission. (5) Clear flushing materials from cooler and lines (c) Shift transmission into neutral, run engine at with short pulses of compressed air. Insert air gun idle speed for 20 seconds, and note flow from valve. nozzle into cooler return line and continue short air Use stopwatch to check test time. pulses until all fluid is cleared from cooler and lines. (d) Replace cooler if fluid flow is less than one (6) Pump one quart of fresh automatic transmis- quart in 20 seconds, is intermittent, or does not sion fluid through cooler and lines before reconnect- flow at all. ing lines. (3) If vehicle is equipped with auxiliary cooler, TRANSMISSION COOLER REPLACEMENTtest cooler flow as described in step (2). Main Cooler ReplacementTRANSMISSION COOLER REVERSE FLUSHING The main transmission cooler is located in the ra- The flushing procedure applies to standard and diator lower tank. The cooler is not a serviceableauxiliary coolers alike. Although pressure equipment component. If the cooler is damaged in any way, theis preferred, reverse flushing can be performed with radiator will have to be replaced.hand operated equipment as follows. (1) Identify and disconnect cooler pressure and re- Auxiliary Cooler Replacementturn lines at transmission. Rear line is return line (1) Remove grille and air conditioning condenser iffrom cooler. Front line is pressure line to cooler. equipped.
    • ZJ 46RH IN-VEHICLE SERVICE 21 - 215 (2) Remove screws and U-nuts securing cooler to (12) If air conditioning condenser lines were dis-radiator and support (Fig. 24). connected during service, evacuate and recharge sys- (3) Tag cooler hoses for installation reference (Fig. tem.25). (4) Position drain pan under cooler hoses. ALUMINUM THREAD REPAIR (5) Loosen cooler connecting hose clamps and dis- Damaged or worn threads in the aluminum trans-connect hoses. mission case and in the valve body can be repaired (6) Remove auxiliary cooler. with Heli-Coil or similar quality thread inserts. Es- (7) Connect cooler hoses. sentially, repair consists of drilling out the worn or (8) Position cooler on radiator and install cooler at- damaged threads, tapping the hole with a special taptaching U-nuts and screws. and installing the thread insert into the tapped hole. (9) Tighten cooler hose clamps securely. This procedure returns the hole threads to original (10) Install grille and and air conditioning con- size. Heli-Coil, or equivalent, tools and inserts aredenser. readily available from most automotive parts suppli- (11) Check and adjust transmission fluid level. ers. Stainless steel inserts are recommended.
    • 21 - 216 46RH TRANSMISSION/OVERDRIVE REMOVAL—INSTALLATION ZJ 46RH TRANSMISSION/OVERDRIVE REMOVAL—INSTALLATION INDEX page pageGeneral Information . . . . . . .. . . . . . . . . . . . . . . . 216 Torque Converter and Drive Plate Service . . . . . . 217Oil Pump Seal Replacement . . . . . . . . . . . . . . . . 217 Transmission and Converter Installation . . . . . . . . 217Overdrive Unit Installation . .. . . . . . . . . . . . . . . . 220 Transmission and Converter Removal . . . . . . . . . 216Overdrive Unit Removal . . .. . . . . . . . . . . . . . . . 220GENERAL INFORMATION (8) Disconnect transfer case shift linkage at range The overdrive unit can be removed for service with- lever. Then remove linkage bracket bolts and removeout having to remove the entire transmission assem- linkage and bracket from transfer case. Move linkagebly. However if the transmission, torque converter, aside for clearance.converter driveplate, or oil pump requires service, (9) Remove nuts attaching transfer case to over-the complete transmission assembly must be re- drive unit gear case.moved for access to these components. (10) Remove transfer case. Support transfer case If only the overdrive unit must be removed, refer to with transmission jack. Secure transfer case to jackthe Overdrive Unit Removal/Installation procedures. with safety chains. Then move transfer case rear-If the complete transmission assembly must be re- ward and off transmission.moved, refer to the Transmission Removal/Installa- (11) Remove transfer case from transmission jacktion procedures. and place transfer case on bench. (12) Support transmission with transmission jack.TRANSMISSION AND CONVERTER REMOVAL (13) Remove nuts and bolts attaching transmission (1) Raise vehicle on hoist. mount to crossmember. (2) If transmission will be disassembled after re- (14) Remove bolts and nuts attaching crossmembermoval, remove transmission oil pan, drain fluid and to frame rails.reinstall oil pan. (15) Rotate crossmember diagonally to clear frame (3) Remove skid plate, if equipped. rails and remove crossmember. (4) Mark front and rear propeller shafts and (16) Disconnect exhaust pipes at manifold and atU-joints for alignment reference (Fig. 1). converter and/or muffler connections as needed. Then (5) Disconnect and remove both propeller shafts. remove Y-pipe from vehicle and move remaining pipes aside for working clearance. (17) Disconnect and remove crankshaft position sensor. Retain sensor attaching bolts. CAUTION: The crankshaft position sensor can be damaged if the transmission is removed (or in- stalled) with the sensor still bolted to the converter housing. To avoid damage, remove the sensor be- fore transmission removal. (18) Disconnect transmission shift cable at shift le- ver on transmission. (19) Disconnect throttle valve cable at transmis- sion and cable mounting bracket. (20) Remove brackets that attach transmission to engine block, if equipped. (21) Remove dust shield cover from front side of Fig. 1 Marking Propeller Shaft And Yoke For transmission converter housing. Alignment Reference (22) Remove starter motor bolts. Pull starter rear- (6) Disconnect vehicle speed sensor wires. ward until clear of housing and position it out of way (7) Disconnect vacuum vent hose at transfer case. on nearby component. Starter does not have to be re- moved from vehicle nor does cable have to be discon- nected.
    • ZJ 46RH TRANSMISSION/OVERDRIVE REMOVAL—INSTALLATION 21 - 217 (23) Remove bolts attaching torque converter todrive plate. (24) Disconnect cooler lines at transmission quickdisconnect fittings. Refer to In-Vehicle Service sectionfor procedures. (25) Disconnect solenoid and park/neutral positionswitch wires at transmission. (26) Remove transmission fill tube and dipstick. (27) Lower transmission for access to converterhousing upper bolts. (28) Remove bolts attaching transmission con-verter housing to engine. Note that some bolts maybe accessible only from front (engine) side of housing. (29) Move transmission rearward until clear of en-gine block dowels. (30) Secure torque converter in housing with smallC-clamp. Fig. 3 Oil Pump Seal Removal (31) Lower transmission and remove it from undervehicle. (32) Remove C-clamp and remove converter fromtransmission. Place converter on workbench for in-spection or reassembly. Cover converter hub withclean, lint free cloth. (33) Oil pump, converter and driveplate can nowbe serviced if necessary. Refer to information in thissection.OIL PUMP SEAL REPLACEMENT The pump oil seal can be replaced without remov-ing the pump and reaction shaft support assemblyfrom the transmission case.Seal Removal Remove the seal with Special Tool C-3861 (Fig. 3).To use the remover tool, First start the tool into the Fig. 4 Oil Pump Seal Installationseal by hand. Next, thread the tool into the seal as particles. Flushing will not remove these con-far as it will go. Use a wrench on the tool hex to turn taminants.the tool. Continue tightening until all the tool Inspect the driveplate. Replace the driveplate if thethreads firmly grip the metal part of the seal. Then hub is cracked, or the plate is bent or damaged intighten the tool puller screw to withdraw the seal any way. Use new bolts to secure the driveplate tofrom the pump body. the crankshaft and use Mopar Lock N’ Seal, or Loc-Seal Installation tite 242 on the bolt threads before installation. Use Installer Tool C-3860-A (Fig. 4). To use thetool, place the seal in the pump opening with the seal TRANSMISSION AND CONVERTER INSTALLATIONlip facing inward. Then tap the seal into place with CAUTION: The transmission cooler and lines mustthe installer tool. Tool Handle C-4171 may be usedwith either installer tool if desired. be flushed if repair was to correct a problem that generated sludge, metal particles, or clutch frictionTORQUE CONVERTER AND DRIVE PLATE SERVICE material. The converter and drainback valve should After the transmission has been removed, the drive also be replaced when contaminated. The transmis-plate and torque converter can be replaced or re- sion, fluid and converter will all be contaminatedmoved for service access. again if residue/debris is not flushed from the The torque converter is not a serviceable part. If cooler and lines beforehand.the converter is contaminated by a transmission mal-function, or damaged in any way, it must be replaced (1) Mount transmission on jack. Secure transmis-as an assembly. Do not attempt to flush a con- sion to jack with safety chains.verter contaminated by metal or clutch facing
    • 21 - 218 46RH TRANSMISSION/OVERDRIVE REMOVAL—INSTALLATION ZJ (2) Check torque converter hub for sharp edgesburrs, scratches, or nicks. Polish hub with crocuscloth or 400 grit paper if necessary. Hub must besmooth to avoid damaging pump seal. (3) Lubricate converter pilot hub, drive hub andpump seal lip with Mopar ATF Plus or Dexron IItransmission fluid. (4) Align and install converter in oil pump. Verifythat converter is fully seated. Use straight edge andsteel ruler to check seating (Fig. 5). Surface of con-verter lugs should be 12.7 mm (1/2 in.) to rear ofstraight edge when converter is fully seated. (5) Temporarily secure converter with C-clamp at-tached to housing or with metal strap attachedacross converter housing. (6) Check condition of converter driveplate. Re-place driveplate if cracked, distorted or damaged. (7) Verify that transmission dowel pins are seatedin engine block and protrude far enough to heldtransmission in alignment. Fig. 5 Checking Torque Converter Seating (8) Move transmission under vehicle and positionit at rear of engine. Remove C-clamp or strap used to (10) Move transmission forward until seated on en-secure converter in housing. gine block dowels. Then install one or two transmis- (9) Align transmission with engine dowels and sion attaching bolts to hold transmission in placealign converter with driveplate. (Fig. 6). Fig. 6 Transmission And Fill Tube Mounting
    • ZJ 46RH TRANSMISSION/OVERDRIVE REMOVAL—INSTALLATION 21 - 219CAUTION: It is essential that correct length bolts beused to attach the converter to the driveplate. Boltsthat are too long will damage the modulated clutchsurfaces in the converter. If new bolts are required,use the bolts specified in this procedure and in theparts catalogue only. (11) Verify converter bolt length. Bolt measure-ment is from bottom (underside) of bolt head to endof bolt threads.• 9.5 in., 3-lug converter bolts are 11.7 mm (0.46 in.)long• 9.5 in., 4-lug converter bolts are 13.2 mm (0.52 in.)long• 10.0 in., 4-lug converter bolts are 13.2 mm (0.52in.) long• 10.75 in., 4-lug converter bolts are 11.2 mm (0.44in.) long (12) Install torque converter bolts. Tighten bolts tofollowing torque:• 54 N⅐m (40 ft. lbs.) with 9.5 in., 3-lug converter• 74 N⅐m (55 ft. lbs.) with 9.5 in., 4-lug converter• 74 N⅐m (55 ft. lbs.) with 10.0 in., 4-lug converter• 31 N⅐m (270 in. lbs.) with 10.75 in., 4-lug converter (13) Install and tighten remaining transmission at-taching bolts. (14) Install dust cover on transmission converterhousing. Two small vise grip pliers van be used tohold and align cover during installation. Fig. 7 Transmission Rear Mount Components (15) Install starter motor. (16) Install strut brackets that secure transmissionto engine block and front axle. (17) Install and connect crankshaft position sensor.Be sure sensor grommet is securely in place. (18) Install transmission fill tube. Install newO-ring seal on tube before installation (Fig. 6). (19) Secure wire harnesses in clips on transmissionand transfer case. (20) Connect exhaust Y-pipe to engine exhaustmanifolds. (21) Install shift and throttle valve cables in brack-ets. (22) Connect shift and throttle cables to transmis-sion levers. (23) Connect solenoid and park/neutral positionswitch wires. Fig. 8 Transfer Case Mounting (24) Install crossmember on frame rails. Placecrossmember at 45° angle to rails. Insert crossmem- (29) Install and tighten transfer case attachingber between rails and rotate crossmember into place. nuts to 47 N⅐m (35 ft. lbs.) torque. (25) Install bolts/nuts attaching transmission to (30) Install damper on transfer case rear retainerrear mount (Fig. 7). if equipped. Tighten damper nuts to 54 N⅐m (40 ft. (26) Install bolts/nuts attaching crossmember to lbs.) torque.frame rails. (31) Install and connect transfer case shift linkage. (27) Remove transmission jack. (32) Connect transmission cooler lines to quick dis- (28) Install transfer case (Fig. 8). Align and posi- connect fittings. Refer to In-Vehicle Service sectiontion transfer case with transmission jack or with aid for procedures.of helper. Tilt case upward and work into position ontransmission mounting studs.
    • 21 - 220 46RH TRANSMISSION/OVERDRIVE REMOVAL—INSTALLATION ZJCAUTION: Be sure the cooler lines are fully secured (15) Rotate crossmember diagonally to clear frameby the fitting retainers. Otherwise, normal fluid rails and remove crossmember.pressure will force the cooler line out of the fitting (16) Support overdrive unit with transmission jack.causing fluid loss and transmission damage. (17) Remove bolts attaching overdrive unit to transmission (Fig. 9). (33) Connect vehicle speed sensor wires. If vehicleis also equipped with speedometer cable, connect ca- CAUTION: The overdrive unit must be fully sup-ble to sensor. ported during removal. This is necessary to prevent (34) Align and install remaining exhaust compo- damaging the intermediate shaft. Do not allow thenents. Tighten all clamp and bracket bolts and nuts shaft to support the entire weight of the overdrivesecurely. Be sure exhaust components are clear of all unit.chassis and driveline components. (35) Align and install propeller shaft(s). Tighten U- (18) Carefully slide overdrive unit off intermediatejoint clamp bolts to 19 N⅐m (170 in. lbs.) torque. shaft. Do not tilt overdrive unit during removal. (36) Verify that all linkage components, hoses and Keep it as level as possible.electrical wires have been connected. (a) If overdrive unit does not require service, im- (37) Check transfer case fluid level. Add Mopar mediately insert Alignment Tool 6227-2 inDexron II, or ATF Plus if necessary. Correct level is splines of planetary gear and overrunningto edge of fill plug hole. Be sure transfer case is level clutch (Fig. 10). If misalignment occurs, over-before checking or adding fluid. drive unit will have to be disassembled in or- (38) Install transfer case skid plate, if equipped. der to realign splines. (39) Lower vehicle. (b) If overdrive unit requires service, refer to (40) Refill transmission with Mopar ATF Plus, type7176 fluid. Overdrive Unit Overhaul procedures. (41) Check and adjust transmission and transfer (19) Remove and retain bearing and select fitcase shift linkage if necessary. spacer. These parts may remain on overdrive piston, (42) Check and adjust transmission throttle valve rear of transmission case, sliding hub, or intermedi-cable if necessary. ate shaft during removal. (20) Place several clean shop towels on a bench.OVERDRIVE UNIT REMOVAL Then position unit on towels to absorb spilled fluid. (1) Disconnect battery negative cable. (21) Position overdrive unit over drain pan and tilt (2) Raise vehicle on hoist. unit to drain residual fluid from case. Examine fluid (3) Remove transfer case skid plate, if equipped. for clutch material or metal fragments. If fluid con- (4) Mark front and rear propeller shafts and tains these items, overhaul will be necessary.U-joints for alignment reference (Fig. 9). (5) Disconnect and remove both propeller shafts. (6) Disconnect vehicle speed sensor wires. (7) Disconnect vacuum switch hoses at transfercase, if equipped. (8) Disconnect transfer case shift linkage at trans-fer case range lever. Then remove linkage bracketbolts and remove linkage and bracket from transfercase. Move linkage aside for clearance. (9) Remove nuts attaching transfer case to over-drive unit. (10) Remove transfer case. Support transfer casewith transmission jack (secure transfer case to jackwith safety chains). Then move transfer case rear-ward and off overdrive case. (11) Remove transfer case from jack and position iton bench. Fig. 9 Removing/Installing Overdrive Unit Attaching (12) Support transmission with adjustable jack Boltsstand. Position wood block between jack and trans-mission case. OVERDRIVE UNIT INSTALLATION (13) Remove nuts and bolts attaching transmission (1) Be sure Alignment Tool 6227-2 is still fullymount to center crossmember. seated in splines of overdrive planetary gear and (14) Remove nuts and bolts attaching crossmemberto frame rails.
    • ZJ 46RH TRANSMISSION/OVERDRIVE REMOVAL—INSTALLATION 21 - 221 Fig. 12 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 lo-Fig. 10 Overdrive Spline Alignment Tool Installation cating lugs are aligned in piston retainer.overrunning clutch. If misalignment occurs, overdrive (8) Install thrust bearing in overdrive clutch hub.will have to be disassembled in order to realign Use liberal quantity of petroleum jelly to hold bear-splines. ing in position. (2) If original case gasket is in good condition, pro-ceed to step (6). If overdrive piston retainer was not CAUTION: Be sure the shoulder on the inside diam-removed during service and original case gasket is eter of the bearing is facing forward.not reusable, prepare new gasket as described in (9) Install thrust plate in overdrive piston hubsteps (3) through (5). (Fig. 13). Use liberal amount of petroleum jelly to (3) Cut out old case gasket around piston retainer hold thrust plate in position.with razor knife. (4) Use old gasket as template and trim new gas-ket to fit (Fig. 11). Fig. 13 Installing Overdrive Piston Thrust Plate (10) Verify that splines in overdrive planetary gear Fig. 11 Trimming Replacement Overdrive Case and overrunning clutch hub are aligned with Tool Gasket 6227-2. Overdrive unit cannot be fully installed if splines have rotated out of alignment. If mis- (5) Position new gasket over piston retainer and on aligned has occurred, overdrive will have to betransmission case. Use petroleum jelly to hold gasket disassembled in order to realign splines.in place if necessary. Do not use any type of (11) Install overdrive unit as follows:sealer to secure gasket. Use petroleum jelly (a) Raise overdrive unit and carefully slide itonly. straight onto intermediate shaft. Avoid tilting (6) Install selective spacer on intermediate shaft, if overdrive unit during installation as plane-removed. Spacer goes in groove just rearward of tary gear and overrunning clutch splinesshaft rear splines (Fig. 12). could rotate out of alignment. If misalignment
    • 21 - 222 46RH TRANSMISSION/OVERDRIVE REMOVAL—INSTALLATION ZJ occurs, overdrive will have to be disassem- (15) Connect transmission and transfer case shift bled in order to realign splines. linkage. (b) Align and insert park rod into park pawl re- (16) Install crossmember and rear mount. action plug. (17) Connect all necessary electrical wires. (c) Align governor tubes in boss on overdrive pis- (18) Align and connect propeller shafts. Tighten U- ton retainer. joint clamp bolts to 19 N⅐m (170 in. lbs.) torque. (d) Work overdrive unit forward on intermediate (19) Check and adjust fluid level in transfer case. shaft until seated against transmission case. If unit Use Mopar ATF Plus, or Dexron II to top off fluid will not seat fully, turn output shaft slightly with level if necessary. socket to align intermediate shaft and overdrive (20) Install skid plate, if equipped. splines. (21) Check and adjust transmission and transfer (12) Apply Mopar Lock N’ Seal or Loctite 242 to case shift linkage if necessary.threads of overdrive attaching bolts. (22) Lower vehicle. (13) Install and tighten overdrive unit attaching (23) Check and adjust transmission fluid level. Usebolts to 34 N⅐m (25 ft. lbs.). (14) Install transfer case. Tighten attaching nuts Mopar ATF Plus, type 7176 fluid.to 41 N⅐m (30 ft. lbs.) torque.
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 223 46RH TRANSMISSION OVERHAUL INDEX page pageAccumulator Overhaul . . . . . . . . . . . . . . . . . . . . . 234 Planetary Geartrain Overhaul . . . . . . . . . . .. . . . 242Front Clutch Overhaul . . . . . . . . . . . . . . . . . . . . . 238 Rear Clutch Overhaul . . . . . . . . . . . . . . . . .. . . . 240Front Servo and Band Overhaul . . . . . . . . . . . . . 234 Rear Servo Overhaul . . . . . . . . . . . . . . . . .. . . . 234Low-Reverse Drum and Rear Band Service . . . . . 231 Transmission Assembly . . . . . . . . . . . . . . . .. . . . 260Oil Pump and Reaction Shaft Support Overhaul . . 235 Transmission Case Cleaning and Inspection . . . . 230Overdrive Piston and Retainer Service . . . . . . . . . 231 Transmission Disassembly . . . . . . . . . . . . .. . . . 223Overhaul Service Information . . . . . . . . . . . . . . . . 230 Valve Body Cleaning and Inspection . . . . . .. . . . 254Overrunning Clutch Overhaul . . . . . . . . . . . . . . . . 231 Valve Body Service and Adjustment . . . . . . .. . . . 247TRANSMISSION DISASSEMBLY (1) Remove torque converter, if not previously re-moved. (2) Clean transmission exterior with steam gun orsolvent. Wear safety goggles while cleaning transmis-sion. (3) Remove shift and throttle levers from shaft ofvalve body manual lever. (4) Remove bolts attaching overdrive unit to trans-mission case (Fig. 1). Note bolt locations as somebolts are different lengths. Fig. 2 Loosening Overdrive (b) If overdrive unit does requires service, refer to Overdrive unit Overhaul section. Fig. 1 Overdrive Attaching Bolt Removal (5) Loosen overdrive unit. Use pry tool to startoverdrive unit off intermediate shaft and transmis-sion case. Position pry tool between flange on over-drive case and transmission rear servo boss (Fig. 2). (6) Work overdrive unit rearward and off transmis-sion intermediate shaft (Fig. 3). (a) If overdrive unit does not require service, in- Fig. 3 Overdrive Removal sert Alignment Tool 6227-2 in overdrive unit over- (7) Remove thrust plate from overdrive piston (Fig. running clutch and planetary gear to maintain 5). spline alignment (Fig. 4). If clutch and gear (8) Remove overdrive piston from retainer (Fig. 6). splines rotate out of alignment, overdrive (9) Remove overdrive piston thrust bearing (Fig. unit will have to be disassembled in order to 7). realign splines. (10) Mount transmission unit on Repair Stand
    • 21 - 224 46RH TRANSMISSION OVERHAUL ZJFig. 4 Overdrive Spline Alignment Tool Installation Fig. 7 Overdrive Piston Thrust Bearing Removal C-3750-B, or support transmission with wood blocks. (11) Remove pump oil seal with Special Tool C-3861 (Fig. 8). Be sure to tighten tool threads com- pletely into seal before using puller bolt to withdraw seal. Fig. 5 Overdrive Piston Thrust Plate Removal Fig. 8 Oil Pump Seal Removal (12) Remove oil pan bolts and remove pan (Fig. 9) and gasket (Fig. 10). Oil pan magnet can be removed or left in pan as needed (Fig. 11). Exercise care when removing pan to avoid distorting or bending pan flange. (13) Remove park/neutral position switch (Fig. 12). If switch gasket is in good condition, retain gasket and keep it with switch. (14) Remove fluid filter attaching screws and re- move filter (Fig. 13). Keep filter screws separate. They are longer than valve body screws. (15) Remove hex head valve body attaching bolts (Fig. 14). A total of 10 hex head bolts are used to se- cure valve body to case. Note bolt locations as bolts are different lengths. (16) Lift valve body upward. Push solenoid connec- Fig. 6 Overdrive Piston Removal tor and manual lever shaft out of case. Then raise
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 225 Fig. 12 Park/Neutral Position Switch Removal Fig. 9 Oil Pan Removal/Installation Fig. 13 Fluid Filter Removal/Installation Fig. 10 Pan Gasket Removal/Installation Fig. 11 Oil Pan Magnet Locationvalve body, guide park rod out of case and remove Fig. 14 Valve Body Bolt Locationsvalve body (Fig. 15). Do not use boost valve tube (19) Remove oil pump and reaction shaft supportto lift valve body. Set valve body aside for disas- assembly as follows:sembly, cleaning and inspection. (a) Tighten front band adjusting screw until (17) Remove accumulator outer spring, piston, and band is tight around front clutch retainer (Fig. 18).inner spring (Fig. 16). Note position of piston and This will prevent retainer from coming out withsprings for assembly reference. Remove and discard pump and possibly damaging clutch or pump com-piston seals if worn or cut. ponents. (18) Remove front band lever pin access plug (Fig. (b) Remove oil pump bolts.17). Use square end of 1/4 in. drive extension to re-move plug as shown.
    • 21 - 226 46RH TRANSMISSION OVERHAUL ZJ Fig. 18 Tightening Front Band To Hold Front Clutch In Place Fig. 15 Valve Body Removal Fig. 19 Positioning Oil Pump Remover Tools (d) Remove oil pump and reaction shaft support by bumping slide hammers outward alternately to pull pump from case (Fig. 20). Fig. 16 Accumulator Component RemovalFig. 17 Front Band Lever Pin Access Plug Removal/ Installation Fig. 20 Oil Pump Removal (c) Thread Slide Hammer Tools C-3752 into threaded holes in flange of oil pump housing (Fig. 19).
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 227 (20) Remove oil pump gasket (Fig. 21). Note gasketposition in case for assembly reference. Fig. 23 Front Band Removal Fig. 21 Oil Pump Gasket Removal (21) Loosen front band adjusting screw until bandis completely loose. (22) Remove front band strut and anchor (Fig. 22). (23) Squeeze front band together slightly and slideband over front clutch retainer and out of case (Fig.23). Fig. 24 Front/Rear Clutch Assembly Removal (26) Remove intermediate shaft thrust washer. Tri- angular shaped washer will either be on shaft pilot hub or in rear clutch retainer (Fig. 26). (27) Remove thrust plate from intermediate shaft hub (Fig. 27). (28) Remove intermediate shaft-planetary geartrain assembly (Fig. 28). Set assembly aside for Fig. 22 Front Band Linkage disassembly and inspection later in procedure. (24) Remove front and rear clutch assemblies as a (29) Loosen rear band locknut and loosen adjustingunit (Fig. 24). Set assemblies aside for disassembly screw 3-4 turns.and inspection after removal. (30) Remove snap ring that retains low-reverse (25) Remove front band reaction pin and lever. drum and thrust washer on overdrive piston retainerStart pin through lever and out of case bore with hub (Fig. 29).drift or punch. Then use pencil magnet to withdraw (31) Slide low-reverse drum and thrust washer offpin completely (Fig. 25). piston retainer hub and out of rear band (Fig. 30).
    • 21 - 228 46RH TRANSMISSION OVERHAUL ZJ Fig. 25 Front Band Lever And Pin Removal Fig. 28 Intermediate Shaft And Planetary Geartrain Assembly Removal/InstallationFig. 26 Intermediate Shaft Thrust Washer Removal Fig. 29 Low-Reverse Drum Snap Ring Removal Fig. 27 Intermediate Shaft Thrust Plate Removal Fig. 30 Low-Reverse Drum And Thrust Washer
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 229 (32) Note that overrunning clutch race will remainon splines of low-reverse drum after removal (Fig.31). The race is a permanent press fit on thehub splines. Do not attempt to remove the race. (33) Remove overrunning clutch assembly (Fig. Fig. 33 Removing Rear Band Levers And Pins Fig. 31 Overrunning Clutch Race Position On Low-Reverse Drum32). Assembly can be removed without displacingrollers and springs if care is exercised. Note positionof rollers and springs for assembly reference. Fig. 34 Removing Rear Band And Link (37) Compress front servo rod guide with large C- clamp and Tool C-4470, or Compressor Tool C-3422-B (Fig. 35). Compress guide only enough to permit snap ring removal (about 1/8 in.). (38) Remove servo piston snap ring (Fig. 35). Un- seat one end of ring. Then carefully work removal tool around back of ring until free of ring groove. Ex- ercise caution when removing snap ring. Servo Fig. 32 Removing Overrunning Clutch Assembly bore can be scratched or nicked if care is not (34) Remove rear band adjusting lever, reaction le- exercised.ver and pin (Fig. 33). (39) Remove tools and remove servo piston and (35) Remove strut from rear band. Keep strut with spring.levers and pin for cleaning, inspection and assembly (40) Compress rear servo piston with C-clamp andreference. Tool C-4470, or Valve Spring Compressor C-3422-B (36) Remove rear band and link (Fig. 34). (Fig. 36). Compress servo spring retainer only enough to permit snap ring removal.
    • 21 - 230 46RH TRANSMISSION OVERHAUL ZJ 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 Sets C-3887-B, or C-3887-J. Pre-sized service bushings are available for replace- ment purposes. Only the sun gear bushings are not serviced. Replace the sun gear and bushings as an assembly if damaged. Heli-Coil inserts are recommended for repairing damaged, stripped or worn threads in aluminum parts. These inserts are available from most automo- tive jobbers. Stainless steel inserts are preferred. The use of crocus cloth is permissible where neces- sary, providing it is used carefully. When used on valves, use extreme care to avoid rounding off sharpFig. 35 Removing Front Servo Retaining Snap Ring edges. Sharp edges are vital as they prevent foreign matter from getting between the valve and valve (41) Remove servo piston snap ring (Fig. 36). Start bore.one end of ring out of bore. Then carefully work re- Do not reuse oil seals, gaskets, seal rings, ormoval tool around back of snap ring until free of ring O-rings during overhaul. Replace these parts as agroove. Exercise caution when removing snap matter of course. Also do not reuse snap rings or E-ring. Servo bore can be scratched or nicked if clips that are bent or distorted. Replace these partscare is not exercised. as well. (42) Remove tools and remove rear servo retainer, Lubricate transmission parts with Mopar ATFspring and piston assembly. Plus, Type 7176 transmission fluid during assembly. Use Mopar Door Ease, or Ru-Glyde to lubricate pis- ton seals and O-rings. Use petroleum jelly on thrust washers and to hold parts in place during reassem- bly. TRANSMISSION CASE CLEANING AND INSPECTION Clean the case in a solvent tank. Flush the case bores and fluid passages thoroughly with solvent. Dry the case and all fluid passages with compressed air. Be sure all solvent is removed from the case and that all fluid passages are 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 components and will circulate throughout theFig. 36 Removing Rear Servo Retaining Snap Ring transmission after assembly. A sufficient quan- (43) Remove overdrive piston retainer bolts and re- tity of lint can block fluid passages and inter-move retainer from case (Fig. 37). fere with valve body operation. (44) Remove gasket from rear of case after remov- Inspect the case for cracks, porous spots, worn servo bores, or damaged threads. Damaged threadsing piston retainer. can be repaired with Helicoil thread inserts. How- ever, the case will have to be replaced if it exhibitsOVERHAUL SERVICE INFORMATION damage or wear. Inspect all the transmission bushings during over- Lubricate the front band adjusting screw and lock-haul. Bushing condition is important as worn, scored nut with petroleum jelly and thread it part way intobushings contribute to low pressures, clutch slip and the case. Be sure the screw turns freely and does notaccelerated wear of other components. Replace worn, bind. Install the locknut on the screw after checkingor scored bushings, or if doubt exists about bushing screw thread operation.condition.
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 231 Fig. 37 Removing Overdrive Piston Retainer Fig. 38 Rear Band And LinkageLOW-REVERSE DRUM AND REAR BAND SERVICE Inspect the check ball in the piston (Fig. 39). Be Clean the drum in solvent but just wipe the drum sure the ball is secure and is not partially dislodged,thrust washer and rear band clean with lint free or loose. Replace the piston if doubt exists about pis-shop towels. ton or check ball condition. Examine the double tabbed thrust washer for wear Check the governor feed tube boss in the retainer.(Fig. 30). If the washer is worn, or damaged, check Be sure the boss is in good condition and is not dam-the spotface area of the drum for wear also. aged in any way. Examine the band and friction material closely. Re- Carefully work new piston seals into place by hand.place the band if bent, or distorted. Also replace the Apply a liberal coating of Mopar Door Ease, or Ru-band if the friction material is burnt, cracked, or Glyde to the seals to ease installation. Then coverflaking away from the band. If the grooves in the the piston with paper or clean plastic sheeting toband are no longer visible, the band lining is severely keep it dust free for assembly installation.worn and should be replaced. Check the band lever, adjusting screw, locknut, OVERRUNNING CLUTCH OVERHAULpivot pin, link and strut (Fig. 38). Replace any com- Inspect condition of the clutch cam, cage-type re-ponent exhibiting wear, or damage. tainer, rollers, springs and clutch race. Remove and replace the O-rings on the band pivot Replace the clutch cam if worn or damaged. Alsopin (Fig. 38). Lubricate the new O-rings with trans- check fit of the cam in the transmission case. If themission fluid after they are installed on the pin. cam is loose, the case may be worn, or cracked. The clutch race is permanently pressed onto theOVERDRIVE PISTON AND RETAINER SERVICE low-reverse drum hub. If either the drum or race are Remove and discard the piston seals. Use a pencil worn or damaged, replace the drum and race as anor length of thin plastic to remove the old seals. Do assembly. Check fit of the race on the low-reversenot use metal tools as they will scratch, or score the drum hub splines. Replace the drum and race as anseal grooves. assembly if the race is loose on the hub splines. Clean the piston and retainer in solvent but do not Examine the overrunning clutch assembly care-use any type of caustic materials for cleaning. Such fully. Replace assembly if the rollers, springs, ormaterials may etch the piston surfaces causing dam- cage-type retainer are worn, or damaged.age. Inspect the piston and retainer carefully. Replace If the clutch cam requires replacement, install aeither part if cracked, porous or damaged in any way. new cam as described in the following procedure.Check condition of the locating lugs on the piston. Besure the lugs are in good condition and are not worn,chipped or broken.
    • 21 - 232 46RH TRANSMISSION OVERHAUL ZJ cam ramps should be to left when cam is viewed from front end of case (Fig. 41). Fig. 41 Positioning Replacement Clutch Cam In Case (6) Insert Adapter Tool SP-5124 into piston re- Fig. 39 Overdrive Piston tainer (Fig. 42).OVERRUNNING CLUTCH CAM REPLACEMENT (1) Tap old cam out of case with pin punch. Insertpunch through bolt holes at rear of case (Fig. 40). Al-ternate position of punch to avoid cocking cam duringremoval. Fig. 42 Positioning Adapter Tool In Overdrive Piston Retainer (7) Assemble Puller Bolt SP-3701 and Press Plate SP-3583-A (Fig. 43). (8) Install assembled puller plate and bolt (Fig. 44). Insert bolt through cam, case and adapter tool. Fig. 40 Overrunning Clutch Cam Removal Be sure plate is seated squarely on cam. (2) Clean clutch cam bore and case. Be sure to re- (9) Hold puller plate and bolt in place and installmove all chips/shavings generated during cam re- puller nut SP 3701 on puller bolt (Fig. 45).moval. (10) Tighten puller nut to press clutch cam into (3) Temporarily install overdrive piston retainer in case (Fig. 45). Be sure cam is pressed into casecase. Use 3-4 bolts to secure retainer. evenly and does not become cocked. (4) Align and start new clutch cam and spring re- (11) Remove clutch cam installer tools.tainer in case. Be sure serrations on cam and in case (12) Stake case in 12 places around clutchare aligned (Fig. 41). Then tap cam into case just cam to help secure cam in case. Use bluntenough to hold it in place. punch or chisel to stake case. (5) Verify that cam is correctly positioned be-fore proceeding any further. Narrow ends of
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 233 Fig. 43 Assembling Clutch Cam Puller Bolt And Fig. 45 Pressing New Overrunning Clutch Cam Into Press Plate Case between spring and retainer stop as shown (Fig. 46). Verify that each roller and spring are fully seated be- fore proceeding. Fig. 44 Positioning Puller Plate On Clutch Cam (13) Remove piston retainer from case. Recover re-tainer with plastic sheeting, or paper to keep it dustfree. (14) Clean case and cam thoroughly. Be sure anychips/shavings generated during cam installation areremoved from case.OVERRUNNING CLUTCH INSTALLATION Fig. 46 Overrunning Clutch Roller And Spring (1) Lubricate overdrive piston retainer hub, clutch Position In Retainerrace, clutch cam, and overrunning clutch rollers withtransmission fluid. (3) Install and seat clutch assembly in cam (Fig. (2) If any overrunning clutch rollers or springs 47). The roller retainer is a one-way fit in thecame out of retainer, reinstall them as follows: Install cam. The flanged side of the retainer should beand seat spring in retainer first. Then insert roller
    • 21 - 234 46RH TRANSMISSION OVERHAUL ZJfacing outward. The retainer and rollers will severely scored, or damaged, it will be necessary toslip easily into the cam when properly posi- replace the case.tioned. Replace any servo component if doubt exists about condition. Do not reuse suspect parts. FRONT SERVO PISTON OVERHAUL (FIG. 49) (1) Remove seal ring from rod guide. (2) Remove small snap ring from servo piston rod. Then remove piston rod, spring and washer from pis- ton. (3) Remove and discard servo component O-ring and seal rings. (4) Lubricate new O-ring and seal rings with petro- leum jelly and install them on piston, guide and rod. (5) Install rod in piston. Install spring and washer on rod. Compress spring and install snap ring. (6) Set servo components aside for installation dur- ing transmission reassembly. Fig. 47 Overrunning Clutch Seated In Cam (4) Check overrunning clutch operation. Low-re-verse drum should rotate freely in clockwise directionand lock in counterclockwise direction.ACCUMULATOR OVERHAUL Inspect the accumulator piston and seal rings (Fig.48). Replace the seal rings if worn or cut. Replace thepiston if chipped or cracked. Check condition of the accumulator inner and outersprings (Fig. 48). Replace the springs if the coils arecracked, distorted or collapsed. Fg. 49 Front Servo Components REAR SERVO OVERHAUL Remove and discard the servo piston seal ring. Then clean the servo components with solvent and dry with compressed air. Replace either spring if col- lapsed, distorted or broken. Replace the plug and pis- ton if cracked, bent, or worn. Discard the servo snap rings and use a new ones at assembly. REAR SERVO PISTON OVERHAUL (FIG. 50) Fig. 48 Accumulator Components (1) Remove small snap ring and remove plug and spring from servo piston.FRONT SERVO AND BAND OVERHAUL (2) Remove and discard servo piston seal ring. Clean the servo piston components with solvent (3) Lubricate piston and guide seals with petro-and dry them with compressed air. Wipe the band leum jelly. Lubricate other servo parts with Moparclean with lint free shop towels. ATF Plus transmission fluid. Replace the front band if distorted, lining is (4) Install new seal ring on servo piston.burned, flaking off, or worn to the point where the (5) Assemble piston, plug, spring and new snapgrooves in the lining material are no longer visible. ring. Inspect the servo components. Replace the springsif collapsed, distorted or broken. Replace the guide, (6) Lubricate piston seal lip with petroleum jelly.rod and piston if cracked, bent, or worn. Discard the (7) Set servo components aside for assembly instal-servo snap ring if distorted or warped. lation. Check the servo piston bore for wear. If the bore is
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 235 Fig. 50 Rear Servo ComponentsOIL PUMP AND REACTION SHAFT SUPPORTOVERHAULPUMP AND SUPPORT DISASSEMBLY (1) Mark position of support in oil pump body forassembly alignment reference. Use scriber or paint tomake alignment marks. (2) Place pump body on two wood blocks. (3) Remove reaction shaft support bolts and sepa-rate support from pump body (Fig. 51). Fig. 52 Pump Gear Removal Check the pump vent (Fig. 54). The vent must be secure. Replace the pump body if the vent is cracked, broken, or loose. Inspect the pump bushing (Fig. 54). Then check the reaction shaft support bushing. Replace either bush- ing only if heavily worn, scored or damaged. It is not necessary to replace the bushings unless they are ac- tually damaged. Install the gears in the pump body and measure end clearance with a feeler gauge and straightedge (Fig. 55). Straightedge should be resting on pump body as shown: • End clearance between outer gear and straight- edge should be 0.010 to 0.063 mm (0.0004 to 0.0025 in.). • End clearance between inner gear and straight- Fig. 51 Reaction Shaft Support Removal edge should be 0.025 to 0.177 mm (0.001 to 0.007 (4) Remove pump inner and outer gears (Fig. 52). in.). (5) Remove O-ring seal from pump body (Fig. 53).Discard seal after removal. (6) Remove oil pump seal with Remover ToolC-3981. Discard seal after removal.INSPECTING PUMP AND SUPPORT Clean pump and support components with solventand dry them with compressed air. Check condition of the seal rings and thrustwasher on the reaction shaft support. The seal ringsdo not need to be replaced unless cracked, severelyworn, or no longer hooked together. Inspect the pump and support components. Replacethe pump or support if the seal ring grooves or ma-chined surfaces are worn, scored, pitted, or damaged.Replace the pump gears if pitted, worn chipped, ordamaged.
    • 21 - 236 46RH TRANSMISSION OVERHAUL ZJ Fig. 53 Oil Pump And Reaction Shaft Components Fig. 54 Pump Vent And Bushing Location
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 237 Measure tip clearances with feeler gauge (Fig. 56): (2) Remove bushing with Tool Handle C-4171 and• Clearance between inner gear tooth and outer gear Bushing Remover SP-3550.should be 0.08 to 0.19 mm (0.0035 to 0.0075 in.). (3) Assemble Tool Handle C-4171 and Bushing In-• Clearance between outer gear and pump housing staller SP-5118.should also be 0.010 to 0.19 mm (0.0035 to 0.0075 (4) Place bushing on installer tool and start bush-in.). ing into shaft. (5) Tap bushing into place until Installer Tool SP- 5118 bottoms in pump cavity. Keep tool and bushing square with bore. Do not allow bushing to become cocked during installation. (6) Stake pump bushing in two places with blunt punch. Remove burrs from stake points with knife blade (Fig. 58). Fig. 55 Checking Pump Gear End Clearance Fig. 57 Replacing Oil Pump Bushing Fig. 56 Checking Pump Gear Tip ClearanceOIL PUMP BUSHING REPLACEMENT (FIG. 57) Fig. 58 Staking-Deburring Oil Pump Bushing (1) Position pump housing on clean, smooth sur-face with gear cavity facing down.
    • 21 - 238 46RH TRANSMISSION OVERHAUL ZJREPLACING REACTION SHAFT SUPPORT CAUTION: The reaction shaft support seal rings willBUSHING (FIG. 59) break if overspread, or twisted. If new rings are be- (1) Assemble Cup Tool SP-3633, Nut SP-1191 and ing installed, spread them only enough for installa-Bushing Remover SP-5301. tion. Also be very sure the ring ends are securely (2) Hold cup tool firmly against reaction shaft. hooked together after installation. Otherwise, theThread remover tool into bushing as far as possible rings will either prevent pump installation, or breakby hand. during installation. (3) Using wrench, thread remover tool an addi-tional 3-4 turns into bushing to firmly engage tool. (4) Align and install reaction shaft support on (4) Tighten tool hex nut against cup tool to pull pump body.bushing from shaft. Clean all chips from shaft and (5) Install bolts attaching reaction shaft support tosupport after bushing removal. pump. Tighten bolts to 20 N⅐m (175 in. lbs.) torque. (5) Place reaction shaft support upright on a clean, (6) Install new pump seal with Installer Toolsmooth surface. C-3860-A (Fig. 60). Use hammer or mallet to tap seal (6) Assemble Bushing Installer Tools C-4171 and into place.SP-5302. Then slide new bushing onto installer tool. (7) Start bushing in shaft. Tap bushing into shaftuntil installer tool bottoms against support flange. (8) Clean reaction shaft support thoroughly afterbushing replacement (to remove any chips). Fig. 60 Oil Pump Seal Installation (7) Install new O-ring on pump body. Lubricate oil seal and O-ring with petroleum jelly. (8) Cover pump assembly to prevent dust entry and set aside for assembly installation. FRONT CLUTCH OVERHAUL FRONT CLUTCH DISASSEMBLY (1) Remove waved snap ring and remove reaction plate, clutch plates and clutch discs (Fig. 61). Note Fig. 59 Reaction Shaft Bushing Replacement number of plates and discs in clutch pack forASSEMBLING OIL PUMP AND REACTION assembly reference. Some models use 3 discs,SHAFT SUPPORT while some may have 4 discs. (1) Lubricate pump gears with transmission fluid (2) Compress clutch piston retainer and pistonand install them in pump body. springs with Compressor Tool C-3863-A (Fig. 62). (2) Install thrust washer on reaction shaft support (3) Remove retainer snap ring and remove com-hub. Lubricate washer with petroleum jelly or trans- pressor tool.mission fluid before installation. (4) Remove clutch piston springs. Note position (3) If reaction shaft seal rings are being replaced, of piston springs for assembly reference.install new seal rings on support hub. Lubricate seal (5) Remove clutch piston from retainer with arings with transmission fluid or petroleum jelly after twisting motion.installation. Squeeze each ring until ring ends are se- (6) Remove and discard clutch piston inner andcurely hooked together. outer seals.
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 239 Fig. 61 Front Clutch Components Replace the piston springs and spring retainer if ei- ther are distorted, warped or broken. Check the lug grooves in the clutch piston retainer. The steel plates should slide freely in the slots. Re- place the piston retainer if the grooves are worn or damaged. Also check action of the check ball in the piston retainer. The ball must move freely and not stick. Replace the retainer bushing if worn, scored, or there is any doubt 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 the clutch piston check ball. The ball should be securely in place. Replace the piston if the ball is missing, or seized in place. FRONT CLUTCH RETAINER BUSHING REPLACEMENT (FIG. 63) (1) Assemble Tool Handle C-4171 and Bushing Re- Fig. 62 Front Clutch Spring Retainer Snap Ring mover SP-3629. Removal (2) Insert remover tool in bushing and drive bush- ing straight out of clutch retainer.FRONT CLUTCH INSPECTION (3) Mount Bushing Installer SP-5511 on tool han- Clean and inspect the front clutch components. Re- dle.place the clutch discs if warped, worn, scored, burned (4) Slide new bushing onto installer tool and startor charred, the lugs are damaged, or if the facing is bushing into retainer.flaking off. Replace the steel plates and reaction (5) Tap new bushing into place until installer toolplate if heavily scored, warped, or broken. Be sure bottoms against clutch retainer.the driving lugs on the discs and plate are also in (6) Remove installer tools and clean retainer thor-good condition. The lugs must not be bent, cracked or oughly.damaged in any way.
    • 21 - 240 46RH TRANSMISSION OVERHAUL ZJ Fig. 64 Front Clutch Spring Position snap ring and pressure plate will have to be changed. Clutch pack waved snap ring is not select fit.Fig. 63 Front Clutch Retainer Bushing Replacement ToolsFRONT CLUTCH ASSEMBLY (1) Soak clutch discs in transmission fluid. (2) Install new inner and outer seals on clutch pis-ton. Be sure seal lips face interior of retainer. (3) Lubricate new inner and outer piston sealswith Ru-Glyde, or Mopar Door Ease. (4) Install clutch piston in retainer. Use twistingmotion to seat piston in bottom of retainer. A thinstrip of plastic (about 0.015 - 0.020 in. thick), can beused to guide seals into place if necessary.CAUTION: Never push the clutch piston straight in.This will fold the seals over causing leakage andclutch slip. In addition, never use any type of metaltool to help ease the piston seals into place. Metaltools will cut, shave, or score the seals. (5) Install and position clutch piston springs (Fig.64). 46RH has 9 spring front clutch. Fig. 65 Typical Method Of Measuring Front Clutch (6) Install spring retainer on top of piston springs. Pack Clearance (7) Compress spring retainer and piston springswith Tool C-3863-A. REAR CLUTCH OVERHAUL (8) Install spring retainer snap ring and remove REAR CLUTCH DISASSEMBLY (FIG. 66)compressor tool. (1) Remove clutch pack select fit snap ring. (9) Install clutch plates and discs (Fig. 61). Three (2) Remove reaction plate and remove clutch platesclutch discs, three steel plates and one reaction plate and discs.are required. (3) Remove pressure plate, wave spring, spacer (10) Install reaction plate followed by waved snap ring and piston spring from clutch retainer.ring. (4) Remove clutch piston from piston retainer with (11) Check clutch pack clearance with feeler gauge(Fig. 65). Clearance between waved spring and pres- a twisting motion.sure plate should 1.78 - 3.28 mm (0.070 - 0.129 in.). (5) Remove input shaft thrust washer, if washerIf clearance is incorrect, clutch plates, clutch discs, remained in piston retainer hub during removal.
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 241 Fig. 66 Rear Clutch Components (6) Remove seals from clutch piston. Discard seals Check thrust washer condition. Washer thicknessafter removal. should be 1.55 to 1.60 mm (0.061 to 0.063 in.). Re- place the washer if worn or damaged.REAR CLUTCH INSPECTION Check condition of the two seal rings on the input Clean the clutch components with solvent and dry shaft and the single seal ring on the piston retainerthem with compressed air. hub. Replace the seal rings only if severely worn, Check condition of the input shaft seal rings. It is cracked, or if they can no longer be hooked together.not necessary to remove or replace rings unless theyare broken, cracked, or no longer securely hooked to- INPUT SHAFT REPLACEMENTgether. If the input shaft must be replaced, first remove Inspect the input shaft splines and machined sur- the retaining ring that secures the shaft in the pistonfaces. Very minor nicks or scratches can be smoothed retainer hub. Then press the old shaft out of the re-off with crocus cloth. replace the shaft if the splines tainer with a shop press.are damaged, or any of the machined surfaces are se- Lubricate the splines of the new shaft with petro-verely scored. leum jelly or ATF Plus. Then align the shaft in the Replace the clutch discs if warped, worn, scored, piston retainer and carefully press it into place. Doburned/charred, the lugs are damaged, or if the fac- not allow the shaft to become cocked during installa-ing is flaking off. tion. The retainer can be cracked if misalignment oc- Replace the steel plates and the pressure plate if curs.heavily scored, warped, or broken. Be sure the driv- Install the shaft retaining ring after pressing theing lugs on the discs and plates are also in good con- shaft into place. Be sure the ring is fully seated be-dition. The lugs must not be bent, cracked or fore proceeding with clutch assembly.damaged in any way. Replace the piston spring and wave spring if either REAR CLUTCH ASSEMBLYpart is distorted, warped or broken. (1) Soak clutch discs in transmission fluid before Check the lug grooves in the clutch retainer. The assembly.steel plates should slide freely in the slots. Replace (2) Install new seals on clutch piston. Lubricatethe retainer if the grooves are worn or damaged. Also piston seals with Mopar Door Ease, or Ru-Glyde tocheck action of the retainer check ball. The ball must ease installation. Be sure seal lips face inputmove freely and not stick. shaft. Inspect the piston and retainer seal surfaces for (3) Install clutch piston in retainer. Use twistingnicks or scratches. Minor scratches can be removed motion to seat piston in bottom of retainer. A thinwith crocus cloth. However, replace the piston and/or strip of plastic (about 0.020Љ thick), can be used toretainer if the seal surfaces are seriously damaged. guide seals into place if necessary.
    • 21 - 242 46RH TRANSMISSION OVERHAUL ZJCAUTION: Never push the clutch piston straight in.This will fold the seals over causing leakage andclutch slip. In addition, never use any type of metaltool to help ease the piston seals into place. Metaltools will cut, shave, or score the seals. (4) Assemble piston retainer and clutch retainer. (5) Support clutch retainer with wood blocks, or in-sert input shaft through predrilled hole in work-bench. Clutch pack components are easier to install ifretainers are properly supported. (6) Install piston spring in clutch retainer. Concaveside of spring faces upward and away from clutchpiston. (7) Install spacer ring on top of piston spring. (8) Install wave spring on top of spacer ring. Then Fig. 68 Measuring Rear Clutch Pack Clearanceseat wave spring in retainer groove. If wave springwill not seat properly, spacer ring has probably PLANETARY GEARTRAIN OVERHAULshifted over and into wave spring groove in re-tainer. Use small screwdriver to realign spacer PLANETARY GEARTRAIN DISASSEMBLYring if necessary. (1) Remove planetary snap ring from intermediate (9) Install inner pressure plate in clutch retainer. shaft (Fig. 69). Discard snap ring as it is not reus- (10) Install first clutch disc followed by steel plate able.until all discs and plates are installed. Four clutchdiscs and steel plates are required (Fig. 66). (11) Install reaction plate on top of last clutch disc. (12) Install selective snap ring to secure clutchpack in retainer. (13) Install new seal rings on input shaft if neces-sary (Fig. 67). Be very sure ring ends are all securelyhooked together before proceeding. Fig. 69 Planetary Snap Ring Removal (2) Remove front planetary gear and front annulus gear as assembly (Fig. 70). (3) Remove front planetary gear and thrust washer from front annulus gear (Fig. 71). Note thrust washer position for assembly reference. (4) Remove tabbed thrust washer from driving shell (Fig. 72). Note washer position for assembly ref- Fig. 67 Input Shaft Seal Ring Locations erence. (14) Check clutch pack clearance with feeler gauge (5) Remove sun gear and driving shell as assembly(Fig. 68). Clearance should be 0.63 to 1.14 mm (0.025 (Fig. 73).to 0.045 in.). (6) Remove tabbed thrust washer from rear plane- (15) If clutch pack clearance is incorrect, clutch tary gear (Fig. 74). Note washer position on gear forpack snap ring, may have to be replaced. assembly reference. (16) Install thrust washer on piston retainer hub (7) Remove rear planetary gear and rear annulus(Fig. 66). Use petroleum jelly to hold thrust washer gear from intermediate shaft (Fig. 75).in place.
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 243Fig. 70 Front Planetary And Annulus Gear Removal Fig. 72 Driving Shell Thrust Washer Removal Fig. 73 Sun Gear And Driving Shell Assembly RemovalFig. 71 Disassembling Front Planetary And Annulus Gears (8) Remove thrust plate from rear annulus gear(Fig. 76).PLANETARY GEARTRAIN CLEANING ANDINSPECTION Clean the intermediate shaft and planetary compo-nents (Fig. 77) in solvent and dry them with com-pressed air. Inspect the planetary gear sets and annulus gears.The planetary pinions, shafts, washers, and retaining Fig. 74 Rear Planetary Thrust Washer Removalpins are serviceable. However, if a pinion carrier is planetary thrust plates and the tabbed thrust wash-damaged, the entire planetary gear set must be re- ers if cracked, scored or worn.placed as an assembly. Inspect the machined surfaces of the intermediate Replace the annulus gears if the teeth are chipped, shaft. Be sure the oil passages are open and clear.broken, or worn, or the gear is cracked. Replace the Replace the shaft if scored, pitted, or damaged.
    • 21 - 244 46RH TRANSMISSION OVERHAUL ZJ Fig. 75 Rear Planetary And Annulus Gear Removal Fig. 76 Rear Annulus Thrust Plate Removal Inspect the sun gear and driving shell (Fig. 77). If PLANETARY GEARTRAIN ASSEMBLY ANDeither component is worn or damaged, remove the ADJUSTMENTsun gear rear retaining ring and separate the sun (1) Lubricate sun gear and planetary gears withgear and thrust plate from the driving shell. Then re- transmission fluid during assembly. Use petroleumplace the necessary component. jelly to lubricate intermediate shaft bushing surfaces, Replace the sun gear as an assembly if the gear thrust washers and thrust plates and to hold theseteeth are chipped or worn. Also replace the gear as parts in place during assembly.an assembly if the bushings are scored or worn. The (2) Install front snap ring on sun gear and installsun gear bushings are not serviceable. Replace the gear in driving shell. Then install thrust plate overthrust plate if worn, or severely scored. Replace the sun gear and against rear side of driving shell (Fig.driving shell if distorted, cracked, or damaged in any 78). Install rear snap ring to secure sun gear andway. thrust plate in driving shell. Replace all snap rings during geartrain assembly. (3) Install rear annulus gear on intermediate shaftReusing snap rings is not recommended. (Fig. 79). (4) Install thrust plate in annulus gear (Fig. 80). Be sure plate is seated on shaft splines and against gear. Fig. 77 Planetary Geartrain Components
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 245 Fig. 78 Sun Gear Installation Fig. 81 Rear Planetary Gear Installation matching slots in face of gear carrier. Use extra pe- troleum jelly to hold washer in place if desired. Fig. 79 Rear Annulus Installation On Intermediate Shaft Fig. 82 Rear Planetary Thrust Washer Installation (7) Lubricate sun gear bushings with petroleum jelly or transmission fluid. (8) Install sun gear and driving shell on intermedi- ate shaft (Fig. 83). Seat shell against rear planetary gear. Verify that thrust washer on planetary gear was not displaced during installation. (9) Install tabbed thrust washer in driving shell (Fig. 84). be sure washer tabs are seated in tab slots of driving shell. Use extra petroleum jelly to hold washer in place if desired. (10) Install tabbed thrust washer on front plane- tary gear (Fig. 85). Seat washer tabs in matching slots in face of gear carrier. Use extra petroleum jelly to hold washer in place if desired. Fig. 80 Rear Annulus Thrust Plate Installation (11) Install front annulus gear over and onto front (5) Install rear planetary gear in rear annulus planetary gear (Fig. 86). Be sure gears are fullygear (Fig. 81). Be sure planetary carrier is seated meshed and seated.against annulus gear. (6) Install tabbed thrust washer on front face ofrear planetary gear (Fig. 82). Seat washer tabs in
    • 21 - 246 46RH TRANSMISSION OVERHAUL ZJ Fig. 83 Sun Gear And Driving Shell Installation Fig. 85 Installing Thrust Washer On Front Planetary Gear Fig. 84 Driving Shell Thrust Washer Installation Fig. 86 Assembling Front Planetary And Annulus Gears
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 247 (12) Install front planetary and annulus gear as-sembly (Fig. 87). Hold gears together and slide themonto shaft. Be sure planetary pinions are seated onsun gear and that planetary carrier is seated on in-termediate shaft. Fig. 88 Planetary Snap Ring Installation Fig. 87 Front Planetary And Annulus Gear Installation (13) Place geartrain in upright position. Rotategears to be sure all components are seated and prop-erly assembled. Snap ring groove at forward end ofintermediate shaft will be completely exposed whencomponents are assembled correctly. (14) Install new planetary snap ring in groove atend of intermediate shaft (Fig. 88). (15) Turn planetary geartrain over. Position woodblock under front end of intermediate shaft and sup-port geartrain on shaft. Be sure all geartrain parts Fig. 89 Checking Planetary Geartrain End Playhave moved forward against planetary snap ring.This is important for accurate end play check. and installation. Remove valves, plugs and springs (16) Check planetary geartrain end play with with a pencil magnet. Do not use pliers to removefeeler gauge (Fig. 89). Insert gauge between rear an- any of the valves, plugs or springs and do not forcenulus gear and shoulder on intermediate shaft as any of the components out or into place. The valvesshown. End play should be 0.15 to 1.22 mm (0.006 to and valve body housings will be damaged if force is0.048 in.). used. Tag or mark the valve body springs for refer- (17) If end play is incorrect, install thinner/thicker ence as they are removed. Do not allow them to be-planetary snap ring as needed. come intermixed.VALVE BODY SERVICE AND ADJUSTMENT (1) Remove boost valve cover (Fig. 90). (2) Remove boost valve retainer, valve spring andVALVE BODY MAIN COMPONENT boost valve (Fig. 91).DISASSEMBLY (3) Secure detent ball and spring with Retainer Tool 6583 (Fig. 92).CAUTION: Do not clamp any valve body component (4) Remove E-clip that secures throttle lever inin a vise. This practice can damage the component manual lever (Fig. 93).resulting in unsatisfactory operation after assembly
    • 21 - 248 46RH TRANSMISSION OVERHAUL ZJ Fig. 90 Boost Valve Cover Location Fig. 93 Removing Throttle Lever E-Clip Fig. 91 Boost Valve Components Fig. 94 Detent Ball And Spring Removal Fig. 92 Securing Detent Ball And Spring (5) Lift and rotate manual lever far enough toclear detent housing. (6) Remove retaining tool and remove detent balland spring (Fig. 94). (7) Remove washer at top of manual lever shaft.Then lift manual lever and park rod assembly up-ward and out of valve body (Fig. 95). (8) Remove throttle lever from valve body housing Fig. 95 Manual Lever Removal(Fig. 96). (10) Remove screws attaching pressure adjusting (9) Remove park rod E-clip and separate rod from screw bracket to valve body and transfer plate. Holdmanual lever (Fig. 97). bracket firmly against spring tension while removing last screw. (11) Remove adjusting screw bracket, line pressure adjusting screw, pressure regulator spring and switch
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 249 tached to housing with shoulder-type screw. Keep this screw with accumulator housing to avoid losing it. Fig. 96 Throttle Lever Removal Fig. 99 Solenoid Connector Position (13) Note routing of solenoid wires for assembly reference (Fig. 100). Fig. 97 Park Rod Removalvalve spring (Fig. 98). Do not remove throttlepressure adjusting screw from bracket and donot disturb adjusting screw settings during re-moval. Fig. 100 Solenoid Wire Routing (14) Remove screws attaching solenoid assembly to valve body lower housing and remove solenoid and connector assembly (Fig. 101). (15) Remove 3-4 accumulator housing attaching screws and remove housing from valve body (Fig. 102). (16) Remove following parts from valve body lower housing: 3-4 shift valve and spring; pressure regula- tor valve spring; clutch valve; clutch valve spring; Fig. 98 Adjusting Screw Bracket And Spring and clutch valve plug (Fig. 103). Removal (17) Bend back tabs on boost valve tube brace (Fig. (12) Remove solenoid connector from 3-4 accumula- 104).tor housing (Fig. 99). Note that connector is at-
    • 21 - 250 46RH TRANSMISSION OVERHAUL ZJ Fig. 101 Solenoid Assembly Removal Fig. 103 Clutch Valve And 3-4 Shift Valve Locations Fig. 102 Removing 3-4 Accumulator Housing (18) Remove boost valve connecting tube (Fig. 105). Fig. 104 Boost Valve Tube Brace (Double Tab Style)Disengage tube from upper housing port first. Thenrock opposite end of tube back and forth to work itout of lower housing.CAUTION: Do not use tools to loosen or pry theconnecting tube out of the valve body housings.Loosen and remove the tube by hand only. (19) Turn valve body over so valve lower housing isfacing upward. In this position, check balls in upperhousing will remain in place and not fall out whenlower housing and transfer plate are removed. (20) Remove screws attaching valve body lowerhousing to upper housing and transfer plate. Noteposition of boost valve tube brace for assemblyreference. (21) Remove lower housing and overdrive separa- Fig. 105 Boost Valve Tube Removaltor plate from transfer plate (Fig. 106). (24) Remove brace plate from lower housing sepa- (22) Remove transfer plate from upper housing rator plate and transfer plate (Fig. 108).(Fig. 107). (23) Turn transfer plate over so upper housing sep-arator plate is facing upward (Fig. 108).
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 251 Fig. 106 Lower Housing Removal Fig. 109 Upper Housing Separator Plate Removal sembly reference before removing it (Fig. 110). Check ball will be plastic or steel depending on valve body production date. Fig. 107 Removing Transfer Plate From Upper Housing Fig. 110 Rear Clutch/Rear Servo Check Ball Locations VALVE BODY UPPER HOUSING DISASSEMBLY (1) Note location of check balls in valve body upper housing (Fig. 111). Then remove the one large and six smaller diameter check balls with magnet (total of 7 check balls are used). (2) Remove E-clip that secure shuttle valve second- ary spring on valve stem (Fig. 112). (3) Remove governor plug and shuttle valve covers (Fig. 113). (4) Remove throttle plug, primary spring, shuttle valve, secondary spring, and spring guides (Fig. 113). Fig. 108 Brace Plate Removal (5) Remove boost valve retainer, spring and valve (25) Remove upper housing separator plate from if not previously removed.transfer plate (Fig. 109). Note position of filter in (6) Turn upper housing over and remove switchseparator plate for assembly reference. valve, regulator valve and spring, and manual valve (26) Remove rear clutch and rear servo check balls (Fig. 114).from transfer plate. Note check ball locations for as-
    • 21 - 252 46RH TRANSMISSION OVERHAUL ZJ Fig. 112 Shuttle Valve E-Clip And Secondary Spring Location (8) Remove throttle plug and 1-2 and 2-3 governor plugs (Fig. 114). Also remove shuttle valve primary spring if not removed in prior step. Fig. 111 Upper Housing Check Ball Locations (9) Turn upper housing around and remove limit (7) Remove kickdown detent, kickdown valve, and valve and shift valve covers (Fig. 115).throttle valve and spring (Fig. 114). (10) Remove limit valve housing. Then remove re- tainer, spring, limit valve, and 2-3 throttle plug from limit valve housing (Fig. 115). Fig. 113 Shuttle And Boost Valve Components
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 253 Fig. 114 Upper Housing Control Valve Locations (11) Remove 1-2 shift control valve and spring (Fig. (13) Remove 2-3 shift valve and spring from valve115). body (Fig. 115). (12) Remove 1-2 shift valve and spring (Fig. 115). (14) Remove pressure plug cover (Fig. 115). Fig. 115 Upper Housing Shift Valves And Pressure Plugs
    • 21 - 254 46RH TRANSMISSION OVERHAUL ZJ Fig. 116 Lower Housing Shift Valves And Springs (15) Remove line pressure plug, sleeve, throttle • throttle valve leverpressure plug and spring (Fig. 115). • manual lever • manual shaft seal, washer, and E-clipVALVE BODY LOWER HOUSING • fluid filterDISASSEMBLY (FIG. 116) • detent ball and spring (1) Remove timing valve cover. The remaining valve body components are serviced (2) Remove 3-4 timing valve and spring. only as part of a complete valve body assembly. (3) Remove quick fill valve, spring, and plug. Clean the valve body components with a standard (4) Remove 3-4 shift valve and spring. parts cleaning solution only. Do not use gasoline, ker- (5) Remove converter clutch valve, spring and osene, or any type of caustic solution.plug. Dry the parts with compressed air. Make sure all (6) Remove converter clutch timing valve, retainer passages are clean and free from obstructions. Doand valve spring. not use rags or shop towels to dry or wipe off valve body components. Lint from these materi-3-4 ACCUMULATOR HOUSING DISASSEMBLY als will stick to the valve body components.(FIG. 117) Lint will interfere with valve operation and (1) Remove end plate from housing. may clog filters and fluid passages. (2) Remove piston spring. Inspect the throttle and manual valve levers and (3) Remove piston. Remove and discard piston shafts (Fig. 118). Do not attempt to straighten a bentseals. shaft or correct a loose lever. Replace these compo- nents if worn, bent, loose or damaged in any way.VALVE BODY CLEANING AND INSPECTION Inspect all of the valve body mating surfaces for The only serviceable valve body components are: scratches, nicks, burrs, or distortion. Use a straight-• solenoid and connector assembly edge to check surface flatness. Minor scratches may• solenoid gasket be removed with crocus cloth using only very light• park rod and E-clip pressure.• switch valve and spring Minor distortion of a valve body mating surface• pressure adjusting screw bracket may be corrected by smoothing the surface with a
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 255 minum valves or plugs with abrasive materials. This practice could damage the special coating and cause the valves and plugs to stick and bind. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves or plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vi- tally 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. Re- place the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils. Check the two separator plates for distortion or damage of any kind. Inspect the upper housing, lower housing, 3-4 accumulator housing, and transfer Fig. 117 3-4 Accumulator Housing Components plate carefully. Be sure all fluid passages are clean and clear. Check condition of the upper housing andsheet of crocus cloth. Position the crocus cloth on a transfer plate check balls as well. The check ballssurface plate, sheet of plate glass or equally flat sur- and ball seats must not be worn or damaged.face. If distortion is severe or any surfaces are Trial fit each valve and plug in its bore to checkheavily scored, the valve body will have to be re- freedom of operation. When clean and dry, the valvesplaced. and plugs should drop freely into the bores.CAUTION: Many of the valves and plugs, such as Valve body bores do not change dimensionally withthe throttle valve, shuttle valve plug, 1-2 shift valve use. If the valve body functioned correctly when new,and 1-2 governor plug, are made of coated alumi- it will continue to operate properly after cleaning andnum. Aluminum components are identified by the inspection. It should not be necessary to replace adark color of the special coating applied to the sur- valve body assembly unless it is damaged in han-face (or by testing with a magnet). Do not sand alu- dling.
    • 21 - 256 46RH TRANSMISSION OVERHAUL ZJ Fig. 118 Upper Housing Components
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 257VALVE BODY REASSEMBLY (2) Position transfer plate assembly on upper hous- ing (Fig. 119).CAUTION: Do not force valves or plugs into place (3) Position lower housing separator plate onduring reassembly. If the valve body bores, valves transfer plate (Fig. 119).and plugs are free of distortion or burrs, the valvebody components should all slide into place easily.In addition, do not overtighten the transfer plateand valve body screws during reassembly. Over-tightening can distort the housings resulting invalve sticking, cross leakage and unsatisfactory op-eration. Tighten valve body screws to recom-mended torque only.Lower Housing Assembly (Fig. 116) (1) Lubricate valves, springs, and the housingvalve and plug bores with Mopar ATF Plus transmis-sion fluid. (2) Install 3-4 timing valve spring and valve inlower housing. (3) Install 3-4 quick fill valve in lower housing. Fig. 119 Lower Housing Separator Plate Installation (4) Install 3-4 quick fill valve spring and plug in (4) Install lower housing on assembled transferhousing. plate and upper housing (Fig. 120). (5) Install timing valve end plate. Tighten end (5) Install all valve body screws except three thatplate screws to 4 N⅐m (35 in. lbs.) torque. secure boost valve tube brace. Start screws by hand (6) Install 3-4 shift valve and spring. and tighten just enough to hold assemblies together (7) Install converter clutch valve, spring and plug. but not to required torque at this time. Screws will (8) Install converter clutch timing valve and not be fully tightened until after boost valvespring. tube and brace are installed.3-4 Accumulator Assembly (Fig. 117) (1) Lubricate accumulator piston, seals and hous-ing piston bore with ATF Plus, type 7176 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 check ball in transfer plate(Fig. 110). (2) Install filter screen in upper housing separatorplate (Fig. 109). (3) Align and position upper housing separatorplate on transfer plate (Fig. 109). (4) Install brace plate (Fig. 108). Tighten brace at-taching screws to 4 N⅐m (35 in. lbs.) torque. Fig. 120 Assembling Upper And Lower Housings (5) Install remaining separator plate attachingscrews. Tighten screws to 4 N⅐m (35 in. lbs.) torque. Upper Housing Valve And Plug Installation (Figs. 114, 115, 118)Upper And Lower Housing Assembly (1) Lubricate valves, plugs, springs with Mopar (1) Position upper housing so internal passages ATF Plus transmission fluid.and check ball seats are facing upward. Then install (2) Assemble regulator valve line pressure plug,check balls in housing (Fig. 111). Seven check balls sleeve, throttle plug and spring. Insert assembly inare used. The single large check ball is approxi- upper housing and install cover plate. Tighten covermately 8.7 mm (11/32 in.) diameter. The remaining 6 plate screws to 4 N⅐m (35 in. lbs.) torque.check balls are approximately 6.3 mm (1/4 in.) in di- (3) Install 1-2 and 2-3 shift valves and springs.ameter. (4) Install 1-2 shift control valve and spring.
    • 21 - 258 46RH TRANSMISSION OVERHAUL ZJ (5) Install shift valve cover plate. (6) Install shuttle valve as follows: (a) Insert plastic guides in shuttle valve second- ary spring and install spring on end of valve. (b) Hold shuttle valve in place. (c) Compress secondary spring and install E-clip in groove at end of shuttle valve. (d) Verify that spring and E-clip are properly seated before proceeding. (7) Install shuttle valve cover plate. Tighten coverplate screws to 4 N⅐m (35 in. lbs.) torque. (8) Install 1-2 and 2-3 valve governor plugs invalve body. (9) Install shuttle valve primary spring and throt-tle plug. (10) Align and install governor plug cover. Tighten Fig. 121 Boost Valve Tube And Brace Installationcover screws to 4 N⅐m (35 in. lbs.) torque. (11) Install manual valve. (12) Install throttle valve and spring. (13) Install kickdown valve and detent. (14) Install regulator valve. (15) Install switch valve.Boost Valve Tube And Brace Installation (1) Position valve body assembly so lower housingis facing upward (Fig. 121). (2) Lubricate tube ends and housing ports withtransmission fluid or petroleum jelly. (3) Start tube in lower housing port first. Thenswing tube downward and work opposite end of tubeinto upper housing port (Fig. 121). (4) Insert and seat each end of tube in housings. (5) Slide tube brace under tube and into alignment Fig. 122 Securing Boost Valve Tube With Bracewith valve body screw holes (Fig. 121). Tabs (6) Install and finger tighten three screws that se- (5) Hold accumulator housing firmly in place andcure tube brace to valve body housings (Fig. 121). install remaining two attaching screws. Be sure (7) Bend tube brace tabs up and against tube to springs and clutch valve plug are properly seatedhold it in position (Fig. 122). (Fig. 124). (8) Tighten all valve body housing screws to 4 (6) Attach solenoid case connector to 3-4 accumula-N⅐m (35 in. lbs.) torque after tube and brace are tor with shoulder-type screw. Connector has small lo-installed. Tighten screws in diagonal pattern cating tang that fits in dimple at top of accumulatorstarting at center and working outward. housing (Fig. 125). Seat tang in dimple before tight- ening connector screw.3-4 Accumulator Installation (7) Install solenoid assembly and gasket. Tighten (1) Position converter clutch valve and 3-4 shift solenoid attaching screws to 8 N⅐m (72 in. lbs.)valve springs in housing (Fig. 123). torque. (2) Loosely attach accumulator housing with right- (8) Verify that solenoid wires are properly routed.side screw (Fig. 123). Install only one screw at this Solenoid wires must be clear of rear band lever,time as accumulator must be free to pivot upward for manual lever and park rod.ease of installation. (3) Position plug on end of converter clutch valve Valve Spring, Detent, And Bracket Installationspring. Then compress and hold springs and plug in (1) Insert manual lever detent spring in upperplace with fingers of one hand. housing. (4) Swing accumulator housing upward over valve (2) Position line pressure adjusting screw in ad-springs and plug. justing screw bracket.
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 259 Fig. 123 Installing Converter Clutch And 3-4 Shift Valve Springs Fig. 125 Solenoid Connector Installation (8) Align manual lever with detent ball and man- ual valve. Hold throttle lever upward. Then press down on manual lever until fully seated. Remove de- tent 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. 126). (12) Install boost valve, valve spring, retainer and cover plate. Tighten cover plate screws to 4 N⅐m (35 Fig. 124 Seating 3-4 Accumulator On Lower in. lbs.) torque. Housing (13) Obtain new fluid filter for valve body but do (3) Install spring on end of line pressure regulator not install filter at this time.valve. (14) If line pressure and/or throttle pressure ad- (4) Install switch valve spring on tang at end of justment screw settings were not disturbed, continueadjusting screw bracket. with overhaul or reassembly. However, if adjustment screw settings were moved or changed, readjust as (5) Position adjusting screw bracket on valve body. described in Valve Body Control Pressure AdjustmentAlign valve springs and press bracket into place. In- procedure.stall short, upper bracket screws first and long bot-tom screw last. Verify that valve springs and bracket VALVE BODY CONTROL PRESSUREare properly aligned. Then tighten all three bracket ADJUSTMENTSscrews to 4 N⅐m (35 in. lbs.) torque. There are two control pressure adjustments on the (6) Install throttle lever in upper housing. Then in- valve body which are, line pressure and throttle pres-stall manual lever over throttle lever and start man- sure.ual lever into housing. Line and throttle pressures are interdependent be- (7) Position detent ball on end of spring. Then hold cause each affects shift quality and timing. As a re-detent ball and spring in detent housing with Re- sult, both adjustments must be performed properlytainer Tool 6583 (Fig. 92). and in the correct sequence. Adjust line pressure first and throttle pressure last.
    • 21 - 260 46RH TRANSMISSION OVERHAUL ZJ 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 bottomed to obtain correct adjustment. Fig. 126 Manual And Throttle Lever AlignmentLine Pressure Adjustment Measure distance from the valve body to the inneredge of the adjusting screw with an accurate steelscale (Fig. 127). Distance should be 33.4 mm (1-5/16 in.). If adjustment is required, turn the adjusting screwin, or out, to obtain required distance setting. Fig. 128 Throttle Pressure Adjustment The 33.4 mm (1-5/16 in.) setting is an approxi- TRANSMISSION ASSEMBLYmate setting. Manufacturing tolerances maymake it necessary to vary from this dimension Assembly Tipsto obtain desired pressure. Do not allow dirt, grease, or foreign material to en- One complete turn of the adjusting screw changes ter the case or transmission components during as-line pressure approximately 1-2/3 psi (9 kPa). sembly. Keep the transmission case and components Turning the adjusting screw counterclockwise in- clean. Also make sure the tools and workbench areacreases pressure while turning the screw clockwise used for reassembly operations are equally clean.decreases pressure. Shop towels used for wiping off tools and your hands must be made from lint free materials. Lint will stick to transmission parts and could interfere with valve operation or even restrict fluid passages. Lubricate transmission clutch and gear components with Mopar ATF Plus during reassembly. Soak clutch discs in transmission fluid before installation. Use Mopar Door Ease, or Ru-Glyde on piston seals and O-rings to ease installation. Petroleum jelly can be used to lubricate and hold thrust washers and plates in position during assembly. Do not use chassis grease, bearing grease, white grease, or similar lubricants on any part. These types of lubricants can eventually block or re- strict fluid passages and valve operation. Use petro- leum jelly only. Do not force parts into place. The transmission components and sub-assemblies are easily installed Fig. 127 Line Pressure Adjustment by hand when properly aligned. If a part seems dif-Throttle Pressure Adjustment ficult to install, it is either misaligned or incorrectly Insert Gauge Tool C-3763 between the throttle le- assembled. Verify that thrust washers, thrust platesver cam and the kickdown valve stem (Fig. 128). and seal rings are correctly positioned. These parts Push the gauge tool inward to compress the kick- will prevent proper assembly is mispositioned (ordown valve against the spring and bottom the throt- ‘‘left out’’ by accident).tle valve. The planetary geartrain, front/rear clutch assem-
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 261blies and oil pump are all much easier to installwhen the transmission case is upright or as close tothis position as possible. Either tilt the case upwardwith wood blocks, or cut a hole in the bench largeenough for the intermediate shaft and rear support.Then lower the shaft and support into the hole andsupport the rear of the case directly on the bench.FRONT/REAR SERVO INSTALLATION (1) Lubricate rear servo piston seal with MoparDoor Ease or ATF Plus. Lubricate servo bore in casewith ATF Plus. (2) Install rear servo piston in case. Position pistonat slight angle to bore and insert piston with twistingmotion (Fig. 129). Fig. 131 Rear Servo Snap Ring Installation (5) Lubricate front servo piston components and servo bore in case with transmission fluid. (6) Install front servo piston in bore. Carefully ‘‘run’’ small, suitable tool around piston ring to press it back into groove and ease installation (Fig. 132). Rotate piston into bore at same time. Rock piston slightly to ease piston ring past snap ring groove and into bore. Fig. 129 Rear Servo Piston Installation (3) Install rear servo spring and retainer in casebore (Fig. 130). Be sure spring is seated on piston. Fig. 132 Front Servo Piston Installation (7) Bottom front servo piston in bore and install servo spring. Fig. 130 Rear Servo Piston Spring And Retainer Installation (8) Install front servo piston rod guide as follows: (a) Place Tool SP-5560 (or similar size tool) on (4) Compress rear servo piston with C-clamp or guide and position C-clamp on tool and case (Fig.Valve Spring Compressor C-3422-B and install servo 133).piston snap ring (Fig. 131).
    • 21 - 262 46RH TRANSMISSION OVERHAUL ZJ (b) Slowly compress rod guide while simulta- (2) Install overdrive piston retainer. Be sure gover- neously easing seal ring into bore with suitable nor tube bores in retainer are aligned with governor tool. feed passages in gasket and case (Fig. 135). Install (9) Install rod guide snap ring (Fig. 133). and tighten retainer bolts to 17 N⅐m (13 ft. lbs.) torque. Fig. 133 Front Servo Rod Guide And Snap Ring InstallationOVERRUNNING CLUTCH, REAR BAND,LOW-REVERSE DRUM, AND OVERDRIVEPISTON RETAINER INSTALLATION (1) Install new gasket at rear of transmission case.Use petroleum jelly to hold gasket in place. Be sureto align governor feed holes in gasket with feed Fig. 135 Overdrive Piston Retainer Installationpassages in case (Fig. 134). Install gasket before (3) Install overrunning clutch components if notoverdrive piston retainer. Center hole in gasket yet installed. Refer to Overrunning Clutch Overhaulis smaller than retainer and cannot be installed in this section for procedures if necessary.over retainer. (4) Position rear band and link in case (Fig. 136). Fig. 134 Case Gasket Installation Fig. 136 Rear Band And Link Installation
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 263 (5) Install low-reverse drum (Fig. 137). Slide drumthrough rear band, onto piston retainer hub and intoengagement with overrunning clutch and race. Fig. 139 Rear Band Reaction Pin Installation Fig. 137 Low-Reverse Drum Installation (6) Install double tab thrust washer in low-reversedrum spotface (Fig. 138). Use petroleum jelly to holdwasher in place. Make sure washer tabs are seatedin notches. (7) Install snap ring that secures low-reverse drumto piston retainer hub (Fig. 138). Fig. 140 Rear Band Levers And Strut PLANETARY GEARTRAIN, FRONT/REAR CLUTCH, AND FRONT BAND INSTALLATION (1) Install assembled intermediate shaft and plan- etary geartrain (Fig. 141). Support shaft carefully during installation. Do not allow shaft bearing/ bushing surfaces to become nicked or scratched. (2) Lubricate intermediate shaft thrust plate with Fig. 138 Low-Reverse Drum Snap Ring Installation petroleum jelly and install plate on shaft pilot hub (Fig. 142). (8) Insert band reaction pin part way into case and (3) Check input shaft front seal rings, fiber thrustband link (Fig. 139). washer and rear seal ring (Fig. 143). Be ends of rear (9) Install rear band adjusting lever, reaction lever, seal ring are hooked together and diagonal cut endsand strut (Fig. 140). Be sure levers and strut are of front seal rings are firmly seated against eachaligned and engaged before seating band reaction pin other as shown. Lubricate seal rings with petroleumin case. jelly after checking them.
    • 21 - 264 46RH TRANSMISSION OVERHAUL ZJ Fig. 141 Intermediate Shaft/Planetary Geartrain Installation Fig. 143 Input Shaft Seal Ring And Thrust Washer InstallationFig. 142 Intermediate Shaft Thrust Plate Installation (4) Assemble front and rear clutches (Fig. 144).Align lugs on front clutch discs. Mount front clutchon rear clutch. Turn front clutch retainer back andforth until front clutch discs are fully seated on rearclutch splined hub. (5) Install intermediate shaft thrust washer in hubof rear clutch retainer (Fig. 145). Use petroleum jellyto hold washer in place. Position washer so groovesare facing outward. Washer only fits one way in Fig. 144 Assembling Front And Rear Clutchesclutch retainer hub. (8) Position front band lever in case and over servo (6) Place transmission case in upright position, or rod guide. Then install front band lever pin in caseplace blocks under front end of transmission repair and slide it through lever.stand to tilt case rearward. This makes it easier to (9) Coat threads of front band pin access plug withinstall front/rear clutch assembly. sealer and install it in case. Tighten plug to 17 N⅐m (7) Align discs in rear clutch. Then install and en- (13 ft. lbs.) torque.gage assembly in front planetary and driving shell (10) Slide front band over front clutch retainer and(Fig. 146). Turn clutch retainers back and forth until install front band strut and anchor (Fig. 147).both clutches are seated.
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 265 Fig. 147 Front Band And Linkage Installation Fig. 145 Intermediate Shaft Thrust Washer (2) Install new oil pump gasket on pilot studs and Installation seat it in case. Be sure gasket is properly aligned with fluid passages in case (Fig. 148). Fig. 148 Oil Pump Gasket And Pilot Stud Tool Installation (3) Coat front clutch thrust washer with petroleum jelly to hold it in place. Then install washer over re- Fig. 146 Front/Rear Clutch Assembly Installation action shaft hub and seat it on pump (Fig. 149). (11) Tighten front band adjusting screw until band CAUTION: The thrust washer bore (I.D.), is cham-is tight on clutch retainer. This will hold clutches in fered on one side. Make sure the chamfered side isplace while oil pump is being installed. Verify that installed so it faces the pump.front/rear clutch assembly is still properlyseated before tightening band. (4) Check seal rings on reaction shaft support. Be sure rings are hooked together correctly. Also be sureOIL PUMP INSTALLATION fiber thrust washer is in position (Fig. 150). Use ex- (1) Install oil pump Pilot Studs C-3288-B in case tra petroleum jelly to hold washer in place if neces-(Fig. 148). sary.
    • 21 - 266 46RH TRANSMISSION OVERHAUL ZJ Fig. 149 Front Clutch Thrust Washer Installation Fig. 151 Oil Pump Installation OVERDRIVE UNIT AND PISTON INSTALLATION (1) Install new seals on overdrive piston. Then lu- bricate seals with Mopar Door Ease, or Ru-Glyde to ease installation. (2) Install overdrive piston in retainer. Align lo- cating lugs on piston in locating bores in re- tainer (Fig. 152). Use thin plastic strip or feeler gauge to help guide piston outer seal into retainer. (3) Install spacer on intermediate shaft, if not pre- viously installed. (4) Install overdrive piston thrust plate (Fig. 153). Use liberal quantity of petroleum jelly to hold thrust plate in position on piston. (5) Install overdrive piston thrust bearing in direct Fig. 150 Reaction Shaft Seal Ring And Thrust clutch hub (Fig. 154). Use liberal quantity of petro- Washer Installation leum jelly to hold thrust bearing in place. Note that one side of bearing has dark coated surface. (5) Lubricate oil pump seals with Mopar ATF Plus. This surface faces overdrive piston. Also be (6) Mount oil pump on pilot studs and slide pump sure raised shoulder on inside diameter ofinto case opening (Fig. 151). Work pump into case bearing faces forward as well.by hand. Do not use a mallet or similar tools to (6) Apply small amount of petroleum jelly to pilotseat pump. hub of intermediate shaft. (7) Remove pilot studs and install oil pump bolts. (7) Verify alignment of splines in overdrive unitTighten pump bolts alternately and evenly to fully planetary gear and overrunning clutch. Be sureseat pump in case. Then final-tighten pump bolts to Alignment Tool 6227-2 is fully seated (Fig. 155). If20 N⅐m (15 ft. lbs.) torque. planetary gear and overrunning clutch splines (8) Verify correct installation. Rotate input and in- become misaligned, overdrive unit cannot betermediate shafts and check for bind. If bind exists, fully installed on intermediate shaft. Overdrivecomponents are either misassembled, or not seated. unit will have to be disassembled in order to re-Disassemble and correct as necessary before proceed- align splines.ing. (8) Carefully withdraw alignment tool from over- drive unit.
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 267 Fig. 154 Installing Overdrive Piston Thrust Bearing Fig. 152 Overdrive Piston Alignment Fig. 155 Checking Alignment Of Overdrive Planetary Gear And Overrunning Clutch Splines (11) Apply 1-2 drops of Mopar Lock N’ Seal (or Loc- tite 242) to overdrive unit attaching bolts. Then in- stall and tighten bolts to 34 N⅐ (25 ft. lbs.) torque. INPUT SHAFT END PLAY CHECK (1) Check input shaft end play as follows. (2) Attach dial indicator to converter housing (Fig. 156). Position indicator plunger against input shaft and zero indicator. (3) Move input shaft in and out and record read- Fig. 153 Installing Overdrive Piston Thrust Plate ing. (9) Lubricate intermediate shaft splines and bush- (4) End play should be 0.86 - 2.13 mm (0.034 -ing surfaces with transmission fluid or petroleum 0.084 in.).jelly. (5) If end play is incorrect, change intermediate (10) Install overdrive unit. Be sure governor tubes shaft thrust washer. The thrust washer controls endare aligned with feed holes in piston retainer boss. play and is available in three thicknesses for adjust-Intermediate shaft is snug fit in overdrive planetary ment purposes.gear and overrunning clutch. If overdrive unit willnot seat fully, rotate overdrive output shaft slightlyto align splines and try again.
    • 21 - 268 46RH TRANSMISSION OVERHAUL ZJ (5) Install seal on park/neutral position switch (Fig. 158). Then install and tighten switch to 34 N⅐m (25 ft. lbs.). Fig. 158 Park/Neutral Position Switch Seal Position (6) Adjust front and rear bands as follows: Fig. 156 Checking Input Shaft End Play (a) Loosen locknut on each band adjusting screwBAND ADJUSTMENTS AND INSTALLATION OF 4-5 turns.ACCUMULATOR, VALVE BODY, OIL PAN, AND (b) Tighten both adjusting screws to 8 N⅐m (72TORQUE CONVERTER in. lbs.). (1) Install accumulator inner spring, piston and (c) Back off front band adjusting screw 2-7/8outer spring (Fig. 157). turns. (d) Back off rear band adjusting screw 2 turns. (e) Hold each adjusting screw in position and tighten locknut to 34 N⅐m (25 ft. lbs.) torque. (7) Install magnet in oil pan. Magnet seats on small protrusion at corner of pan. (8) Position new oil pan gasket on case and install oil pan. Tighten pan bolts to 17 N⅐m (13 ft. lbs.). (9) Install new valve body manual shaft seal in case (Fig. 159). 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.Fig. 157 Installing Accumulator Piston And Springs (2) Verify that park/neutral position switch hasnot been installed in case. Valve body can not be in-stalled if switch is in position. (3) Install valve body as follows: (a) Start park rod into park pawl. If rod will not slide past park pawl, pawl is engaged in park gear. Rotate overdrive output shaft with suitable size 12 point socket; this will free pawl and allow rod to engage. (b) Align and seat valve body on case. Be sure manual lever shaft and overdrive connector are fully seated in case. (c) Install and start all valve body attaching Fig. 159 Manual Lever Shaft Seal Installation bolts by hand. Then tighten bolts evenly, in a diag- (10) Install throttle valve and shift selector levers onal pattern to 12 N⅐m (105 in. lbs.) torque. Do not on valve body manual lever shaft. overtighten valve body bolts. This could re- (11) Cap or cover transmission openings (cooler sult in distortion and cross leakage after in- line fittings, filler tube bore, etc.) to prevent dirt en- stallation.. try. (4) Install new filter on valve body. Tighten filterscrews to 4 N⅐m (35 in. lbs.).
    • ZJ 46RH TRANSMISSION OVERHAUL 21 - 269 (12) Install and seat torque converter. Use C-clamp tion that generated sludge, metal particles, oror metal strap to hold converter in place for installa- clutch friction material. The torque converter andtion. Be sure converter is fully seated before install- drainback valve should also be replaced if contam-ing clamp. inated by the same malfunction. Debris and residue (13) Mount transmission on jack for installation in not flushed from the cooler and lines will flow backvehicle. into the transmission and converter. The result (14) Apply small quantity of dielectric grease to could be a repeat failure and shop comeback.terminal pins of solenoid case connector and neutralswitch.CAUTION: The transmission cooler and lines mustbe reverse flushed if overhaul corrected a malfunc-
    • 21 - 270 46RH OVERDRIVE UNIT OVERHAUL ZJ 46RH OVERDRIVE UNIT OVERHAUL INDEX page pageDirect Clutch and Geartrain Assembly . . . . . . . . . 281 Overdrive Geartrain and Case Assembly . . . . . . . 286Governor Overhaul . . . . . . . . . . . . . . . . . . . . . . . 278 Overdrive Geartrain Disassembly . . . . . . . . . . . . . 272Overdrive Clutch Installation and Adjustment . . . . 288 Overdrive Unit Disassembly . . . . . . . . . . . . . . . . . 270Overdrive Component Cleaning and Inspection . . 276OVERDRIVE UNIT DISASSEMBLY (1) Remove overdrive piston thrust plate (Fig. 1).Retain thrust plate. It is a select fit part and can bereused. Fig. 3 Overdrive Piston Removal Fig. 1 Overdrive Piston Thrust Plate Removal/ Installation (2) Remove intermediate shaft spacer (Fig. 2). Re-tain spacer. It is a select fit part and can be reused. Fig. 4 Overdrive Piston Thrust Bearing Removal (5) Remove overdrive clutch pack retaining ring (Fig. 5). (6) Remove overdrive clutch pack (Fig. 6). Note that thickest plate is positioned at rear of clutch pack. (7) Remove overdrive clutch wave spring (Fig. 7). (8) Remove overdrive clutch reaction snap ring Fig. 2 Intermediate Shaft Spacer Location (Fig. 8). Note that snap ring is located in same (3) Remove overdrive piston from retainer (Fig. 3). groove as wave spring. (4) Remove overdrive piston thrust bearing fromdirect clutch hub (Fig. 4).
    • ZJ 46RH OVERDRIVE UNIT OVERHAUL 21 - 271 Fig. 5 Overdrive Clutch Pack Retaining Ring Fig. 8 Overdrive Clutch Reaction Snap Ring Removal Removal Fig. 9 Locating Ring Access Cover Removal/ Fig. 6 Overdrive Clutch Pack Removal Installation snap ring pliers. Then push output shaft forward to re- lease shaft front bearing from locating ring (Fig. 10). Fig. 7 Overdrive Clutch Wave Spring Removal (9) Remove access cover and gasket from case (Fig. Fig. 10 Releasing Shaft Front Bearing From9). Cover provides access to output shaft front bear- Locating Ringing locating ring. (10) Expand output shaft bearing snap ring with
    • 21 - 272 46RH OVERDRIVE UNIT OVERHAUL ZJ (11) Remove geartrain assembly from housing (Fig.11). Set geartrain aside. Fig. 11 Overdrive Geartrain Removal (12) Remove output shaft front bearing locatingring and governor support snap ring (Fig. 12). Fig. 13 Governor Support And Tube Assembly RemovalFig. 12 Front Bearing Locating Ring And Governor Support Snap Ring Location (13) Remove governor support and tube assembly Fig. 14 Park Lock Component Removalfrom case (Fig. 13). (14) Remove park pawl retaining bolt and reaction OVERDRIVE GEARTRAIN DISASSEMBLYplug snap ring (Fig. 14). Compress snap ring only (1) Remove E-clip from one end of governor valveenough to remove it. Snap ring can be distorted if shaft and remove shaft and valve (Fig. 16).overcompressed. (2) Remove governor snap ring (fig. 17). (15) Remove park pawl shaft, park pawl, pawl (3) Remove governor body and drive as assemblyspring and reaction plug (Fig. 14). (Fig. 18). Set assembly aside for disassembly, inspec- (16) Remove output shaft rear bearing snap ring tion, and overhaul. Refer to Governor Overhaul pro-(Fig. 15). Remove snap ring with long jaw internal cedures.type snap ring pliers. Or, rotate snap ring until one (4) Remove governor drive key (Fig. 19).end is adjacent to notch in case. Then unseat ring (5) Remove output shaft front bearing snap ringwith extra long flat blade screwdriver. (Fig. 20). (17) Remove rear bearing by tapping overdrive (6) Remove front bearing from output shaft (Fig.case on wood block to dislodge bearing. 21).
    • ZJ 46RH OVERDRIVE UNIT OVERHAUL 21 - 273 Fig. 15 Output Shaft Rear Bearing And Snap Ring Fig. 18 Governor Body And Drive Assembly Location Removal/Installation Fig. 16 Governor Valve And Shaft Removal/ Installation Fig. 19 Governor Drive Key Removal Fig. 20 Front Bearing Snap Ring Removal/ Fig. 17 Governor Snap Ring Removal/Installation InstallationWARNING: THE NEXT STEP IN GEARTRAIN DISAS- THAT PROPER EQUIPMENT BE USED TO COM-SEMBLY INVOLVES COMPRESSING THE DIRECT PRESS THE SPRING AS SPRING FORCE IS AP-CLUTCH SPRING. IT IS EXTREMELY IMPORTANT
    • 21 - 274 46RH OVERDRIVE UNIT OVERHAUL ZJ (7) Mount geartrain in shop press (8) Position Compressor Tool 6227-1 on clutch hub (Fig. 22). Support output shaft flange with steel press plates as shown and center assembly under press ram. (9) Use bushing remover style tool that is approx- imately 2-3 in. in diameter at top of Tool 6227-1. Tool will help distribute load and provide needed extra press length. (10) 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. 22). (11) Remove direct clutch pack snap ring first (Fig. 22). (12) Remove direct clutch hub retaining ring (Fig. Fig. 21 Output Shaft Front Bearing Removal/ 23). InstallationPROXIMATELY 830 POUNDS. USE SPRINGCOMPRESSOR TOOL 6227-1 AND A HYDRAULICSHOP PRESS WITH A MINIMUM RAM TRAVEL OF5-6 INCHES. THE PRESS MUST ALSO HAVE A BEDTHAT CAN BE ADJUSTED UP OR DOWN AS RE-QUIRED. RELEASE CLUTCH SPRING TENSIONSLOWLY AND COMPLETELY TO AVOID PERSONALINJURY. Fig. 23 Direct Clutch Hub Retaining Ring Removal (13) Release press load on clutch spring slowly and completely. Remove press tools and geartrain. (14) Remove direct clutch pack from hub (Fig. 24). (15) Remove direct clutch hub and spring (Fig. 25). Fig. 22 Direct Clutch Pack Snap Ring Removal Fig. 24 Direct Clutch Pack Removal
    • ZJ 46RH OVERDRIVE UNIT OVERHAUL 21 - 275 (18) Remove thrust bearing from overrunning clutch hub (Fig. 28). (19) Remove overrunning clutch from hub (Fig. 28). Fig. 25 Direct Clutch Hub And Spring Removal (16) Remove sun gear and spring plate, planetarythrust bearing and planetary gear (Fig. 26). Fig. 28 Overrunning Clutch Components Fig. 26 Sun Gear-Thrust Bearing-Planetary Gear (20) Mark position of annulus gear and direct Removal clutch drum for assembly alignment reference (Fig. (17) Remove overrunning clutch assembly with ex- 29). Use small center punch or scriber to make align-panding type snap ring pliers (Fig. 27). Insert pliers ment marks.into clutch hub. Expand pliers to grip hub splines andremove clutch with counterclockwise, twisting motion. Fig. 29 Marking Direct Clutch Drum And Annulus Gear For Assembly Alignment Fig. 27 Overrunning Clutch Assembly Removal
    • 21 - 276 46RH OVERDRIVE UNIT OVERHAUL ZJ (21) Remove direct clutch drum rear retaining ring(Fig. 30). Fig. 32 Marking Annulus Gear And Output Shaft For Assembly AlignmentFig. 30 Clutch Drum Inner Retaining Ring Removal (22) Remove direct clutch drum outer retainingring (Fig. 31). Fig. 33 Annulus Gear Removal Discard the old case gasket and seals. Do not at- tempt to salvage these parts. They are not reusable.Fig. 31 Clutch Drum Outer Retaining Ring Removal Replace any of the overdrive unit snap rings if dis- torted or damaged. (23) Mark annulus gear and output shaft for as-sembly alignment reference (Fig. 32). (24) Remove annulus gear from output shaft (Fig.33). Use rawhide or plastic mallet to tap gear offshaft. (25) Remove output shaft front bearing if not pre-viously removed.OVERDRIVE COMPONENT CLEANING ANDINSPECTION Clean the geartrain (Fig. 34) and case components(Fig. 35) with solvent. Dry all parts except the bear-ings with compressed air. Allow bearings to air dry. Do not use shop towels for wiping parts dry unlessthe towels are made from a lint-free material. A suf-ficient quantity of lint (from shop towels, cloths, rags,etc.) could plug the transmission filter and fluid pas-sages.
    • ZJ 46RH OVERDRIVE UNIT OVERHAUL 21 - 277 Fig. 34 Overdrive Geartrain Components Minor nicks or scratches on components can be Be sure the splines and lugs on the gear, drum andsmoothed with crocus cloth. However, do not attempt hub are in good condition. The clutch plates andto reduce severe scoring on any components with discs should slide freely in these components.abrasive materials. Replace severely scored compo- Inspect the thrust bearings and spring plate (Fig.nents; do not try to salvage them. 34). Replace the plate if worn or scored. Replace the Check condition of the park lock components and bearings if rough, noisy, brinneled, or worn.the overdrive case (Fig. 36). Inspect the planetary gear assembly and the sun Replace the case if cracked, scored, or damaged. gear and bushings (Fig. 34). If either the sun gear orReplace the park lock pawl, plug, or spring if worn or the bushings are damaged, replace the gear anddamaged. Be sure the bullet at the end of the park bushings as an assembly. The gear and bushings arelock rod is in good condition. Replace the rod if the not serviced separately.bullet is worn or the rod itself is bent or distorted. The planetary carrier and pinions must be in goodDo not attempt to straighten the rod. condition. Also be sure the pinion pins are secure and Check the bushings in the overdrive case. Replace in good condition. Replace the carrier if worn or dam-the bushings if severely scored or worn. Also replace aged.the case seal if loose, distorted, or damaged. Inspect the overrunning clutch and race. The race Examine the overdrive and direct clutch discs and surface should be smooth and free of scores. Replaceplates (Fig. 34). Replace the discs if the facing is the overrunning clutch assembly or the race if eitherworn, severely scored, or burned and flaking off. Re- assembly is worn or damaged in any way.place the clutch plates if worn, heavily scored, or Inspect the output shaft and governor componentscracked. Check the lugs on the clutch plates for wear. (Fig. 36). Replace the shaft pilot bushing and innerThe plates should slide freely in the drum. Replace bushing if damaged. Replace either shaft bearing ifthe plates or drum if binding occurs. rough or noisy. Replace the bearing snap rings if dis- Check condition of the annulus gear, direct clutch torted or cracked.hub, clutch drum and clutch spring (Fig. 34). Replace Check the machined surfaces on the output shaft.the gear, hub and drum if worn or damaged. Replace These surfaces should clean and smooth. Very minorthe spring if collapsed, distorted, or cracked.
    • 21 - 278 46RH OVERDRIVE UNIT OVERHAUL ZJ Fig. 35 Overdrive Case And Park Lock Componentsnicks or scratches can be smoothed with crocus cloth.Replace the shaft if worn, scored or damaged in anyway. Inspect the output shaft bushings (Fig. 36). Thesmall bushing is the intermediate shaft pilot bush-ing. The large bushing is the overrunning clutch hubbushing. Replace either bushing if scored, pitted,cracked, or worn. The bushings can be removed with ‘‘blind holepuller tools’’ such as Snap-On set CG40CB for smallbushings and set CG46 for large bushings. Newbushings can be installed with tools from an all pur-pose installer kit such as the Snap-On A257 bushingdriver set.GOVERNOR OVERHAUL Fig. 36 Output Shaft Bushing LocationGovernor Changes A 3-stage governor weight assembly is now in pro- The governor body was also changed. A retainerduction. The assembly consists of an outer weight, a washer was added to help secure the outer weight insmaller weight spring and inner weight, and a new the bore; the washer backs up the original snap ringintermediate weight. The sleeve-like intermediate which is still used. The governor body on was alsoweight fits inside the outer weight; the inner weight changed. The weight assembly bore is slightly longernow fits inside the intermediate weight. on these models. Only the new style governor body A steel outer weight was used in early models. Cur- will be supplied for service.rent production models have an aluminum outerweight. Only the aluminum weight assembly will besupplied for service.
    • ZJ 46RH OVERDRIVE UNIT OVERHAUL 21 - 279 Fig. 37 Governor ComponentsGOVERNOR DISASSEMBLY (1) Remove snap ring and washer that retain gov-ernor weight assembly in governor body (Fig. 38). (2) Remove governor weight assembly from gover-nor body. (3) Note position of governor body on drive for in-stallation reference. (4) Clamp edge of governor drive in vise equippedwith brass protective jaws. Then loosen governorbody attaching bolts. (5) Remove bolts attaching governor body to drive. (6) Remove governor body (Fig. 39). (7) Remove filter from governor drive. Note posi-tion of filter for assembly reference (Fig. 39). (8) Disassemble governor weight components: (a) Remove inner weight and intermediate weight from outer weight. (b) Position intermediate weight on suitable size socket (Fig. 40). (c) Push inner weight downward with nut driver tool. Then remove inner weight snap ring with Snap Ring Plier Tool 6823 (Fig. 40). (d) Remove inner weight and spring from inter- mediate weight. Fig. 38 Retainer Washer And Snap Ring Removal
    • 21 - 280 46RH OVERDRIVE UNIT OVERHAUL ZJ Inspect the governor support and oil pressure tubes. The tubes must not be pinched, kinked, col- lapsed, or distorted. Blow them out with compressed air to clear them. The tubes are designed to be a slip fit in the piston retainer boss. Do not modify the tube ends in an effort to make them fit tighter. Both tubes are an integral part of the support. Do not attempt to remove them. Replace the sup- port and oil tubes as an assembly if either part is damaged. Check condition of the governor snap rings. Re- place any snap ring that appears bent or distorted, or condition is doubtful. Inspect the governor body for damage. Replace it if cracked, or if the bores are worn. GOVERNOR ASSEMBLY (1) Lubricate governor components with Mopar ATF Plus transmission fluid during assembly. (2) Install new seal rings on governor drive as fol- lows:Fig. 39 Governor Body And Filter Position On Drive (a) Compress (squeeze) each seal over center be- fore installation (Fig. 41); this provides tighter ring fit on drive. (b) Carefully work seal into each groove of drive. Avoid overspreading seals during installation to en- sure tight fit. (c) Verify that diagonally cut ring ends are prop- erly interlocked (Fig. 42). (d) Stagger position of seal ring ends so they are at least 30° apart. Ring ends must not be aligned.Fig. 40 Inner Weight Snap Ring Removal/InstallationGovernor Inspection Check condition of the governor components. Checkoperation of the governor valve, weights and shaft. Fig. 41 Compressing Seal RingsThe valves and weights should slide freely in the (2) Insert filter in governor drive. Filter goes ingovernor body. hole to right of key slot (Fig. 43). Check condition of the governor drive seal rings. (3) Align and position governor body on drive. BeReplace the seal rings only if they exhibit wear or sure filter is seated in recess in governor body (Fig.damage. Be sure the seal ring grooves in the drive 43).are in good condition as well. (4) Apply 1-2 drops of Mopar Lock N’ Seal, or Loc- tite 242 to threads of all four governor body attach-
    • ZJ 46RH OVERDRIVE UNIT OVERHAUL 21 - 281 Fig. 42 Governor Drive Seal Rings Installeding bolts. Then install and tighten governor bodybolts snug but not to specified torque at this time. (5) Assemble governor weight components (Fig.44). (a) Be sure weights are clean; then lubricate Fig. 43 Governor Body And Filter Installation them with ATF Plus. (6) Lubricate seal rings, drive hub and governor (b) Insert spring and inner weight in intermedi- body bores with Mopar ATF Plus. Then set assembly ate weight. Position intermediate weight on suit- aside until final installation on output shaft. able size socket (Fig. 40). (c) Press inner weight downward with nutdriver DIRECT CLUTCH AND GEARTRAIN ASSEMBLY and install inner weight snap ring with Tool 6823 (1) Soak direct clutch and overdrive clutch discs in (Fig. 40). Mopar ATF Plus before installation. Also lubricate (d) Set weight assembly aside temporarily. geartrain components with ATF Plus during reassem- Assembly will not be installed until after gov- bly. ernor drive is seated on output shaft. Fig. 44 Governor Weight Components
    • 21 - 282 46RH OVERDRIVE UNIT OVERHAUL ZJ (2) Install new pilot bushing and clutch hub bush-ing in output shaft if necessary (Fig. 45). Lubricatenew (or old) bushings with petroleum jelly. (3) Install front bearing and bearing snap ring onoutput shaft (Fig. 45) (4) Align and install annulus gear on output shaft(Fig. 45). (5) Install annulus snap ring (Fig. 45). Fig. 47 Clutch Drum Inner Retaining Ring Installation place during installation. Bearing fits one way only. Be sure bearing is seated squarely against hub. Reposition bearing if it does not seat squarely. Fig. 45 Annulus Gear And Snap Ring Installation (6) Align and install clutch drum on annulus gear(Fig. 46). Be sure drum is engaged in annulus gearlugs. (7) Install clutch drum outer retaining ring (Fig.46). Fig. 48 Assembling Overrunning Clutch And Hub (11) Install overrunning clutch (Fig. 50). Insert snap ring pliers in hub splines. Expand pliers to grip hub. Then install assembly with counterclockwise, twisting motion. (12) Install planetary gear in annulus gear (Fig. 51). Be sure planetary pinions are fully seated in annulus gear before proceeding. Fig. 46 Clutch Drum And Outer Retaining Ring (13) Install direct clutch spring plate on sun gear. Installation Then secure plate to sun gear with snap ring (Fig. (8) Slide clutch drum forward and install inner re- 52). Shoulder side of plate should face outward andtaining ring (Fig. 47). toward front. (9) Install overrunning clutch on hub (Fig. 48). (14) Coat planetary thrust bearing and bearingNote that clutch only fits one way. Shoulder on contact surface of spring plate with petroleum jelly.clutch should seat in small recess at edge of This will help hold bearing in place during installa-hub. tion. (10) Install thrust bearing on overrunning clutch (15) Install planetary thrust bearing on sun gearhub (Fig. 49). Use petroleum jelly to hold bearing in (Fig. 53). Slide bearing onto gear and seat it against
    • ZJ 46RH OVERDRIVE UNIT OVERHAUL 21 - 283 Fig. 49 Overrunning Clutch Thrust Bearing Fig. 51 Planetary Gear Installation Installation Fig. 52 Sun Gear And Spring Plate Assembly Fig. 50 Overrunning Clutch Installationspring plate as shown. Bearing fits one way only.If it does not seat squarely against spring plate,remove and reposition bearing. (16) Install assembled sun gear, spring plate and Fig. 53 Planetary Thrust Bearing Installationthrust bearing (Fig. 54). Be sure sun gear and thrust 55). Insert tool through sun gear and into splines ofbearing are fully seated before proceeding. both hubs. Be sure alignment tool is fully seated be- (17) Align splines in hubs of planetary gear and fore proceeding.overrunning clutch with Alignment Tool 6227-2 (Fig. (18) Install direct clutch spring. Be sure spring is properly seated on spring plate (Fig. 55).
    • 21 - 284 46RH OVERDRIVE UNIT OVERHAUL ZJ Fig. 54 Sun Gear Installation (19) Assemble direct clutch pack for installation onhub (Fig. 56). (20) Install direct clutch reaction plate on clutchhub. Note that one side of reaction plate iscounterbored. Be sure this side faces rearward. Fig. 55 Direct Clutch Spring InstallationSplines at rear of hub are raised slightly andcounterbore in plate fits over these splines. (23) Mount geartrain assembly in shop press (Fig.Plate should be flush with this end of hub (Fig. 60)57). WARNING: THE NEXT STEP IN GEARTRAIN ASSEM- (21) Install remainder of direct clutch componentsas follows: BLY INVOLVES COMPRESSING THE DIRECT (a) Install first clutch disc on reaction plate fol- CLUTCH HUB AND SPRING. IT IS EXTREMELY IM- lowed by a steel plate. PORTANT THAT PROPER EQUIPMENT BE USED TO (b) Alternately install remaining clutch discs and COMPRESS THE SPRING AS SPRING FORCE IS AP- steel plates until required number of discs and PROXIMATELY 800 POUNDS. USE SPRING COM- plates are installed. 46RH requires 8 discs and 7 PRESSOR TOOL C-6227-1 AND A HYDRAULIC-TYPE steel plates (Fig. 56). SHOP PRESS WITH A MINIMUM RAM TRAVEL OF (c) Last clutch pack item installed is clutch pres- 5-6 INCHES. THE PRESS MUST ALSO HAVE A BED sure plate. Be sure plate is installed with shoulder THAT CAN BE ADJUSTED UP OR DOWN AS RE- side of plate facing upward (Fig. 58). QUIRED. RELEASE CLUTCH SPRING TENSION (22) Install clutch hub and clutch pack on direct SLOWLY AND COMPLETELY TO AVOID PERSONALclutch spring (Fig. 59). INJURY. Fig. 56 Direct Clutch Pack Components
    • ZJ 46RH OVERDRIVE UNIT OVERHAUL 21 - 285 Fig. 59 Installing Assembled Direct Clutch Pack And Hub (25) Slide direct clutch pack upwards on hub (Fig. 60). Slide pack upward and set it partially on edge of hub and compressor tool as shown in Figure 60. Fig. 57 Correct Position Of Direct Clutch Reaction Plate Fig. 58 Correct Position Of Direct Clutch Pressure Plate (24) Position Compressor Tool 6227-2 on clutch hub(Fig. 60). Fig. 60 Mounting Geartrain Assembly In Shop Press
    • 21 - 286 46RH OVERDRIVE UNIT OVERHAUL ZJ (26) Slowly compress clutch hub and spring (Fig.61). Compress spring and hub only enough to exposering grooves for clutch pack snap ring and clutch hubretaining ring. (27) Realign clutch pack on hub and seat clutchdiscs and plates in clutch drum (Fig. 61). Fig. 63 Clutch Hub Retaining Ring Installation 64). Use petroleum jelly to hold key in place if nec- essary. Fig. 61 Seating Clutch Pack In Drum (28) Install direct clutch pack snap ring (Fig. 62).Be very sure snap ring is fully seated in clutchdrum ring groove. (29) Install clutch hub retaining ring (Fig. 63). Bevery sure retaining ring is fully seated in sungear ring groove. (30) Slowly release press ram, remove compressortools and remove geartrain assembly. Fig. 64 Front Bearing And Drive Key Installation (3) Install governor body and drive assembly on output shaft as follows (Fig. 65). (a) Be sure drive key is fully engaged in shaft drive slot. (b) Align key with slot in governor drive and slide drive assembly into place. To avoid displacing drive key, reach through weight opening in gover- nor body with fingers and guide key into place. (4) Install governor weight assembly in governor body (Fig. 66). Fig. 62 Direct Clutch Pack Snap Ring Installation (5) Install retainer washer and snap ring that se-OVERDRIVE GEARTRAIN AND CASE ASSEMBLY cure governor weight assembly in governor body (Fig. (1) Install front bearing and snap ring on output 67).shaft (Fig. 64). Be sure locating ring groove in (6) Verify that governor valve shaft bores in gover-bearing is toward rear of shaft. Otherwise, nor body and output shaft are aligned.housing locating ring and bearing ring groove (7) Install governor valve in body bore. Large di-will not align. Remove and reposition bearing if ameter end of valve faces outward. Then install gov-necessary. ernor valve shaft and secure it with E-clips. (2) Install governor drive key in output shaft (Fig.
    • ZJ 46RH OVERDRIVE UNIT OVERHAUL 21 - 287 Fig. 65 Governor Assembly Installation Fig. 67 Governor Weight Retainer Washer And Snap Ring Installation Fig. 66 Installing Governor Weight AssemblyCAUTION: Be very sure the E-clips are fully seatedin the valve shaft grooves and that the roundedsides of the clips are facing outward. Otherwise, theclips will pop off the shaft causing a governor fail-ure. Fig. 68 Governor Snap Ring Installation (8) Install governor assembly snap ring (Fig. 68). (14) Install reaction plug snap ring (Fig. 70). Com- (9) Tighten governor body attaching bolts to 11 press snap ring only enough for installation; doN⅐m (8 ft. lbs.) torque. not distort it. (10) Install output shaft rear bearing in case andinstall bearing snap ring. Be sure snap ring is fullyseated. (11) Position park pawl and spring in case and in-stall park pawl shaft (Fig. 14). Verify that spring endis hooked to pawl and straight end of spring (12) Install pawl shaft retaining bolt. Tighten boltto 27 N⅐m (20 ft. lbs.) torque. (13) Install park lock reaction plug. Note thatplug has locating pin at rear (Fig. 69). Be surepin is seated in hole in case before installingsnap ring. Fig. 69 Reaction Plug Locating Pin And Snap Ring
    • 21 - 288 46RH OVERDRIVE UNIT OVERHAUL ZJ Fig. 70 Reaction Plug And Snap Ring Installation Fig. 73 Installing Governor Support Snap Ring (15) Install alignment clip on governor tubes (Fig.71). Slide clip up against shoulder on each tube. Fig. 71 Positioning Governor Tube Alignment Clip (16) Install governor support and pressure tubes in Fig. 74 Front Bearing Locating Ring Installationcase (Fig. 72). (17) Install governor support snap ring (Fig. 73). (19) Support geartrain on Tool 6227-1 (Fig. 75). Be sure tool is securely seated in clutch hub. (20) Install overdrive unit case over geartrain (Fig. 75). (21) Expand front bearing locating ring with snap ring pliers. Then slide case downward until locating ring locks in bearing groove and release snap ring. (22) Install locating ring access plate and gasket in overdrive unit case (Fig. 9). OVERDRIVE CLUTCH INSTALLATION AND ADJUSTMENT (1) Install overdrive clutch components as follows: (a) Install reaction ring first. Reaction ring is flat with notched ends (Fig. 76). (b) Install wave spring on top of reaction ring. Reaction ring and wave ring both fit in same Fig. 72 Installing Governor Support And Pressure ring groove. Use screwdriver to seat each ring se- Tubes curely in groove. (18) Install output shaft front bearing locating ring (c) Install reaction plate (Fig. 77).in case (Fig. 74). (d) Install first clutch disc followed by first clutch plate.
    • ZJ 46RH OVERDRIVE UNIT OVERHAUL 21 - 289 Fig. 77 Overdrive Clutch Pack Components (a) Insert Special Tool 6312 through sun gear, planetary gear and into pilot bushing in output shaft. Be sure tool bottoms against planetary shoulder. (b) Position Gauge Tool 6311 across face of over- Fig. 75 Installing Overdrive Case On Geartrain drive case (Fig. 78). Then position Dial Caliper (e) Install remaining clutch discs and plates in C-4962 over gauge tool. same order. (c) Extend sliding scale of dial caliper downward (f) Verify clutch pack. Four clutch discs, 3 through gauge tool slot until scale contacts end of steel plates, 1 reaction plate and 1 pressure Gauge Alignment Tool 6312. Lock scale in place. plate are required. Remove dial caliper tool and note distance mea- (g) Install clutch pack pressure plate (Fig. 77). sured (Fig. 78). (h) Install clutch pack wire-type retaining ring (d) Select proper thickness end play spacer from (Fig. 76). spacer chart based on distance measured (Fig. 79). (e) Remove Gauge Alignment Tool 6312. Fig. 76 Overdrive Clutch Ring Identification (2) Place overdrive unit in vertical position. Mount Fig. 78 Shaft End Play Measurementit on blocks, or in workbench with appropriate size (4) Determine correct thickness overdrive pistonmounting hole cut into it. Be sure unit is facing up- thrust plate as follows:ward for access to direct clutch hub. Also be sure out- (a) Position Gauge Tool 6311 across face of over-put shaft is not loaded and internal components are drive case. Then position Dial Caliper C-4962 overmoved rearward for accurate measurement. gauge tool (Fig. 80). (3) Determine correct thickness intermediateshaft spacer as follows:
    • 21 - 290 46RH OVERDRIVE UNIT OVERHAUL ZJ Fig. 79 Intermediate Shaft End Play Spacer Selection (b) Measure distance to clutch hub thrust bear- ing seat at four points 90° apart. Then average measurements by adding them and dividing by 4. Fig. 80 Overdrive Piston Thrust Plate Measurement (c) Select and install required thrust plate from information in thrust plate chart (Fig. 81). (5) Leave Alignment Tool 6227-2 in place. Tool willkeep planetary and clutch hub splines in alignmentuntil overdrive unit is ready for installation on trans-mission. Fig. 81 Overdrive Piston Thrust Plate Selection
    • ZJ NP231 TRANSFER CASE 21 - 291 NP231 TRANSFER CASE INDEX page pageGeneral Information . . . . . . . . . . . . . . . . . . . . . . . 291 Speedometer Service . . . . . . . . . . . . . . ... . . . . 294NP231 Service Diagnosis . . . . . . . . . . . . . . . . . . 293 Transfer Case Assembly . . . . . . . . . . . . ... . . . . 303Operating Ranges . . . . . . . . . . . . . . . . . . . . . . . . 292 Transfer Case Disassembly and Overhaul .. . . . . 297Overhaul Cleaning and Inspection . . . . . . . . . . . . 301 Transfer Case Identification . . . . . . . . . . ... . . . . 292Recommended Lubricant . . . . . . . . . . . . . . . . . . . 292 Transfer Case Installation . . . . . . . . . . . ... . . . . 296Shift Linkage Adjustment . . . . . . . . . . . . . . . . . . . 294 Transfer Case Removal . . . . . . . . . . . . . ... . . . . 296Shift Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . 292 Transfer Case Specifications . . . . . . . . . ... . . . . 292GENERAL INFORMATION three operating ranges plus a Neutral position. A low The NP231 is a part-time transfer case with a low range system provides a reduction ratio for increasedrange reduction gear system (Fig. 1). The NP231 has low speed torque capability. Fig. 1 NP231 Transfer Case
    • 21 - 292 NP231 TRANSFER CASE ZJ Two versions of the NP231 are used. One versionretains the synchronizer components used in previ-ous models. A newer version does not have synchrocomponents.OPERATING RANGES Transfer case operating ranges are:• 2-wheel drive high (2H)• 4-wheel drive high (4H)• 4-wheel drive low (4L) The 2H range is for use on all road surfaces. The4H and 4L ranges are for off-road use only. Use theseranges on low traction surfaces such as sand, dirt, orsnow/ice covered road surfaces only.SHIFT MECHANISM Operating ranges are selected with a floor mounted Fig. 2 Transfer Case Identification Tagshift lever. The shift lever is connected to the trans-fer case range lever by an adjustable linkage rod. RECOMMENDED LUBRICANT A straight line shift pattern is used. Range posi- Recommended lubricant for the NP231 is Mopartions are marked on the shifter knob and bezel cover Dexron II. Do not use any type of anti-friction addi-plate. A synchronizer assembly in the transfer case tives in the NP231 transfer case. Use the recom-allows the unit to be shifted between two and four mended lubricant only.high ranges while in motion. NP231 lubricant capacity is approximately 1.2 li- ters (2.5 pints). Correct fill level is to the bottom edgeTRANSFER CASE IDENTIFICATION of the fill plug hole. A circular ID tag is attached to the rear case ofeach NP231 transfer case (Fig. 2). The ID tag pro- TRANSFER CASE SPECIFICATIONSvides the transfer case model number, assembly The NP231 transfer case torque specifications arenumber, serial number and low range ratio. provided at the end of Group 21. Recommended lu- The transfer case serial number also represents the bricants and adjustments are included in the over-date of build. For example, a serial number of 11- haul section.7-94 would represent November 7, 1994.
    • ZJ NP231 TRANSFER CASE 21 - 293NP231 SERVICE DIAGNOSIS
    • 21 - 294 NP231 TRANSFER CASE ZJSHIFT LINKAGE ADJUSTMENT (4) Remove speed sensor and speedometer adapter (1) Shift transfer case into 4L position. as assembly. (2) Secure shift lever in 4L position. (5) Remove speed sensor retaining screw and re- (3) Raise vehicle. move sensor from adapter. (4) Loosen lock bolt that secures shift rod in ad- (6) Remove speedometer pinion from adapter.justing swivel (Fig. 4). (7) Inspect sensor and adapter O-rings (Fig. 5). Re- (5) Make sure shift rod slides freely in adjusting move and discard O-rings if worn or damaged.swivel. Lube rod and swivel if necessary. (8) Inspect terminal pins in speed sensor. Clean (6) Verify that transfer case range lever is in 4L pins with Mopar electrical spray cleaner if dirty ordetent. oxidized. Replace sensor if faulty, or pins are loose, (7) Center pin on adjusting swivel in shift arm and severely corroded, or damaged.tighten lock bolt to 10 N⅐m (90 in. lbs.) torque. (8) Lower vehicle just enough to enter vehicle. Be SPEEDOMETER INSTALLATION ANDsure all wheels are off shop floor. Then start engine, INDEXINGshift transmission into gear, and shift transfer case (1) Thoroughly clean adapter flange and adapterthrough all ranges to verify correct adjustment. mounting surface in housing. Surfaces must be clean for proper adapter alignment and speedometer oper-SPEEDOMETER SERVICE ation. Rear axle gear ratio and tire size determine speed- (2) Install new O-rings on speed sensor and speed-ometer pinion requirements. If the pinion must be re- ometer adapter if necessary.placed, refer to the parts catalogue information for (3) Lubricate sensor and adapter O-rings withthe correct part. transmission fluid. (4) Install vehicle speed sensor in speedometerSPEEDOMETER ASSEMBLY REMOVAL adapter. Tighten sensor attaching screw to 2-3 N⅐m (1) Raise vehicle. (15-27 in. lbs.) torque. (2) Disconnect wires from vehicle speed sensor. (5) Install speedometer pinion in adapter. (3) Remove adapter clamp and screw (Fig. 5). Fig. 3 Transfer Case Shift Linkage (Manual Transmission)
    • ZJ NP231 TRANSFER CASE 21 - 295 Fig. 4 Transfer Case Shift Linkage (Automatic Transmission) Fig. 5 Speedometer Components (6) Count number of teeth on speedometer pinion. (7) Note index numbers on adapter body (Fig. 6).Do this before installing assembly in housing. Then These numbers will correspond to number of teeth onlubricate pinion teeth with transmission fluid. pinion. (8) Install speedometer assembly in housing.
    • 21 - 296 NP231 TRANSFER CASE ZJ (9) Rotate adapter until required range numbers (3) Align transfer case and transmission shafts andare at 6 o-clock position. Be sure range index num- install transfer case on transmission (Fig. 7).bers correspond to number of teeth on pinion gear. (4) Install and tighten transfer case attaching (10) Install speedometer adapter clamp and retain- nuts. Tighten 5/16 nuts to 35 N⅐m (26 ft. lbs.) torque.ing screw. Tighten clamp screw to 10-12 N⅐m (90-110 Tighten 3/8 nuts to 47 N⅐m (35 ft. lbs.) torque.in. lbs.) torque. (11) Connect wires to vehicle speed sensor. (12) Lower vehicle and top off transmission fluidlevel if necessary. Fig. 7 Transfer Case Attachment (5) Install speedometer adapter, pinion, and speed sensor. (6) Connect electrical wires to speed sensor.Fig. 6 Location Of Index Numbers On Speedometer (7) Connect vent hose to transfer case vent (Fig. 8). Adapter (8) Align and connect propeller shafts. TightenTRANSFER CASE REMOVAL (1) Shift transfer case into Neutral. (2) Raise vehicle. (3) Drain transfer case lubricant. (4) Mark front and rear propeller shaft yokes foralignment reference. (5) Place support stand under transmission. (6) Remove rear crossmember. (7) Disconnect front/rear propeller shafts at trans-fer case. (8) Disconnect speed sensor and remove speedome-ter adapter and sensor if necessary. (9) Disconnect transfer case shift lever from shiftlever rod. (10) Disconnect vent hose and electrical connec-tors. (11) Support transfer case with transmission jack. (12) Remove nuts attaching transfer case to trans-mission. (13) Secure transfer case to jack with chains. (14) Pull transfer case and jack rearward to disen-gage transfer case. Fig. 8 Transfer Case Vent Hose Routing (15) Remove transfer case from under vehicle. shaft attaching bolts to 19 N⅐m (170 in. lbs.) torque. (9) Fill transfer case with recommended lubricant.TRANSFER CASE INSTALLATION Correct level is to bottom edge of fill plug hole. (1) Mount transfer case on a transmission jack. Se- (10) Install rear crossmember if removed. Tightencure transfer case to jack with chains. crossmember bolts to 41 N⅐m (30 ft. lbs.) torque. (2) Position transfer case under vehicle.
    • ZJ NP231 TRANSFER CASE 21 - 297 (11) Remove transmission jack and transmissionsupport stand. (12) Connect transfer case shift lever to shift leverrod. (13) Check and adjust transfer case shift linkage ifnecessary. (14) Lower vehicle.TRANSFER CASE DISASSEMBLY AND OVERHAUL Two versions of the NP231 are used in cur-rent models. One version retains the synchro-nizer components used in previous years. Anewly introduced version does not have syn-chro components. The non-synchro version isnot equipped with a synchro gear, struts,springs, or stop ring. During overhaul, note Fig. 2 Rear Bearing Snap Ring Removalwhich version is being serviced and order (8) Remove rear retainer. Position screwdriver un-needed parts accordingly. der each tab on retainer housing (Fig. 3). Then care- (1) Remove fill and drain plugs. Also remove fully pry retainer upward and off rear case.speedometer adapter and pinion if not previously re-moved. CAUTION: Do not pry against the sealing surfaces (2) Remove front yoke. Discard yoke seal washer of the retainer or rear case. The surfaces could beand nut. They should not be reused. damaged. (3) Move transfer case range lever rearward to 4Lposition. (4) Remove extension housing attaching bolts. (5) Tap extension housing in clockwise direction tobreak sealer bead and remove housing (Fig. 1).CAUTION: To avoid damaging the sealing surfacesof the extension housing and rear retainer, do notpry or wedge the housing off the retainer. Fig. 3 Rear Retainer Removal (9) Remove bolts attaching rear case to front case. Retain bolts and washers. (10) Separate rear case from front case (Fig. 4) In- sert screwdrivers into slots cast in case ends. Then gently pry upward to break sealer bead and loosen rear case. CAUTION: Do not pry against the sealing surfaces of the retainer or rear case. The surfaces could be damaged. (11) Remove oil pump and rear case as an assem- Fig. 1 Extension Housing Removal bly (Fig. 5). (12) Slide oil pickup tube screen out of case pocket. (6) Remove rear bearing snap ring (Fig. 2). (13) Remove oil pump and pickup tube as assembly (7) Remove rear retainer attaching bolts. (Fig. 6).
    • 21 - 298 NP231 TRANSFER CASE ZJ Fig. 4 Loosening Rear Case Fig. 6 Oil Pump And Pickup Tube Removal Fig. 7 Removing Oil Screen And Pickup Tube Fig. 5 Rear Case And Oil Pump Removal (14) Disconnect screen from pickup tube and re-move screen (Fig. 7). (15) Remove pickup tube from oil pump (Fig. 7). (16) Remove pickup tube O-ring from oil pump(Fig. 8). (17) Remove mode spring (Fig. 9). (18) Tap front output shaft upward with rawhidemallet to free it from shaft bearing. Fig. 8 Pickup Tube O-Ring Location (19) Remove front output shaft and drive chain(Fig. 10).
    • ZJ NP231 TRANSFER CASE 21 - 299 (21) Remove mode fork and shift rail from synchro sleeve (Fig. 12). Fig. 9 Mode Spring Removal Fig. 12 Removing Mode Fork And Rail From Sleeve (22) Remove hub snap ring and remove spacer if equipped (Fig. 13). Fig. 10 Front Output Shaft And Drive Chain Removal (20) Remove mainshaft, mode fork and shift rail asassembly d (Fig. 11). Fig. 13 Hub Snap Ring And Spacer Removal Fig. 11 Removing Mainshaft, Mode Fork And Shift Rail
    • 21 - 300 NP231 TRANSFER CASE ZJ (23) Remove sleeve from hub (Fig. 14). Fig. 14 Removing Sleeve From Hub (24) Remove hub from mainshaft. On synchro mod-els, also remove synchro stop ring (Fig. 15). Fig. 17 Disengaging Range Fork Fig. 15 Hub And Stop Ring Removal (25) Remove drive sprocket (Fig. 16). Fig. 18 Range Fork And Hub Removal/Installation Fig. 16 Drive Sprocket Removal/Installation (26) Slide range fork pin out of shift sector (Fig.17). (27) Remove range fork and shift hub (Fig. 18). Fig. 19 Shift Sector Removal/Installation (28) Remove range lever from sector shaft. (29) Remove shift sector (Fig. 19).
    • ZJ NP231 TRANSFER CASE 21 - 301 (30) Remove sector shaft bushing and O-ring (Fig.20). Fig. 22 Front Bearing Retainer Bolt Locations Fig. 20 Removing/Installing Sector Shaft Bushing And O-Ring (31) Remove shift detent plunger, spring and plug(Fig. 21). Remove O-ring from plug after removal. Fig. 23 Removing Front Bearing Retainer Fig. 21 Detent Component Removal (32) Turn front case over and remove front bearingretainer bolts (Fig. 22). (33) Remove front bearing retainer. Position screw-drivers in retainer slots and lift upward to loosenand remove retainer (Fig. 23). (34) Remove input gear snap ring (Fig. 24). (35) Press input and low range gear assembly outof input gear bearing with shop press (Fig. 25). (36) Remove low range gear snap ring (Fig. 26). (37) Remove retainer, thrust washers and inputgear from low range gear (Fig. 27). Fig. 24 Removing Input Gear Snap Ring (38) Remove oil seals from rear retainer, rear ex- OVERHAUL CLEANING AND INSPECTIONtension housing, oil pump feed housing and case Clean the transfer case components thoroughlyhalves. with solvent. Remove all traces of sealer from the (39) Remove magnet from pocket in front case. case and retainer seal surfaces.
    • 21 - 302 NP231 TRANSFER CASE ZJ Inspect the splines and bearing surfaces on both shafts. Replace either shaft as necessary if wear, or damage is evident. Check condition of the shift forks, fork pads and shift rail. Minor scratches/nicks on the rail can be smoothed with 320/400 grit emery cloth. Replace the mode fork pads if worn. Replace the range fork if the pads are worn, missing, or damaged. On synchro equipped models, inspect the synchro sleeve, hub, struts, springs, and the stop ring. Re- place worn, or damaged parts as necessary. Do not attempt to salvage and reuse snap rings that were bent, or distorted. It is recommended that all snap rings be replaced during overhaul. Replace the front yoke nut as it should not be re- used. Also replace the rubber seal if worn, cut, or Fig. 25 Removing Input And Low Range Gear torn. Assembly Inspect the low range annulus gear (Fig. 28). If the gear is damaged, replace the gear and front case as an assembly. Do not attempt to remove the gear. Fig. 26 Removing Low Range Gear Snap Ring Fig. 28 Low Range Annulus Gear Location Inspect the case halves, extension housing and re- tainers for cracks, porosity, or damaged sealing sur- faces. Inspect the drive sprockets and drive chain care- fully. Replace the sprockets if worn, chipped, or cracked. Also replace the chain if distorted, binds at any point, or is stretched. Replace the oil pump if any pump part is worn or damaged. Do not disassemble the pump as parts are not available separately. The pump is only available as an assembly. Inspect all of the transfer case bearings for wear, Fig. 27 Input And Low Range Gear Components roughness, pitting, or galling. Replace worn or dam- Clean the oil pickup screen with solvent. Shake ex- aged bearings as outlined in the transfer case assem-cess solvent from screen and allow it air dry. Use bly procedures.compressed air to remove solvent residue from all oil Clean the sealing (mating) surfaces of the casefeed passages and channels in the case halves. halves, retainer and extension with a scraper, a wire
    • ZJ NP231 TRANSFER CASE 21 - 303brush and 3M All Purpose cleaning solvent. Thesesurfaces must be clean in order for the sealer to ad-here properly.TRANSFER CASE ASSEMBLYCAUTION: The bearing bores in various transfercase components contain oil feed holes. Be sure re-placement bearings do not block these feed holes.In addition, the drive sprocket, synchro hub andsleeve are different for non-synchro and synchromodels. Do not interchange these parts. Do not in-stall synchro struts or a stop ring in a non-synchromodel; this will cause the drive sprocket to bind onthe shaft and hub. Fig. 30 Removing/Installing Front Output ShaftFRONT CASE ASSEMBLY Bearing Snap Ring (1) Lubricate components with automatic transmis-sion fluid (or petroleum jelly where indicated) duringassembly. (2) Remove front output shaft seal from front casewith crowfoot style pry tool (Fig. 29). Fig. 31 Installing Front Output Shaft Front Bearing In Case Fig. 29 Front Output Shaft Oil Seal Removal (3) Remove snap ring retaining front output shaftfront bearing in case (Fig. 30). (4) Tap old front output shaft bearing out of frontcase with plastic mallet. Install new bearing withTool Handle C-4171 and Installer Tool 5064 (Fig. 31). (5) Secure front output shaft bearing in front casewith new snap ring (Fig. 30). (6) Install new front output shaft seal in front casewith suitable size socket or installer tool. (7) If front output shaft rear bearing is to be re-placed, install new bearing as follows: (a) Remove bearing from rear case with Bearing Remover MD-998346 and two suitable size Fig. 32 Front Output Shaft Rear Bearing Removal wrenches (Fig. 32). (8) Remove input gear bearing from front case (b) Seat new bearing in rear case with Tool Han- with Tool Handle C-4171 and Tool C-4210, 7828, or dle C-4171 and Bearing Installer 5063 (Fig. 33). 5062. Use tool that is best fit in bearing (Fig. 34).
    • 21 - 304 NP231 TRANSFER CASE ZJ INPUT AND LOW RANGE GEAR ASSEMBLY AND INSTALLATION (1) Remove mainshaft pilot bearing from input gear with Tool MD-998346 as follows: (a) Turn puller tool bolt until jaws retract enough to fit into bearing (Fig. 36). (b) Insert puller bolt and jaws into bearing. Then turn puller bolt clockwise so ramp on bolt spreads jaws forcing them under bearing (Fig. 37). (c) Install puller bridge over puller bolt (Fig. 38). Then install flat washer and nut on bolt. (d) Hold puller bridge from turning by hand or with locking pliers. Then tighten nut on puller bolt in clockwise direction to draw bearing out of input gear (Fig. 39).Fig. 33 Front Output Shaft Rear Bearing Installation (9) Turn front case over. (10) Start bearing in case by hand. Then seat bear-ing with Tools C-4171 and C-4210, or 7828 until snapring seats against case surface (Fig. 35). Fig. 36 Puller Jaws In Retracted Position Fig. 34 Input Gear Bearing Removal Fig. 35 Input Gear Bearing Installation Fig. 37 Puller Bolt And Jaws Seated Under Needle Bearing
    • ZJ NP231 TRANSFER CASE 21 - 305 Fig. 40 Installing Mainshaft Pilot Bearing In Input Gear Fig. 38 Installing Puller Bridge Fig. 41 Input And Low Range Gear Components Fig. 39 Removing Mainshaft Pilot Bearing From Input Gear (2) Install new needle bearing in input gear withTool Handle C-4171 and Installer 5065 (Fig. 40). (3) Lubricate and install thrust washers, inputgear and retainer in low range gear (Fig. 41). Theninstall retainer snap ring. Be sure snap ring isfully seated before proceeding. (4) Align and install input/low range gear assem-bly in case. Use hammer handle to tap low rangegear into annulus and input gear into bearing if nec-essary. Fig. 42 Installing Input Gear Snap Ring (5) Install input gear snap ring (Fig. 42). (6) Install new oil seal in input bearing retainer (7) Apply 3 mm (1/8 in.) wide bead of Mopar Gas-with suitable size installer tool (Fig. 43). ket Maker, silicone adhesive/sealer, or Loctite 518 to front bearing retainer seal surface (Fig. 44).
    • 21 - 306 NP231 TRANSFER CASE ZJ Fig. 45 Aligning Retainer Oil Channel With Feed Hole In Case Fig. 43 Installing Input Bearing Retainer Oil Seal Fig. 46 Bearing Retainer Installation Fig. 44 Applying Sealer Bead To Bearing Retainer (8) Align oil channel in retainer with oil feed holein case (Fig. 45). (9) Install input (front) bearing retainer on frontcase (Fig. 46). Tighten retainer bolts to 21 N⅐m (16 ft.lbs.) torque. Fig. 47 Installing Sector O-Ring And RetainerSHIFT SECTOR, RANGE FORK AND SLEEVE BushingINSTALLATION (3) Install range lever and lever attaching nut on (1) Install new sector shaft O-ring and retainer shift sector. Tighten attaching nut to 30 N⅐m (22 ft.bushing (Fig. 47). lbs.) torque. (2) Install shift sector in the case (Fig. 48).
    • ZJ NP231 TRANSFER CASE 21 - 307 Fig. 48 Shift Sector Installation Fig. 50 Range Fork Pad Locations (4) Install detent plunger, spring and plug (Fig.49). Tighten plug to 20 N⅐m (15 ft. lbs.) torque. Fig. 51 Assembling Range Fork And Shift Hub Fig. 49 Installing Detent Plunger, Spring And Plug (5) Inspect pads on range fork (Fig. 50). Be surepads are secure and in position. Replace fork as anassembly if pads are worn through, or broken. (6) Assemble range fork and shift hub (Fig. 51). (7) Engage range fork pin in shift sector slot (Fig.52). (8) Insert shift hub in low range gear. Be sure hubis fully seated.MAINSHAFT ASSEMBLY (1) If drive sprocket bearings are to be replaced,remove and install them as follows: (a) Press both bearings out of sprocket simulta- neously with Tool Handle C-4171 and Remover Tool Fig. 52 Seating Range Fork Pin In Shift Sector Slot C-4667, or 5066 (Fig. 53). CAUTION: Do not press the bearings any farther (b) Before installing new bearings, refer to Fig- into the sprocket than indicated in Figure 54. The ure 54 and note correct bearing position in bearings could block the mainshaft oil feed hole if sprocket. Bearings must also be installed in proper pressed too deeply into the sprocket. sequence. Install front bearing first and rear bear- ing last.
    • 21 - 308 NP231 TRANSFER CASE ZJ (c) Install new front bearing first. Press bearing flush with edge of sprocket bore (Fig. 55). (d) Install new rear bearing (Fig. 56). Press bearing in until 4.6 mm (3/16 in.) below edge of bore as shown in Figure 46. Fig. 55 Drive Sprocket Front Bearing Installation Fig. 53 Drive Sprocket Bearing Removal Fig. 56 Drive Sprocket Rear Bearing Installation Fig. 57 Installing Synchro Springs And Struts In Hub Fig. 54 Correct Bearing Position In Drive Sprocket (2) On synchro models, install struts and spring(s)in hub (Fig. 57).
    • ZJ NP231 TRANSFER CASE 21 - 309 (3) Lubricate drive sprocket bearings, stop ring CAUTION: Correct sleeve alignment is important toand hub with automatic transmission fluid. Bearings proper shifting on synchro models. Be sure acan also be lubricated with petroleum jelly if desired. sleeve tooth is aligned (centered) over each syn- (4) Install sprocket, stop ring (synchro models chro strut (Fig. 60). Gear clash will occur if theonly) and hub on mainshaft (Fig. 58). Be sure to struts and sleeve teeth are misaligned.seat hub struts on stop ring lugs. Fig. 58 Sprocket, Stop Ring And Hub Installation (5) Install spacer washer on hub, if equipped. (6) Install new hub retaining snap ring (Fig. 59). Fig. 60 Correct Synchro Strut And Sleeve Alignment (Synchro Models Only) (2) Install new pads on mode fork. (3) Engage mode fork in sleeve (Fig. 61). (4) Install mode fork-mainshaft assembly in case (Fig. 61). Be sure the mode fork rail is seated in case bore. (5) Lift mainshaft upward about 2.54 cm (1-inch). (6) Position front output shaft in drive chain. (7) Install chain on drive sprocket and start front shaft into front bearing at same time (Fig. 62). Fig. 59 Hub Retaining Snap Ring Installation (8) Seat mainshaft and front output shaft (Fig. 54). If front shaft is hard to seat, lift mainshaft slightly toMAINSHAFT AND MODE FORK INSTALLATION allow front shaft to seat. (1) Install sleeve on hub. Be sure sleeve is in- (9) Reseat mainshaft in input gear and seat sleevestalled with beveled spline ends facing stop ring and on hub if necessary.short end of sleeve toward rear of shaft. In addition, (10) Install mode spring on shift rail (Fig. 63).on synchro models, be sure a sleeve tooth is alignedwith each synchro strut (Fig. 60).
    • 21 - 310 NP231 TRANSFER CASE ZJ OIL PUMP, REAR CASE, REAR RETAINER AND EXTENSION INSTALLATION (1) Install new seal in oil pump feed housing with Special Tool 7888 (Fig. 64). Fig. 61 Installing Mainshaft And Mode Fork Assembly Fig. 64 Oil Pump Seal Installation (2) Install new pickup tube O-ring in oil pump (Fig. 65). Fig. 62 Installing Drive Chain And Front Output Shaft Fig. 65 Pickup Tube O-Ring Installation (3) Prime oil pump by pouring transmission fluid into pump through pickup tube opening. (4) Insert pickup tube in oil pump. Then attach oil screen and connecting hose to pickup tube (Fig. 66). (5) Install assembled pump, pickup tube and screen in rear case. Be sure screen is seated in case slot as shown (Fig. 66). (6) Install magnet in front case pocket. (7) Clean sealing surfaces of rear case front case, retainer and extension. Use 3M all purpose cleaner or equivalent product. Fig. 63 Installing Mode Spring On Shift Rail (8) Apply 3 mm (1/8 in.) wide bead of Mopar gas- ket maker, silicone adhesive sealer, or Loctite 518 to sealing surface of front case.
    • ZJ NP231 TRANSFER CASE 21 - 311 (11) Install output bearing in rear retainer. Tap old bearing out of retainer with hammer and brass drift. Then install new bearing with Tool Handle C-4171 and Installer 5064 (Fig. 68). Fig. 66 Pickup Tube, Oil Screen And Pump Fig. 68 Installing Mainshaft Rear Bearing In Rear Installation Retainer (9) Align and install rear case/oil pump assembly (12) Apply 3 mm (1/8 in.) wide bead of Mopar gas-on front case (Fig. 67). Be sure case locating dowels ket maker, silicone adhesive sealer, or Loctite 518 toare in place and that mainshaft splines are engaged flange surface of rear retainer.in oil pump inner gear. (13) Align and install rear retainer on rear case. Install and tighten retainer bolts to 27-34 N⅐m (20-25 ft. lbs.) torque. (14) Install new output bearing snap ring (Fig. 69). Lift mainshaft slightly to seat snap ring in shaft groove if necessary. Fig. 69 Installing Output (Rear) Bearing Snap Ring (15) Remove extension housing seal if not removed previously. (16) Remove extension housing bushing with Bush- ing Installer Tools C-4171 and 7889-A (Fig. 70). (17) Install new extension housing bushing with Installer Tools C-4171 and 5066 (Fig. 71). Fig. 67 Installing Rear Case On Front Case (18) Install new seal in extension. Use suitable (10) Install and tighten front case-to-rear case at- size socket, or installer tool to seat seal.taching bolts to 27-34 N⅐m (20-25 ft. lbs.) torque. Be (19) Apply 3 mm (1/8 in.) wide bead of Mopar gas-sure to install a washer under each bolt used at ket maker, silicone adhesive sealer, or Loctite 518 tocase dowel locations. mounting surface of extension housing.
    • 21 - 312 NP231 TRANSFER CASE ZJ (21) Install new seal on front output shaft (Fig. 72). Fig. 70 Extension Housing Bushing Removal Fig. 72 Front Shaft Seal Installation (22) Install front yoke on front shaft. Secure yoke with replacement nut. Tighten nut to 149 N⅐m (110 ft. lbs.) torque. (23) Install replacement gasket on indicator/vac- uum switch and install switch in front case. Tighten switch to 27-34 N⅐m (20-25 ft. lbs.) torque. (24) Install and tighten drain plug to 47 N⅐m (35 ft. lbs.) torque. (25) Install speedometer pinion and adapter and speed sensor. (26) Fill transfer case with Mopar Dexron II. Cor- rect level is to bottom edge of fill plug hole. (27) Install and tighten fill plug to 41 N⅐m (35 ft. Fig. 71 Extension Housing Bushing Installation lbs.) torque. (20) Align and install extension on retainer. Theninstall and tighten extension bolts to 27-34 N⅐m(20-25 ft. lbs.) torque.
    • ZJ NP231 TRANSFER CASE 21 - 313 NP231 TRANSFER CASE
    • 21 - 314 NP231 TRANSFER CASE ZJ LEGEND FOR NP231 TRANSFER CASE
    • ZJ NP242 TRANSFER CASE 21 - 315 NP242 TRANSFER CASE INDEX page pageGeneral Information . . . . . . . . . . . . . . . . . . . . . . . 315 Transfer Case Disassembly and Overhaul . . . . . . 321Operating Ranges . . . . . . . . . . . . . . . . . . . . . . . . 315 Transfer Case Fill Level . . . . . . . . . . . . . . . . . . . . 316Overhaul Cleaning and Inspection . . . . . . . . . . . . 328 Transfer Case Identification . . . . . . . . . . . . . . . . . 315Shift Linkage Adjustment . . . . . . . . . . . . . . . . . . . 318 Transfer Case Installation . . . . . . . . . . . . . . . . . . 320Speedometer Service . . . . . . . . . . . . . . . . . . . . . 318 Transfer Case Lubricant . . . . . . . . . . . . . . . . . . . 316Transfer Case Assembly . . . . . . . . . . . . . . . . . . . 329 Transfer Case Removal . . . . . . . . . . . . . . . . . . . . 320Transfer Case Changes . . . . . . . . . . . . . . . . . . . . 316GENERAL INFORMATION The only exception being when the road surface is The NP242 is a full and part time transfer case covered by ice and snow.with four operating ranges (Fig. 1). The NP242 pro- The low range reduction gear system is operativevides both 2-wheel drive and full time 4-wheel drive in 4 Lo range only. This range is for extra pullingoperation. power in off road situations. Low range reduction ra- The differential has a locking mechanism for undif- tio is 2.72:1.ferentiated 4-wheel drive in low range. A low rangegear reduction system provides increased low speed SHIFT MECHANISMtorque capability. Transfer case operating ranges are selected with a floor mounted shift lever. The shift lever is connected to the transfer case range lever by an adjustable linkage rod. Range positions are marked on the shifter bezel plate. TRANSFER CASE IDENTIFICATION A circular I.D. tag is attached to the rear case of each NP242 transfer case (Fig. 2). The tag provides the transfer case model number, assembly number, serial number and low range ratio. The transfer case serial number also represents the date of build. For example, a serial number of 7-10-94 would represent July 10, 1994. Fig. 1 NP242 Transfer CaseOPERATING RANGES The NP242 transfer case operating ranges are:• 2WD (2-wheel drive)• 4x4 part-time• 4x4 full time• 4 Lo (4-wheel drive low). The 2WD and 4x4 full time ranges are for use onany road surface at any time. The 4x4 part time and 4 Lo ranges are for off roaduse only. They are not for use on hard surface roads. Fig. 2 Transfer Case I.D. Tag
    • 21 - 316 NP242 TRANSFER CASE ZJTRANSFER CASE CHANGES TRANSFER CASE FILL LEVEL The only service change for 1995 involves the front Correct fill level for the NP242 transfer case is tooutput seal which is new. The new seal does not have the bottom edge of the fill plug hole.the flange used on prior seals and affects seal instal-lation. The new seal must be seated below the edgeof the seal bore in the front case. Refer to the over-haul procedures for seal installation.TRANSFER CASE LUBRICANT Mopar Dexron II is the recommended lubricant forthe NP242 transfer case. Lubricant capacity is ap-proximately 1.4 liters (1.45 qts.).
    • ZJ NP242 TRANSFER CASE 21 - 317 NP242 SERVICE DIAGNOSIS
    • 21 - 318 NP242 TRANSFER CASE ZJSHIFT LINKAGE ADJUSTMENT SPEEDOMETER ASSEMBLY REMOVAL (1) Move transfer case shift lever into Neutral po- (1) Raise vehicle.sition. (2) Disconnect wires from vehicle speed sensor. (2) Raise vehicle on hoist that will allow all four (3) Remove adapter clamp and screw (Fig. 5).wheels to rotate freely. (4) Remove speed sensor and speedometer adapter (3) Loosen trunnion lock bolt (Figs. 3 and 4). as assembly.Loosen bolt enough so selector rod slides freely in (5) Remove speed sensor retaining screw and re-trunnion. move sensor from adapter. (4) Verify that shift lever on transfer case is in (6) Remove speedometer pinion from adapter. Re-Neutral position. place pinion if worn, cracked, or chipped. (5) Tighten trunnion lock bolt to 8-14 N⅐m (72-120 (7) Inspect sensor and adapter O-rings (Fig. 5). Re-in. lbs.) torque. move and discard O-rings if worn or damaged. (6) Lower vehicle enough for entry into driver seat (8) Inspect terminal pins in speed sensor. Cleanbut keep all wheels off shop floor. pins with Mopar electrical spray cleaner if dirty or (7) Verify correct linkage adjustment. Start engine, oxidized. Replace sensor if faulty, or pins are loose,shift transmission into gear and shift transfer case severely corroded, or damaged.into all ranges. Be sure transfer case is fully engagedin high and low range. Readjust linkage if necessary. SPEEDOMETER INSTALLATION AND (8) Shut engine off and lower vehicle completely. INDEXING (1) Thoroughly clean adapter flange and adapterSPEEDOMETER SERVICE mounting surface in housing. Surfaces must be clean Rear axle gear ratio and tire size determine speed- for proper adapter alignment and speedometer oper-ometer pinion requirements. If the pinion must be re- ation.placed, refer to the parts catalogue information for (2) Install new O-rings on speed sensor and speed-the correct part. ometer adapter if necessary (Fig. 5). (3) Lubricate sensor and adapter O-rings with transmission fluid. Fig. 3 Transfer Case Shift Linkage (Manual Transmission)
    • ZJ NP242 TRANSFER CASE 21 - 319 Fig. 4 Transfer Case Shift Linkage (Automatic Transmission) Fig. 5 Speedometer Components (4) Install vehicle speed sensor in speedometer (6) Count number of teeth on speedometer pinion.adapter. Tighten sensor attaching screw to 2-3 N⅐m Do this before installing assembly in housing. Then(15-27 in. lbs.) torque. lubricate pinion teeth with transmission fluid. (5) Install speedometer pinion in adapter.
    • 21 - 320 NP242 TRANSFER CASE ZJ (7) Note index numbers on adapter body (Fig. 6). TRANSFER CASE INSTALLATIONThese numbers will correspond to number of teeth on (1) Mount transfer case on a transmission jack. Se-pinion. cure transfer case to jack with chains. (8) Install speedometer assembly in housing. (2) Position transfer case under vehicle. (9) Rotate adapter until required range numbers (3) Align transfer case and transmission shafts andare at 6 o-clock position. Be sure range index num- install transfer case on adapter (Fig. 7).bers correspond to number of teeth on pinion gear. (4) Install and tighten transfer case attaching (10) Install speedometer adapter clamp and retain- nuts. Tighten nuts to 35 N⅐m (26 ft. lbs.) torque ifing screw. Tighten clamp screw to 10-12 N⅐m (90-110 case has 5/16 studs. Tighten nuts to 47 N⅐m (35 ft.in. lbs.) torque. lbs.) torque if case has 3/8 studs. (11) Connect wires to vehicle speed sensor. (12) Lower vehicle and top off transmission fluidlevel if necessary. Fig. 7 Transfer Case Attachment (5) Install speedometer adapter, pinion, and speed sensor.Fig. 6 Location Of Index Numbers On Speedometer (6) Connect electrical wires to speed sensor. Adapter (7) Connect vent hose to transfer case vent (Fig. 8).TRANSFER CASE REMOVAL (8) Align and connect propeller shafts. Tighten (1) Shift transfer case into Neutral. (2) Raise vehicle. (3) Drain transfer case lubricant. (4) Mark front and rear propeller shaft yokes foralignment reference. (5) Place support stand under transmission. (6) Remove rear crossmember. (7) Disconnect front/rear propeller shafts at trans-fer case. (8) Disconnect speed sensor and remove speedome-ter adapter and sensor if necessary. (9) Disconnect transfer case shift lever from shiftlever rod. (10) Disconnect vent hose and electrical connec-tors. (11) Support transfer case with transmission jack. (12) Remove bolts attaching transfer case to trans-mission. (13) Secure transfer case to jack with chains. (14) Pull transfer case and jack rearward to disen-gage transfer case. (15) Remove transfer case from under vehicle. Fig. 8 Transfer Case Vent Hose Routing shaft attaching bolts to 19 N⅐m (170 in. lbs.) torque.
    • ZJ NP242 TRANSFER CASE 21 - 321 (9) Fill transfer case with Dexron II. Correct levelis to bottom edge of fill plug hole. (10) Install rear crossmember if removed. Tightencrossmember bolts to 41 N⅐m (30 ft. lbs.) torque. (11) Remove transmission jack and transmissionsupport stand. (12) Connect transfer case shift lever to shift leverrod. (13) Check and adjust transfer case shift linkage ifnecessary. (14) Lower vehicle.TRANSFER CASE DISASSEMBLY AND OVERHAUL (1) Remove fill and drain plugs. (2) Remove front yoke. Discard yoke seal washerand nut. (3) Place transfer case range lever in 4L position. (4) Remove extension housing attaching bolts. (5) Tap extension housing in a clockwise directionto break sealer bead and remove housing (Fig. 1).CAUTION: To avoid damaging the sealing surfaces Fig. 2 Removing Rear Bearing Snap Ringof the extension housing and rear retainer, do notattempt to pry or wedge the housing off the re- (8) Loosen rear retainer (Fig. 3). Position longtainer. screwdriver under each tab at ends of retainer hous- ing and pry retainer upward. CAUTION: Do not pry against the sealing surfaces of the retainer or rear case. The surfaces could be damaged. Fig. 1 Extension Housing Removal (6) Remove rear bearing snap ring from mainshaft(Fig. 2). Discard snap ring. (7) Remove rear retainer attaching bolts. Fig. 3 Loosening Rear Retainer
    • 21 - 322 NP242 TRANSFER CASE ZJ(9) Lift rear retainer up and off case and mainshaft (12) Remove rear case and oil pump as assembly(Fig. 4). (Fig. 6). Fig. 4 Rear Retainer Removal Fig. 6 Rear Case And Oil Pump Removal (10) Remove bolts attaching rear case to front case. (13) Slide oil screen (Fig. 7) out of case pocket.Retain bolts and the washers. (11) Loosen rear case with two screwdrivers (Fig.5). Insert screwdrivers into slots cast in case ends.Then gently pry upward to break sealer bead.CAUTION: Do not pry against the sealing surfacesof the front case or rear case. The surfaces couldbe damaged. Fig. 7 Unseating Oil Screen Fig. 5 Loosening Rear Case
    • ZJ NP242 TRANSFER CASE 21 - 323 (14) Remove oil pump, pickup tube and oil screen (17) Remove and discard oil pump seal.from rear case (Fig. 8). (18) Remove magnet from front case. (19) Remove drive sprocket snap ring (Fig. 10). Fig. 8 Oil Pump/Pickup Tube/Screen Removal (15) Remove pickup tube and screen from pump.Do not disassemble oil pump; it is not repair- Fig. 10 Drive Sprocket Snap Ring Removalable. Pumps are serviced only as an assembly. (20) Remove drive sprocket and chain (Fig. 11). (16) Remove pickup tube O-ring from oil pump(Fig. 9). Fig. 9 Pickup Tube O-Ring Removal fig. 11 Drive Sprocket And Chain Removal
    • 21 - 324 NP242 TRANSFER CASE ZJ (21) Remove front output shaft (Fig. 12). (25) Remove range fork lockpin with size number one easy-out tool. Grip easy-out tool with locking pli- ers and remove pin with counterclockwise, twist and pull motion (Fig. 14). Fig. 12 Removing Front Output Shaft (22) Remove transfer case shift lever nut and lever. (23) Remove shift detent plug, spring and pin (Fig.13) Fig. 14 Low Range Fork Lockpin Removal (26) Remove shift rail by pulling it straight up and out of fork (Fig. 15). Fig. 13 Detent Component Removal (24) Remove seal plug from low range fork lockpinaccess hole. Then move shift sector to align low rangefork lockpin with access hole (Fig. 14). Fig. 15 Shift Rail Removal
    • ZJ NP242 TRANSFER CASE 21 - 325 (27) Remove mode fork and mainshaft as assembly (29) Remove intermediate clutch shaft snap ring(Fig. 16). (Fig. 18). Fig. 16 Mode Fork And Mainshaft Removal Fig. 18 Intermediate Clutch Shaft Snap Ring (28) Remove mode shift sleeve and mode fork as- Removalsembly from mainshaft (Fig. 17). Note position of (30) Remove clutch shaft thrust ring (Fig. 19).mode sleeve in fork and remove sleeve. Fig. 19 Clutch Shaft Thrust Ring Removal Fig. 17 Mode Fork And Sleeve Removal
    • 21 - 326 NP242 TRANSFER CASE ZJ (31) Remove intermediate clutch shaft (Fig. 20). (34) Remove differential needle bearings and both needle bearing thrust washers from mainshaft. Fig. 20 Intermediate Clutch Shaft Removal Fig. 22 Differential Removal (32) Remove differential snap ring (Fig. 21). (35) Slide low range fork pin out of shift sector slot (Fig. 23) Fig. 21 Differential Snap Ring Removal (33) Remove differential (Fig. 22). Fig. 23 Disengaging Low Range Fork
    • ZJ NP242 TRANSFER CASE 21 - 327 (36) Remove low range fork and hub (Fig. 24). (38) Remove shift sector bushing and O-ring (Fig. 26). Fig. 24 Low Range Fork And Hub Removal Fig. 26 Sector Bushing And O-Ring Removal (37) Remove shift sector (Fig. 25). (39) Remove front bearing retainer bolts. (40) Remove front bearing retainer. Carefully pry retainer loose with screwdriver (Fig. 27). Position screwdriver in slots cast into retainer. Fig. 25 Shift Sector Position Fig. 27 Front Bearing Retainer Removal
    • 21 - 328 NP242 TRANSFER CASE ZJ (41) Remove input gear snap ring (Fig. 28). Fig. 28 Input Gear Snap Ring Removal (42) Remove input/low range gear assembly from Fig. 30 Low Range Gear Snap Ring Removal/bearing with Tool Handle C-4171 and Tool 7829A Installation(Fig. 29). Fig. 29 Input And Low Range Gear Assembly Removal Fig. 31 Low Range Gear Disassembly (43) Remove low range gear snap ring (Fig. 30). (48) Remove differential case bolts and separate (44) Remove input gear retainer, thrust washers top case from bottom case. Use slots in case halves toand input gear from low range gear (Fig. 31). pry them apart (Fig. 33). (45) Inspect low range annulus gear (Fig. 32). (49) Remove thrust washers and planet gears fromGear is not a serviceable component. If dam- case pins (Fig. 34).aged, replace gear and front case as assembly. (50) Remove mainshaft and sprocket gears from (46) Remove oil seals from following components: bottom case (Fig. 35). Note gear position for reference• rear retainer before separating them.• extension housing• oil pump OVERHAUL CLEANING AND INSPECTION• case halves Clean the transfer case components thoroughly (47) Mark differential case halves for reference. with solvent. Remove all traces of sealer from the case and retainer seal surfaces.
    • ZJ NP242 TRANSFER CASE 21 - 329 Fig. 32 Inspecting Low Range Annulus Gear Fig. 34 Planet Gears And Thrust Washer Removal Fig. 33 Separating Differential Case Halves Clean the oil pickup screen with solvent and allow Fig. 35 Mainshaft And Sprocket Gear Removalit to air dry. Use compressed air to remove solvent faces. Inspect the shafts, gears, chain and shiftresidue from all oil feed passages and channels in components for wear or damage.case halves. Inspect all of the transfer case bearings for wear, Inspect the differential gears, thrust washers and roughness, pitting, or galling. Replace worn or dam-case halves. Replace the mainshaft gear if the gear aged bearings as outlined in the assembly section.teeth or the brass ring on the underside of the gearare damaged. Replace the differential as an assembly TRANSFER CASE ASSEMBLYif the gears, case halves, or the pins in the lower case (1) Lubricate transfer case components with auto-half are damaged. matic transmission fluid or petroleum jelly (where in- Inspect the case halves, extension housing and re- dicated) during assembly.tainers for cracks, porosity, or damaged sealing sur-
    • 21 - 330 NP242 TRANSFER CASE ZJCAUTION: The bearing bores in various transfer (b) Seat seal 2.03 to 2.5 mm (0.080 to 0.100 in.)case components contain oil feed holes. Be sure re- below top edge of seal bore in front case (Fig. 39).placement bearings do not block these feed holes. Tool 6888 will seat seal to desired depth. Check seal depth with dial caliper. (2) Remove snap ring that retains front outputshaft front bearing in case (Fig. 36). Then remove CAUTION: Be sure the front output seal is seatedbearing. Use hammer handle, or hammer and brass below the top edge of the case bore as shown (Fig.punch to tap bearing out of case. 39). The seal could work loose if not seated to the recommended depth. Fig. 38 Starting Front Output Shaft Seal Into Case BoreFig. 36 Front Output Shaft Front Bearing Snap Ring Removal (3) Install new front output shaft bearing with ToolHandle C-4171 and Installer 8033A (Fig. 37). Fig. 39 Front Output Seal Installation Depth (6) Remove input gear bearing with Tool Handle C-4171 and Remover C-4210 (Fig. 40). (7) Install snap ring on new input gear bearing. (8) Install new input gear bearing with shop press and wood block. Install bearing far enough to seatFig. 37 Front Output Shaft Front Bearing Installation snap ring against case (Fig. 41). (4) Install front bearing snap ring (Fig. 36). (9) Remove input gear pilot bearing with slide (5) Install new front output shaft oil seal with Tool hammer and internal puller (Fig. 42).6888 or suitable size tool as follows: (10) Install new pilot bearing with Tool Handle (a) Tap seal into bore until flush with upper edge C-4171 and Installer 5065 (Fig. 43). of case bore (Fig. 38).
    • ZJ NP242 TRANSFER CASE 21 - 331 Fig. 40 Input Gear Bearing Removal Fig. 42 Input Gear Pilot Bearing Removal Fig. 43 Input Gear Pilot Bearing Installation Fig. 41 Seating Input Gear Bearing (11) Assemble low range gear, input gear thrustwashers, input gear and input gear retainer (Fig. 44). Fig. 44 Low Range And Input Gear Assembly
    • 21 - 332 NP242 TRANSFER CASE ZJ (12) Install low range gear snap ring (Fig. 45). (16) Install new input gear snap ring (Fig. 47). Fig. 47 Input Gear Snap Ring Installation (17) Install new seal in front bearing retainer with Fig. 45 Install Low Range Gear Snap Ring Tool Handle C-4171 and Installer 7884 (Fig. 48). (13) Lubricate input gear and low range gears withautomatic transmission fluid. (14) Start input gear shaft into front case bearing. (15) Press input gear shaft into front bearing.CAUTION: Be sure the input gear installer tool isthe proper size. The wrong size tool could push theinput gear pilot bearing too far into the gear bore(Fig. 46). Also, do not press against the end sur-faces of the low range gear. The gear case andthrust washers could be damaged. Fig. 48 Front Bearing Retainer Seal Installation Fig. 46 Input Gear Installation
    • ZJ NP242 TRANSFER CASE 21 - 333(18) Apply 3 mm (1/8 in.) wide bead of Mopar gasketmaker. silicone adhesive sealer, or Loctite 518 to sealsurface of front bearing retainer. (19) Install front bearing retainer (Fig. 49).Tighten retainer bolts to 16 ft. lbs. (21 N⅐m) torque. Fig. 51 Assembling Low Range Fork And Hub (24) Position low range fork and hub in case. Be sure low range fork pin is engaged in shift sector slot (Fig. 52). Fig. 49 Installing Front Bearing Retainer (20) Install new sector shaft O-ring and bushing(Fig. 50). Fig. 52 Positioning Low Range Fork (25) Lubricate differential components with auto- matic transmission fluid. (26) Install sprocket gear in differential bottom case (Fig. 53). (27) Install differential planet gears and new thrust washers (Fig. 54). Be sure thrust washers Fig. 50 Sector O-Ring And Bushing Installation are installed at top and bottom of each planet (21) Install shift sector. gear. (22) Install new pads in low range fork (Fig. 51). (28) Install differential mainshaft gear (Fig. 54). (23) Assemble low range fork and hub (Fig. 51). (29) Align and position differential top case on bot- tom case (Fig. 55). Align using scribe marks made at disassembly.
    • 21 - 334 NP242 TRANSFER CASE ZJ Fig. 53 Installing Differential Sprocket Gear Fig. 55 Differential Case Assembly Fig. 54 Installing Mainshaft And Planet Gears Fig. 56 Installing Mainshaft Bearing Rollers and (30) Install and tighten differential case bolts to Spacersspecified torque. (31) Install first mainshaft bearing spacer onmainshaft (Fig. 56). (32) Install bearing rollers on mainshaft (Fig. 56).Coat bearing rollers with generous quantity ofpetroleum jelly to hold them in place. (33) Install remaining bearing spacer on mainshaft(Fig. 56). Do not displace any bearings while install-ing spacer.
    • ZJ NP242 TRANSFER CASE 21 - 335 (34) Install differential (Fig. 57). Do not displacemainshaft bearings when installing differential. (35) Install differential snap ring (Fig. 58). Fig. 59 Installing Intermediate Clutch Shaft Fig. 57 Differential Installation Fig. 60 Installing Clutch Shaft Thrust Washer check springs and slider bracket (Fig. 62). Replace worn, damaged components. Fig. 58 Installing Differential Snap Ring (40) Install mode sleeve in mode fork (Fig. 63). (36) Install intermediate clutch shaft (Fig. 59). Then install assembled sleeve and fork on mainshaft. (37) Install clutch shaft thrust washer (Fig. 60). Be sure mode sleeve splines are engaged in differen- (38) Install clutch shaft snap ring (Fig. 61). tial splines. (39) Inspect mode fork assembly (Fig. 62). Replace (41) Install mode fork and mainshaft assembly inpads and bushing if necessary. Replace fork tube if case (Fig. 64). Rotate mainshaft slightly to engagebushings inside tube are worn or damaged. Also shaft with low range gears. (42) Rotate mode fork pin into shift sector slot.
    • 21 - 336 NP242 TRANSFER CASE ZJ Fig. 61 Installing Clutch Shaft Snap Ring Fig. 63 Installing Mode Fork And Sleeve Fig. 62 Mode Fork Assembly Inspection Fig. 64 Assembled Mainshaft And Mode Fork Installation
    • ZJ NP242 TRANSFER CASE 21 - 337 (43) Install shift rail (Fig. 65). Be sure rail is (47) Install plug in lockpin access hole.seated in both shift forks. (48) Install transfer case shift lever and attaching nut. Tighten nut to 30 N⅐m (22 ft. lbs.) torque. (49) Install detent plunger, detent spring and de- tent plug in case (Fig. 67). Fig. 67 Detent Pin, Spring And Plug Installation (50) Install front output shaft (Fig. 68). Fig. 65 Shift Rail Installation (51) Install drive chain (Fig. 68). Engage chain (44) Rotate shift sector to align lockpin hole in low with front output shaft sprocket teeth.range fork with access hole in case. (52) Install drive sprocket (Fig. 68). (45) Insert an easy-out in range fork lockpin to (53) Engage drive sprocket teeth with chain. Thenhold it securely for installation (Fig. 66). Lockpin is engage sprocket splines with mainshaft splines.slightly tapered on one end. Insert tapered endinto fork and rail. (46) Insert lockpin through access hole and intoshift fork (Fig. 66). Then remove easy-out and seatthe pin with pin punch. Fig. 68 Drive Chain And Sprocket Installation (54) Install drive sprocket snap ring (Fig. 69). (55) Replace front output shaft rear bearing (Fig. 70). Remove bearing with internal puller and slide Fig. 66 Installing Low Range Fork Lockpin
    • 21 - 338 NP242 TRANSFER CASE ZJ Fig. 71 Oil Pump Seal Installation (57) Install new pickup tube O-ring in oil pump (Fig. 72). Fig. 69 Drive Sprocket Snap Ring Installationhammer. Install new bearing with Tool HandleC-4171 and Installer 5066. Lubricate bearing afterinstallation. Fig. 72 Pickup Tube O-Ring Installation (58) Insert oil pickup tube in oil pump and attach oil screen and connecter hose to pickup tube. Then install assembled pump, tube and screen in rear case (Fig. 73). Be sure screen is seated in case slot as shown. (59) Install magnet in front case pocket (Fig. 74). (60) Apply 3 mm (1/8 in.) wide bead of Mopar gas- ket maker, silicone adhesive sealer, or Loctite 518 to seal surface of front case. (61) Align and install rear case on front case. BeFig. 70 Front Output Shaft Rear Bearing Installation sure case locating dowels are in place and that main- shaft splines are engaged in oil pump inner gear. (56) Install new seal in oil pump feed housing withSpecial Tool 7888 (Fig. 71).
    • ZJ NP242 TRANSFER CASE 21 - 339 Fig. 73 Oil Screen And Pickup Tube Installation Fig. 75 Installing Rear Bearing In Retainer (68) Remove extension housing seal if not removed Fig. 74 Installing Case Magnet (62) Install and tighten front case-to-rear casebolts to 41 N⅐m (30 ft. lbs.) torque. Be sure to in-stall a washer under each bolt used at casedowel locations. (63) Tap rear retainer bearing out of retainer withhammer and brass drift. (64) Install bearing in rear retainer with Driver Fig. 76 Rear Bearing Snap Ring InstallationHandle C-4171 and Installer 5064 (Fig. 75). previously. (65) Apply 3 mm (1/8 in.) wide bead of Mopar gas- (69) Replace extension housing bushing (Fig. 77).ket maker, silicone adhesive sealer, or Loctite 518 to • Use Tools C-4171 and 7889-A to remove bushingseal surface of rear retainer. • Use Tools C-4171 and 5066 to install bushing (66) Install locating dowel in rear retainer (if re- (70) Install new extension housing oil seal withmoved) and install retainer on the case. Tighten re- Special Tool 7891 (Fig. 78).tainer bolts to 41 N⅐m (30 ft. lbs.) torque. (71) Apply 3 mm (1/8 in.) wide bead of Mopar gas- (67) Install new rear bearing snap ring (Fig. 76). ket maker, silicone adhesive sealer, or Loctite 518 toLift mainshaft slightly to seat snap ring if necessary. seal surface of extension housing.
    • 21 - 340 NP242 TRANSFER CASE ZJ Fig. 78 Seating Extension Housing Seal (74) Install new gasket on vacuum switch and in- stall switch in case. Tighten switch to 27 N⅐m (20 ft. lbs.) torque. (75) Install speedometer components. Fig. 77 Extension Housing Bushing Replacement (76) Install and tighten drain plug to 47 N⅐m (35 ft. lbs.) torque. (72) Install extension housing on case. Tighten (77) After installing transfer case, refill with rec-housing bolts to 41 N⅐m (30 ft. lbs.) torque. ommended lubricant. (73) Install front yoke. Secure yoke with new seal (78) Tighten fill plug to 47 N⅐m (35 ft. lbs.) torque.washer and nut. Tighten nut to 149 N⅐m (110 ft. lbs.) (79) Adjust transfer case shift linkage.torque.
    • ZJ NP242 TRANSFER CASE 21 - 341 NP242 TRANSFER CASE
    • 21 - 342 NP242 TRANSFER CASE ZJ LEGEND FOR NP242 TRANSFER CASE
    • ZJ NP249 TRANSFER CASE 21 - 343 NP249 TRANSFER CASE INDEX page pageComponent Cleaning and Inspection . . . . . . . . . . 357 Transfer Case Changes . . . . . . . . . . . . . .. . . . . . 344General Information . . . . . . . . . . . . . . . . . . . . . . . 343 Transfer Case Disassembly and Overhaul . . . . . . 348Recommended Lubricant and Fill Level . . . . . . . . 344 Transfer Case Identification . . . . . . . . . . .. . . . . . 344Shift Linkage Adjustment . . . . . . . . . . . . . . . . . . . 344 Transfer Case Installation . . . . . . . . . . . .. . . . . . 347Speedometer Service . . . . . . . . . . . . . . . . . . . . . 345 Transfer Case Removal . . . . . . . . . . . . . .. . . . . . 347Transfer Case Assembly and Adjustment . . . . . . . 360GENERAL INFORMATION Operating ranges are 4-high and 4-low. The 4-low The NP249 is an all the time, transfer case with range is used for extra pulling power in off road sit-two operating ranges and a neutral position (Fig. 1). uations. Engine torque is distributed to the front and rear axles through a differential and viscous coupling. The Fig. 1 NP249 Transfer Case
    • 21 - 344 NP249 TRANSFER CASE ZJNP249 low range is provided by a gear reduction sys-tem for increased low speed, off road torque capabil-ity.SHIFT MECHANISM Transfer case operating ranges are selected with afloor mounted shift lever. The shift lever is connectedto the transfer case range lever by an adjustablelinkage rod. Range positions are marked on theshifter bezel plate.TRANSFER CASE IDENTIFICATION A circular I.D. tag is attached to the rear case ofeach NP249 transfer case (Fig. 2). The tag providesthe transfer case model number, assembly number,serial number and low range ratio. The transfer case serial number also represents the Fig. 2 Transfer Case I.D. Tagdate of build. For example, a serial number of8-12-94 would represent August 12, 1994. TRANSFER CASE CHANGES The only service change for 1995 involves the frontRECOMMENDED LUBRICANT AND FILL LEVEL output seal which is new. The new seal does not have Mopar Dexron II is the recommended lubricant for the flange used on prior seals and affects seal instal-the NP249 transfer case. Approximate fluid refill ca- lation. The new seal must be seated below the edgepacity is approximately 1.18 liters (2.50 pints). of the seal bore in the front case. Refer to the over- haul procedures for seal installation. Correct fill level is to the bottom edge of the fillplug hole. SHIFT LINKAGE ADJUSTMENT (1) Shift transfer case into Neutral position. NP249 SERVICE DIAGNOSIS
    • ZJ NP249 TRANSFER CASE 21 - 345 (2) Raise vehicle on hoist that will allow all four (4) Remove speed sensor and speedometer adapterwheels to rotate freely. as assembly. (3) Loosen trunnion lock bolt (Figs. 3 and 4). (5) Remove speed sensor retaining screw and re-Loosen bolt enough so selector rod slides freely in move sensor from adapter.trunnion. (6) Remove speedometer pinion from adapter. Re- (4) Verify that shift lever on transfer case is in place pinion if chipped, cracked, worn.Neutral position. (7) Inspect sensor and adapter O-rings (Fig. 5). Re- (5) Tighten trunnion lock bolt to 11-20 N⅐m (96-180 move and discard O-rings if worn or damaged.in. lbs.) torque. (8) Inspect terminal pins in speed sensor. Clean (6) Lower vehicle enough for entry into driver seat pins with Mopar electrical spray cleaner if dirty or oxidized. Replace sensor if faulty, or pins are loose,but keep all wheels off shop floor. severely corroded, or damaged. (7) Verify correct linkage adjustment. Start engine,shift transmission into gear and shift transfer case SPEEDOMETER INSTALLATION ANDinto all ranges. Be sure transfer case is fully engaged INDEXINGin high and low range. Readjust linkage if necessary. (1) Thoroughly clean adapter flange and adapter (8) Shut engine off and lower vehicle completely. mounting surface in housing. Surfaces must be clean for proper adapter alignment and speedometer oper-SPEEDOMETER SERVICE ation. Rear axle gear ratio and tire size determine speed- (2) Install new O-rings on speed sensor and speed-ometer pinion requirements. If the pinion must be re- ometer adapter if necessary (Fig. 5).placed, refer to the parts catalogue information for (3) Lubricate sensor and adapter O-rings withthe correct part. transmission fluid. (4) Install vehicle speed sensor in speedometerSPEEDOMETER ASSEMBLY REMOVAL adapter. Tighten sensor attaching screw to 2-3 N⅐m (1) Raise vehicle. (15-27 in. lbs.) torque. (2) Disconnect wires from vehicle speed sensor. (5) Install speedometer pinion in adapter. (3) Remove adapter clamp and screw (Fig. 5). (6) Count number of teeth on speedometer pinion. Do this before installing assembly in housing. Then lubricate pinion teeth with transmission fluid. Fig. 3 Transfer Case Shift Linkage (Automatic Transmission)
    • 21 - 346 NP249 TRANSFER CASE ZJ Fig. 4 Transfer Case Shift Linkage (Manual Transmission) Fig. 5 Speedometer Components
    • ZJ NP249 TRANSFER CASE 21 - 347 (7) Note index numbers on adapter body (Fig. 6). TRANSFER CASE INSTALLATIONThese numbers will correspond to number of teeth on (1) Mount transfer case on a transmission jack. Se-pinion. cure transfer case to jack with safety chains. (8)