Transmission and Transfer Case 21 - 1

TJ TRANSMISSION AND TRANSFER CASE 21 - 1

TRANSMISSION AND TRANSFER CASE

TABLE OF CONTENTS

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MANUAL - NV1500 ...... 1 TRANSFER CASE - NV231 ...... 194 MANUAL - NV3550 ...... 31 TRANSFER CASE - NV241 ...... 229 AUTOMATIC TRANSMISSION - 42RLE ...... 68

MANUAL - NV1500

TABLE OF CONTENTS

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MANUAL - NV1500 CLEANING ...... 10 DESCRIPTION ...... 1 INSPECTION ...... 10 OPERATION ...... 1 ASSEMBLY ...... 12 DIAGNOSIS AND TESTING ...... 1 INSTALLATION ...... 28 REMOVAL ...... 2 SPECIFICATIONS ...... 29 DISASSEMBLY ...... 3 SPECIAL TOOLS ...... 29

MANUAL - NV1500 tioned in a groove in the outer circumference of the synchronizer sleeve. As the shift fork moves the syn- DESCRIPTION chronizer sleeve, the synchronizer begins to speed-up or slow down the selected gear (depending on The NV1500 is a 5-speed, constant mesh, fully syn- whether we are up-shifting or down-shifting). The chronized manual transmission. The transmission is synchronizer does this by having the synchronizer available in vehicles equipped with a 2.4L engine. hub splined to the mainshaft, or the countershaft in The transmission gear case consists of two alumi- some cases, and moving the blocker ring into contact num gear housings and a detachable clutch housing. with the gear’s friction cone. As the blocker ring and The mainshaft is supported by two sealed ball friction cone come together, the gear speed is brought bearings, and the countershaft is supported by two up or down to the speed of the synchronizer. As the tapered roller bearings. The transmission gears all two speeds match, the splines on the inside of the rotate on caged type needle bearings. A roller bearing synchronizer sleeve become aligned with the teeth on is used between the input and output shaft. the blocker ring and the friction cone and eventually The Transmission has a single shaft shift mecha- will slide over the teeth, locking the gear to the nism with three shift forks all mounted on the shaft. mainshaft, or countershaft, through the synchronizer. The shaft is supported in the front and rear housings by bushings. Internal shift components consist of the DIAGNOSIS AND TESTING forks, shaft, shift lever socket, and detent components. LOW LUBRICANT LEVEL The drain plug in on the bottom of the transmis- A low transmission lubricant level is generally the sion and fill plug is on the side. result of a leak, inadequate lubricant fill, or an incor- OPERATION rect lubricant level check. Leaks can occur at the mating surfaces of the gear The driver selects a particular gear by moving the case, intermediate plate and adaptor or extension shift lever to the desired gear position. As the shift housing, or from the front/rear seals. A suspected lever moves the selected shift rail, the shift fork leak could also be the result of an overfill condition. attached to that rail begins to move. The fork is posi- 21 - 2 MANUAL - NV1500 TJ MANUAL - NV1500 (Continued) Leaks at the rear of the extension or adapter hous- REMOVAL ing will be from the housing oil seals. Leaks at com- (1) Shift transmission into neutral. ponent mating surfaces will probably be the result of (2) Raise and support the vehicle. inadequate sealer, gaps in the sealer, incorrect bolt (3) Support engine with jack stand. Position wood tightening, or use of a non–recommended sealer. block between jack and oil pan to avoid damaging A leak at the front of the transmission will be from pan. either the front bearing retainer or retainer seal. (4) Remove skid plate/crossmember. Lubricant may be seen dripping from the clutch (5) Support transmission with a trans jack. housing after extended operation. If the leak is (6) Remove transmission mount from transmission severe, it may also contaminate the clutch disc caus- and exhaust. ing the disc to slip, grab, and/or chatter. (7) Remove propeller shafts. A correct lubricant level check can only be made (8) Remove transfer case shift linkage and vent when the vehicle is level. Also allow the lubricant to hose. settle for a minute or so before checking. These rec- (9) Remove wiring connectors from transmission ommendations will ensure an accurate check and and transfer case. avoid an underfill or overfill condition. Always check (10) Remove transfer case. the lubricant level after any addition of fluid to avoid (11) Remove slave cylinder from clutch housing. an incorrect lubricant level condition. (12) Remove starter. (13) Remove transmission dust shield. HARD SHIFTING (14) Lower trans jack enough to remove shift Hard shifting is usually caused by a low lubricant tower bolts. level, improper, or contaminated lubricants. The con- (15) Lower transmission jack and remove trans- sequence of using non–recommended lubricants is mission from under vehicle. noise, excessive wear, internal bind, and hard shift- (16) Pull transmission jack rearward (Fig. 1) until ing. Substantial lubricant leaks can result in gear, input shaft clears clutch. shift rail, synchro, and bearing damage. If a leak goes undetected for an extended period, the first indications of component damage are usually hard shifting and noise. Shift component damage, incorrect clutch adjustment, or a damaged clutch pressure plate or disc are additional probable causes of increased shift effort. Incorrect adjustment or a worn/damaged pressure plate or disc can cause incorrect release. If the clutch problem is advanced, gear clash during shifts can result. Worn or damaged synchro rings can cause gear clash when shifting into any forward gear. In some new or rebuilt transmissions, new synchro rings may tend to stick slightly causing hard or noisy shifts. In most cases, this condition will decline as the rings wear-in.

TRANSMISSION NOISE Fig. 1 TRANSMISSION ASSEMBLY Most manual transmissions make some noise dur- 1 - CLUTCH HOUSING ing normal operation. Rotating gears generate a mild 2 - TRANSMISSION JACK 3 - TRANSMISSION whine that is audible, but generally only at extreme speeds. Severe, highly audible transmission noise is generally the initial indicator of a lubricant problem. Insufficient, improper, or contaminated lubricant will promote rapid wear of gears, synchros, shift rails, forks and bearings. The overheating caused by a lubricant problem, can also leads to gear and bearing damage. TJ MANUAL - NV1500 21 - 3 MANUAL - NV1500 (Continued)

(17) Remove clutch release bearing, release fork (4) Remove shift tower bolts and remove tower and and retainer clip (Fig. 2). lever assembly (Fig. 4).

Fig. 4 SHIFT TOWER Fig. 2 CLUTCH RELEASE BEARING 1 - SHIFT TOWER AND LEVER ASSEMBLY 1 - FORK 2 - SHIFT SOCKET 2 - BEARING 3 - SEAL 3 - CLIP (5) Remove shift shaft lock bolt (Fig. 5). Bolt (18) Remove clutch housing from transmission. secures the shift shaft bushing and lever. DISASSEMBLY

FRONT HOUSING (1) Shift transmission into Neutral. (2) Remove drain plug and drain lubricant into a container. (3) Remove backup light switch (Fig. 3).

Fig. 5 SHIFT SHAFT BUSHING LOCK BOLT 1 - SHIFT SHAFT LOCK BOLT 2 - SHAFT SOCKET

Fig. 3 BACKUP LIGHT SWITCH 1 - BACKUP LAMP SWITCH 21 - 4 MANUAL - NV1500 TJ MANUAL - NV1500 (Continued)

(6) Remove shift shaft detent plug with Remover 8117A (Fig. 6).

Fig. 6 DETENT PULLER Fig. 8 INPUT SHAFT BEARING RETAINER 1 - REMOVER 1 - BEARING RETAINER 2 - DETENT PLUG 2 - OIL FEED

(7) Remove shift shaft detent plunger and spring with a pencil magnet. (8) Remove input shaft bearing retainer bolts (Fig. 7).

Fig. 9 INPUT SHAFT SNAP RING 1 - INPUT SHAFT SNAP RING 2 - OIL FEED

(11) Remove front housing bolts (Fig. 10). Leave one bolt in place until geartrain is ready to be removed from case. Three bolts at the rear of housing are for the output shaft bearing retainer. (12) Tap front housing off alignment dowels with a Fig. 7 BEARING RETAINER BOLTS plastic mallet and separate the housing. 1 - BOLTS (5) (13) Remove input shaft bearing (Fig. 11). 2 - BEARING RETAINER (14) Note position of input shaft, shift shaft, forks, and geartrain components in housing (Fig. 12). (9) Remove bearing retainer from input shaft with a pry tool (Fig. 8). (10) Remove snap ring securing input shaft in front bearing (Fig. 9). TJ MANUAL - NV1500 21 - 5 MANUAL - NV1500 (Continued)

Fig. 12 GEARTRAIN AND SHIFT COMPONENT 1 - SHIFT SHAFT 2 - BUSHING 3 - REAR HOUSING 4 - REVERSE IDLER AND SUPPORT 5 - OUTPUT SHAFT AND GEARS 6 - COUNTERSHAFT Fig. 10 HOUSING AND BEARING RETAINER BOL 7 - 1-2 FORK 8 - INPUT SHAFT 1 - RETAINER BOLTS 9 - 3-4 FORK 2 - HOUSING BOLTS 3 - RETAINER BOLT SHIFT SHAFT, SHIFT FORKS AND REVERSE IDLER 4 - HOUSING BOLT LOCATIONS (1) Drive out roll pin that secures shift bushing and lever to shift shaft with a hammer and punch (Fig. 13).

Fig. 11 INPUT SHAFT/COUNTERSHAFT BEARING 1 - COUNTERSHAFT FRONT BEARING RACE 2 - INPUT SHAFT BEARING 3 - FRONT HOUSING Fig. 13 SHIFT SHAFT LEVER & BUSHING ROLL PIN 1 - PIN PUNCH 2 - BUSHING AND LEVER 3 - SHIFT SHAFT 21 - 6 MANUAL - NV1500 TJ MANUAL - NV1500 (Continued)

(2) Position shift socket off to the side so roll pin removal does not interfere with gears. (3) Drive out shift socket roll pin with a hammer and punch.

NOTE: Use proper size punch to prevent damage to the shift shaft.

(4) Pull shift shaft straight out of rear housing and shift forks (Fig. 14).

Fig. 16 SHIFT SHAFT LEVER AND BUSHING 1 - SHAFT LEVER AND BUSHING 2 - 3-4 FORK

Fig. 14 SHIFT SHAFT 1 - SHIFT SHAFT 2 - 3-4 FORK 3 - SHAFT DETENT NOTCHES

(5) Remove shift socket from rear housing (Fig. 15).

Fig. 17 3-4 SHIFT FORK 1 - 3-4 FORK 2 - 1-2 AND 5TH-REVERSE FORK ARMS 3 - 3-4 SYNCHRO SLEEVE

Fig. 15 SHIFT SOCKET AND ROLL PIN 1 - SHAFT BORE 2 - ROLL PIN 3 - SHIFT SOCKET

(6) Remove lever and bushing (Fig. 16). (7) Rotate 3-4 fork around synchro sleeve until fork clears shift arms on 1-2 and fifth-reverse forks, then remove 3-4 fork (Fig. 17). (8) Remove front reverse idler shaft support bolt and loosen rear bolt (Fig. 18). (9) Remove reverse idler shaft support by sliding it straight out of housing. Fig. 18 REVERSE IDLER SHAFT/SUPPORT BOLT (10) Remove rear reverse idler shaft bolt. 1 - SUPPORT BOLT 2 - SHAFT BOLT TJ MANUAL - NV1500 21 - 7 MANUAL - NV1500 (Continued)

(11) Remove reverse idler shaft, idler gear, bearing and thrust washer (Fig. 19).

Fig. 21 REAR HOUSING GEARTRAIN Fig. 19 REVERSE IDLER ASSEMBLY (1) Remove 1-2 and fifth-reverse forks from syn- 1 - SUPPORT 2 - BEARING chro sleeves. 3 - WASHER (2) Separate countershaft from mainshaft. 4 - GEAR (3) Separate input shaft from output shaft. 5 - SHAFT COUNTERSHAFT GEARTRAIN (1) Remove countershaft front and rear bearing (1) Remove output shaft bearing retainer bolts with Puller 8356. (Fig. 20). (2) Remove rear bearing race (in rear housing) with Bearing Race Remover L-4454. Install new race with Driver C-4656 and Driver Handle C-4171. (3) Remove bearing shim cap from front housing (below input shaft bearing retainer). Remove shim. Drive race through and out of housing with Driver C-4656 and Driver Handle C-4171. Install new race into housing from outside. Do not drive all the way into position. Tightening the shim cap will install the race to the proper position. Install shim and shim cap and torque cap bolts to 28.5 N·m (21 ft. lbs.).

OUTPUT SHAFT

NOTE: Synchronizer hubs and sleeves are different. Remove synchronizer unit as an assembly to avoid Fig. 20 BEARING RETAINER BOLTS intermixing parts. Mark each synchro hub and 1 - BEARING RETAINER BOLT sleeve for assembly reference. 2 - REAR HOUSING (1) Remove snap ring that secures 3-4 synchro hub (2) Hold the geartrain while lifting the rear hous- on output shaft. ing off (Fig. 21). (2) Remove 3-4 synchro assembly, third gear synchro ring and third gear with a shop press and Split- ter 1130. Position splitter between second and third gears. 21 - 8 MANUAL - NV1500 TJ MANUAL - NV1500 (Continued)

(3) Remove third gear needle bearing (Fig. 22).

Fig. 24 SECOND GEAR AND NEEDLE BEARING Fig. 22 THIRD GEAR NEEDLE BEARING 1 - SECOND GEAR 1 - THIRD GEAR NEEDLE BEARING 2 - SECOND GEAR NEEDLE BEARING

(4) Remove retaining ring that secures two-piece thrust washer on shaft. (5) Remove two-piece thrust washer (Fig. 23). Note position of washer locating lugs in shaft notches for installation reference.

Fig. 25 1-2 SYNCHRO HUB AND SLEEVE 1 - 1-2 SYNCHRO HUB AND SLEEVE 2 - BEARING SPLITTER

Fig. 23 TWO-PIECE THRUST WASH 1 - WASHER (2 HALVES) 2 - PIN RELIEF 3 - PIN

(6) Remove second gear and needle bearing (Fig. 24). (7) Remove 2nd-3rd gear thrust washer locating pin. (8) Remove second gear synchro ring and synchro cone. (9) Remove 1-2 synchro hub snap ring. Fig. 26 FIRST GEAR NEEDLE BEARING (10) Remove 1-2 synchro hub and sleeve and first 1 - FIRST GEAR NEEDLE BEARING gear from output shaft with shop press and Splitter 1130 (Fig. 25). Position splitter between first and reverse gears. (11) Remove first gear needle bearing (Fig. 26). TJ MANUAL - NV1500 21 - 9 MANUAL - NV1500 (Continued)

(12) Remove output shaft bearing snap ring (Fig. 27).

Fig. 29 FIFTH GEAR NEEDLE BEARING 1 - FIFTH GEAR NEEDLE BEARING Fig. 27 OUTPUT SHAFT BEARING SNAP RING 1 - OUTPUT SHAFT BEARING 2 - BEARING SNAP RING 3 - SNAP RING PLIERS

(13) Remove output shaft bearing from shaft with shop press and Splitter 1130. Position splitter between bearing and fifth gear. (14) Remove fifth gear (Fig. 28).

Fig. 30 FIFTH REVERSE SYNCHRO HUB SNAP RING Fig. 28 FIFTH GEAR 1 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE 1 - FIFTH GEAR AND SYNCHRO RING 2 - SYNCHRO HUB SNAP RING 3 - SNAP RING PLIERS (15) Remove fifth gear needle bearing. Spread bearing apart just enough to clear shoulder on output shaft (Fig. 29). (16) Remove fifth-reverse synchro hub snap ring (Fig. 30). 21 - 10 MANUAL - NV1500 TJ MANUAL - NV1500 (Continued)

(17) Remove fifth-reverse synchro hub and sleeve Clean the shaft bearings with a mild solvent such with shop press (Fig. 31). as Mopar௡ degreasing solvent, Gunk, or similar sol- vents. Do not dry the bearings with compressed air. Allow the bearings to either air dry, or wipe them dry with clean shop towels. INSPECTION

NOTE: Minor nicks on the surface can be smoothed off with 320/420 grit emery cloth and final polished with oil coated crocus cloth.

SHIFT LEVER ASSEMBLY The shift lever assembly is not serviceable. Replace the lever and shift tower as an assembly if the tower, lever, lever ball or internal components are worn or damaged. SHIFT SHAFT AND FORKS Inspect the shift fork interlock arms and synchro sleeve contact surfaces (Fig. 33). Replace any fork exhibiting wear or damage in these areas. Do not attempt to salvage shift forks. Check condition of the shift shaft detent plunger and spring. The plunger should be smooth and free of nicks or scores. Replace the plunger and spring if in Fig. 31 FIFTH-REVERSE SYNCHRO HUB AND doubt about condition. Check condition of detent SLEEVE plunger bushings. Replace if damaged. Inspect the shift shaft, shift shaft bushing and 1 - PRESS 2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE bearing. The shaft lever and the lever bushing that 3 - REVERSE GEAR fits over the lever. Replace the shaft if bent, cracked 4 - OUTPUT SHAFT or severely scored. Replace the shift shaft bushing or bearing if damaged. (18) Remove reverse gear and needle bearing (Fig. Replace the shaft lever and bushing if either part 32). is deformed or worn. Do not attempt to salvage these parts as shift fork binding will occur. Replace the roll pin that secures the lever to the shaft. FRONT/REAR HOUSINGS AND BEARING RETAINERS Clean the gears, shafts, shift components and transmission housings with a standard parts cleaning solvent. Do not use acid or corrosive base sol- vents. Dry all parts except bearings with compressed air. Clean the shaft bearings with a mild solvent such Fig. 32 REVERSE GEAR AND NEEDLE BEARING as Mopar degreasing solvent, Gunk or similar sol- 1 - REVERSE GEAR AND NEEDLE BEARING vents. Do not dry the bearings with compressed air. Allow the bearings to either air dry or wipe them dry CLEANING with clean shop towels. Clean the gears, shafts, shift components and Inspect the housings carefully for cracks, stripped transmission housings with a standard parts clean- threads, scored mating surfaces, damaged bearing ing solvent. Do not use acid or corrosive base sol- bores or worn dowel pin holes. vents. Dry all parts except bearings with compressed air. TJ MANUAL - NV1500 21 - 11 MANUAL - NV1500 (Continued)

Fig. 33 SHIFT FORKS AND SHAFT 1 - SHIFT SHAFT 4 - 3-4 SHIFT FORK 2 - SHAFT LEVER 5 - 1-2 SHIFT FORK 3 - SHAFT LEVER BUSHING 6 - FIFTH-REVERSE SHIFT FORK

NOTE: The front housing contains the countershaft front bearing race. The rear housing contains the countershaft rear bearing race. If a countershaft bearing failure results, the bearing races must be replaced also.

Inspect input shaft bearing retainer. Be sure the release bearing slide surface of the retainer is in good condition. Replace the retainer seal if necessary. Inspect output shaft bearing retainer. Be sure the U-shaped retainer is flat and free of distortion. Replace the retainer if the threads are damaged or if the retainer is bent or cracked. COUNTERSHAFT BEARINGS AND RACES The countershaft bearings are standard tapered roller bearings with matching races. The races are Fig. 34 REVERSE IDLER ASSEMBLY pressed into the front and rear housings. Inspect 1 - SUPPORT countershaft bearings and races for abnormal wear 2 - BEARING 3 - WASHER or damage. 4 - GEAR 5 - SHAFT REVERSE IDLER COMPONENTS Inspect idler gear, bearing, shaft, thrust washer Replace thrust washer, if cracked, chipped or worn. and support for excessive wear or failure (Fig. 34). Replace idler gear if the teeth are chipped, cracked or Replace bearing if any of the needle bearing rollers worn thin. Replace shaft if worn, scored or the bolt are worn, chipped, cracked, flat-spotted or brinnelled. threads are damaged beyond repair. Replace support Also replace the bearing if the plastic bearing cage is segment if cracked or chipped and replace the idler damaged or distorted. attaching bolts if the threads are damaged. 21 - 12 MANUAL - NV1500 TJ MANUAL - NV1500 (Continued) Shift Socket Inspect shift socket for wear or damage. Replace socket if the roll pin or shift shaft bores are damaged. Replace socket if the ball seat is worn, or cracked. Do not reuse the original shift socket roll pin. The socket roll pin is approximately is approximately 33 mm (1-1/4 in.) long. Output Shaft And Geartrain Inspect all gears for worn, cracked, chipped or broken teeth. Check condition of the bearing bore in each gear. The bores should be smooth and free of surface damage. Discoloration of the gear bores is a normal occurrence and is not a reason for replacement. Replace gears only when tooth damage has occurred or if the bores are brinnelled or severely scored. Inspect shaft splines and bearings surfaces. Replace the shaft if the splines are damaged or bearing surfaces are deeply scored, worn or brinnelled. ASSEMBLY Fig. 35 ASSEMBLED SYNCHRO COMPONENTS 1 - SLEEVE 2 - HUB SHOULDER SYNCHRONIZER 3 - SPRING (3) 4 - STRUT (3) NOTE: The easiest method of assembling each syn- 5 - DETENT BALL (3) 6 - HUB chro is to install the springs, struts and detent balls one at a time. (1) Install reverse gear needle bearing on shaft (Fig. 36). Slide bearing up against shoulder on output (1) Slide the sleeve part way onto the hub. Leave shaft. enough room to install the spring in the hub and the strut in the hub groove. (2) Install first spring in the hub and then install a strut over the spring. Verify spring is seated in the spring bore in the strut. (3) Slide the sleeve onto the hub just far enough to hold the first strut and spring in place. (4) Place detent ball in the top of the strut. Then work the sleeve over the ball to hold it in place. Use a small flat blade screwdriver to press the ball into place while moving the sleeve over it. (5) Repeat procedure for the remaining springs, struts and balls. Tape or rubber band each strut and Fig. 36 REVERSE GEAR BEARING ball temporarily as they are installed. (6) Verify the three springs, struts and detent balls 1 - REVERSE GEAR BEARING 2 - SHOULDER are all in place (Fig. 35). (2) Install reverse gear over needle bearing (Fig. OUTPUT SHAFT 37). (3) Install solid brass synchro ring on reverse gear NOTE: Lubricate shaft, gears and bearings with rec- (Fig. 38). ommended lubricant and immerse each synchro ring in lubricant before installation. Petroleum jelly NOTE: This synchro ring is different than all the can be used to hold parts in place. rest. The angle on the friction face is 9° versus the 6.5° of all the other synchro rings. TJ MANUAL - NV1500 21 - 13 MANUAL - NV1500 (Continued)

Fig. 37 REVERSE GEAR 1 - REVERSE GEAR

Fig. 39 FIFTH-REVERSE SYNCHRO ASSEMBLY 1 - SPACER 2 - PRESS RAM 3 - REVERSE GEAR 4 - FIFTH-REVERSE SYNCHRO ASSEMBLY Fig. 38 REVERSE GEAR SYNCHRO RING 5 - CUP 1 - REVERSE GEAR 6 - PRESS BLOCKS 2 - SYNCHRO RING (SOLID BRASS) 7 - OUTPUT SHAFT

(4) Start fifth-reverse synchro assembly on output shaft splines by hand. Then seat synchro onto shaft with shop press and Cup 6310-1 (Fig. 39).

CAUTION: Fifth-reverse synchro hub and sleeve can be installed backwards. One side of the sleeve has double grooves and offset teeth. This side must be installed away from reverse gear (towards 5th).

NOTE: The synchro hub is a press fit design. There may be instances where the press is not necessary. As long as there is a snug fit between the hub and the shaft, the hub does not need to be replaced.

(5) Install new fifth-reverse hub snap ring (Fig. 40) and verify snap ring is seated in the shaft groove. Fig. 40 FIFTH-REVERSE SYNCHRO HUB SNAP NOTE: Install thickest snap ring that will fit in shaft RING groove. 1 - FIFTH-REVERSE SYNCHRO ASSEMBLY 2 - SNAP RING 3 - PRESS BED 4 - PRESS BLOCKS 21 - 14 MANUAL - NV1500 TJ MANUAL - NV1500 (Continued)

(6) Install fifth gear synchro ring in synchro hub and sleeve (Fig. 41).

Fig. 43 FIFTH GEAR 1 - FIFTH GEAR 2 - BEARING Fig. 41 FIFTH GEAR SYNCHRO RING 1 - FIFTH-SPEED SYNCHRO RING (10) Install output shaft bearing snap ring, spread 2 - FIFTH-REVERSE SYNCHRO ASSEMBLY snap ring only enough to install it (Fig. 44). Verify snap ring is seated in shaft groove. (7) Install fifth gear bearing, spreading bearing only enough to clear shoulder on output shaft (Fig. 42). Verify bearing is seated.

Fig. 44 OUTPUT SHAFT BEARING 1 - BEARING SNAP RING 2 - HEAVY DUTY SNAP RING PLIERS

Fig. 42 FIFTH GEAR BEARING (11) Invert output shaft and set the shaft in Cup 1 - SHAFT SHOULDER 6310-1 so that fifth gear is seated on the tool (Fig. 2 - FIFTH GEAR BEARING 45). (12) Install first gear bearing on output shaft (Fig. (8) Install fifth gear on shaft and onto bearing 45). Verify bearing is seated on shaft shoulder and is (Fig. 43). properly joined. (9) Install output shaft bearing. TJ MANUAL - NV1500 21 - 15 MANUAL - NV1500 (Continued)

(13) Install synchro cone onto first gear. Verify (15) Install first gear synchro ring (Fig. 47). synchro cone locating tabs are properly located to the recesses in first gear.

Fig. 47 FIRST GEAR SYNCHRO RING 1 - FIRST GEAR SYNCHRO RING 2 - CUP 3 - FIRST GEAR

(16) Start 1-2 synchro assembly on shaft by hand (Fig. 48). Be sure synchro sleeve is properly positioned.

Fig. 45 FIRST GEAR BEARING CAUTION: The 1-2 synchro hub and sleeve can be 1 - FIRST GEAR BEARING installed backwards. One side of the sleeve has a 2 - SHAFT SHOULDER groove and offset teeth. This side must be installed 3 - CUP 4 - PRESS BLOCKS towards 1st gear (away from 2nd gear).

(14) Install first gear on shaft and over bearing with bearing synchro cone facing up (Fig. 46). NOTE: The synchro hub is a press fit design. There may be instances where the press is not necessary. As long as there is a snug fit between the hub and the shaft, the hub does not need to be replaced.

Fig. 46 FIRST GEAR 1 - FIRST GEAR 2 - CUP 3 - BEARING Fig. 48 START 1-2 SYNCHRO ON SHAFT 1 - 1-2 SYNCHRO ASSEMBLY 2 - FIRST GEAR 3 - CUP 4 - SINGLE GROOVE SIDE OF SYNCHRO SLEEVE 21 - 16 MANUAL - NV1500 TJ MANUAL - NV1500 (Continued)

(17) Press 1-2 synchro onto output shaft with suitable size pipe and shop press (Fig. 49).

CAUTION: Align synchro ring and sleeve as hub is being pressed onto the shaft. The synchro ring can be cracked if it becomes misaligned.

Fig. 50 1-2 SYNCHRO HUB SNAP RING 1 - 1-2 SYNCHRO 2 - CUP 3 - SYNCHRO SNAP RING

Fig. 49 PRESS 1-2 SYNCHRO ASSEMBLY 1 - SUITABLE SIZE PIPE TOOL 2 - SYNCHRO RING 3 - CUP 4 - 1-2 SYNCHRO ASSEMBLY 5 - PRESS RAM Fig. 51 SECOND GEAR SYNCHRO RING (18) Install new 1-2 synchro hub snap ring (Fig. 1 - SECOND GEAR SYNCHRO RING 50) with the thickest snap ring that will fit in shaft 2 - 1-2 SYNCHRO groove. Verify snap ring is seated in shaft groove. 3 - CUP (19) Install second gear synchro ring in 1-2 synchro hub and sleeve (Fig. 51). Verify synchro ring is seated in sleeve. (20) Install synchro cone into synchro ring. TJ MANUAL - NV1500 21 - 17 MANUAL - NV1500 (Continued)

(21) Install second gear needle bearing on shaft (23) Install thrust washer pin to shaft and install (Fig. 52). two-piece thrust washer (Fig. 54). Verify washer halves are seated in shaft groove and pin reliefs are positioned at washer locating pin.

Fig. 52 SECOND GEAR BEARING 1 - SECOND GEAR BEARING 2 - CUP Fig. 54 TWO-PIECE THRUST WASH 1 - WASHER (2 HALVES) (22) Install second gear onto shaft and bearing 2 - PIN RELIEF (Fig. 53). Verify second gear is seated on synchro 3 - PIN components. (24) Seat retaining ring around two-piece thrust washer. (25) Install third gear needle bearing on shaft (Fig. 55).

Fig. 53 SECOND GEAR 1 - CUP 2 - 1-2 SYNCHRO ASSEMBLY 3 - BEARING Fig. 55 THIRD GEAR BEARING 4 - SECOND GEAR 1 - THIRD GEAR BEARING 21 - 18 MANUAL - NV1500 TJ MANUAL - NV1500 (Continued)

(26) Install third gear on shaft and bearing (Fig. 56).

Fig. 58 START 3-4 SYNCHRO HUB ON OUTPUT SHAFT 1 - GROOVED SIDE OF SLEEVE (TO FRONT) Fig. 56 THIRD GEAR 2 - 3-4 SYNCHRO ASSEMBLY 1 - THIRD GEAR 2 - BEARING (29) Press 3-4 synchro assembly onto output shaft with shop press and suitable size pipe tool (Fig. 59). (27) Install third speed synchro ring on third gear Press tool must be as close to the hub center as pos- (Fig. 57). sible but not contacting the shaft splines.

Fig. 57 THIRD SPEED SYNCHRO RING 1 - THIRD SPEED SYNCHRO RING 2 - THIRD GEAR

(28) Start 3-4 synchro hub on output shaft splines by hand (Fig. 58).

CAUTION: The 3-4 synchro hub and sleeve can be installed backwards. One side of the sleeve has two Fig. 59 3-4 SYNCHRO ASSEMBLY ON SHAFT grooves and offset teeth. This side must be installed towards 3rd gear (away from 4th gear). 1 - PRESS RAM 2 - PIPE TOOL 3 - 3-4 SYNCHRO 4 - THIRD SPEED SYNCHRO RING NOTE: The synchro hub is a press fit design. There may be instances where the press is not necessary. (30) Install 3-4 synchro hub new snap ring (Fig. As long as there is a snug fit between the hub and 60) with thickest snap ring that will fit in shaft the shaft, the hub does not need to be replaced. groove. Verify snap ring is seated in groove. TJ MANUAL - NV1500 21 - 19 MANUAL - NV1500 (Continued)

GEARTRAIN (1) Install input shaft into Support Stand 8355 (Fig. 62). (2) Install pilot bearing in input shaft (Fig. 62). (3) Install fourth gear synchro ring on input shaft (Fig. 63).

Fig. 60 3-4 SYNCHRO HUB SNAP RING 1 - 3-4 SYNCHRO HUB SNAP RING 2 - HEAVY DUTY SNAP RING PLIERS

(31) Verify position of synchro sleeves before proceeding (Fig. 61).

Fig. 61 SYNCHRO SLEEVE POSITION 1 - 2 GROOVES 6 - SECOND GEAR 2 - 1 GROOVE 7 - FIRST GEAR 3 - 2 GROOVES 8 - REVERSE GEAR 4 - FOURTH GEAR 9 - FIFTH GEAR 5 - THIRD GEAR 21 - 20 MANUAL - NV1500 TJ MANUAL - NV1500 (Continued)

(4) Install assembled output shaft and geartrain in input shaft (Fig. 64). Rotate output shaft until the 3-4 synchro ring seats in synchro hub and sleeve.

Fig. 62 INPUT SHAFT AND PILOT BEARING 1 - PILOT BEARING 2 - INPUT SHAFT 3-STAND

Fig. 64 MAINSHAFT ON SUPPORT STAND 1 - MAIN SHAFT 2 - SUPPORT STAND

(5) Slide countershaft into fixture slot. Verify countershaft and output shaft gears are fully meshed with the mainshaft gears (Fig. 65). (6) Thread one Pilot Stud 8120 in center or passenger side hole of output shaft bearing retainer. Then position retainer on fifth gear. (7) Assemble 1-2 and fifth reverse-shift forks (Fig. 66). Arm of fifth-reverse fork goes through slot in 1-2 fork. (8) Install assembled shift forks in synchro sleeves Fig. 63 FOURTH GEAR SYNCHRO RING ON INPUT (Fig. 67). Verify forks are seated in sleeves. SHAFT 1 - FOURTH GEAR SYNCHRO RING 2 - INPUT SHAFT 3-STAND TJ MANUAL - NV1500 21 - 21 MANUAL - NV1500 (Continued)

Fig. 67 SHIFT FORKS AND SYNCHROS 1 - FIFTH REVERSE SHIFT FORK 2 - 1-2 SHIFT FORK Fig. 65 COUNTERSHAFT ON SUPPORT STAND 1 - COUNTER SHAFT REAR HOUSING 2 - MAIN SHAFT (1) Lubricate countershaft rear bearing race. 3 - SUPPORT STAND (2) Install rear housing onto geartrain (Fig. 68). Verify bearing retainer pilot stud is in correct bolt hole and countershaft and output shaft bearings are aligned in housing and on countershaft.

Fig. 66 1-2 AND FIFTH-REVERSE SHIFT FORKS 1 - FIFTH-REVERSE FORK ARM 2 - 1-2 FORK 3 - FIFTH-REVERSE FORK Fig. 68 REAR HOUSING (3) Seat rear housing on output shaft rear bearing and countershaft. Tap housing into place with plastic or rawhide hammer. 21 - 22 MANUAL - NV1500 TJ MANUAL - NV1500 (Continued)

(4) Apply Mopar௡ Gasket Maker or equivalent to REVERSE IDLER bolt threads, bolt shanks and under bolt heads (Fig. (1) Remove geartrain and housing assembly from 69). support stand with aid of helper. (2) Assemble shaft, gear and washer (without bearing or support) and install into housing (Fig. 71).

NOTE: The small shoulder on the reverse idler gear goes toward the front of the transmission.

Fig. 69 RETAINER AND HOUSING BOLTS 1 - MOPAR GASKET MAKER 2 - RETAINER AND HOUSING BOLTS 3 - APPLY SEALER TO UNDERSIDE OF BOLT HEAD, SHANK AND THREADS

(5) Start first two bolts in retainer (Fig. 70). It Fig. 71 REVERSE IDLER ASSEMBLY may be necessary to move retainer rearward (with 1 - SUPPORT pilot stud) in order to start bolts. 2 - BEARING 3 - WASHER (6) Remove Pilot Stud 8120 and install last 4 - GEAR retainer bolt (Fig. 70). 5 - SHAFT (7) Tighten all three retainer bolts to 22 N·m (16 ft. lbs.). (3) Apply Mopar௡ Gasket Maker or equivalent sealer to underside of idler shaft and support bolt NOTE: All bolts except the reverse idler shaft bolts heads, bolt shanks and bolt threads (Fig. 69). have o-rings to seal the bolts to the transmission (4) Align hole in housing with threaded hole in case. Inspect the o-rings to ensure that they are in shaft and start shaft rear bolt a few threads. good condition. (5) Install bearing into position. (6) Install segment (Fig. 71), align housing hole with segment threaded hole, and start support bolt a few threads. (7) Tighten large idler shaft bolt to 43 N·m (31.7 ft. lbs.). Tighten small idler shaft bolt to 22 N·m (16.2 ft. lbs.).

CAUTION: Verify idler shaft and support segment are properly seated and firmly in place while tightening the shaft bolts. The segment, housing or shaft threads can be damaged if the idler shaft is allowed to shift out of position.

Fig. 70 PILOT STUD AND RETAINER BOLTS 1 - BEARING RETAINER BOLT 2 - REAR HOUSING TJ MANUAL - NV1500 21 - 23 MANUAL - NV1500 (Continued)

SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET (1) Verify all synchro sleeves are in Neutral position (centered on hub).

CAUTION: Synchros must all be in Neutral position to prevent damage to the housings, shift forks and gears during installation of the two housings.

(2) Install 3-4 shift fork in synchro sleeve (Fig. 72). Verify groove in fork arm is aligned with grooves in 1-2 and fifth-reverse fork arms.

Fig. 74 SHIFT SHAFT LEVER AND BUSHING 1 - SHAFT LEVER 2 - LEVER BUSHING 3 - BUSHING LOCK PIN SLOT

(5) Install assembled lever and bushing on shift shaft (Fig. 75).

Fig. 72 3-4 SHIFT FORK 1 - 3-4 FORK 2 - ALIGN GROOVES IN FORK ARMS

(3) Slide shift shaft through the shift forks (Fig. 73).

Fig. 75 SHIFT SHAFT LEVER AND BUSHING 1 - SHIFT SHAFT 2 - SHAFT LEVER AND BUSHING 3 - 3-4 FORK

(6) Slide shift shaft through 1-2 and fifth-reverse fork and into shift lever opening in rear housing (Fig. 76). (7) Align shift socket with shaft and slide shaft through socket and into shift shaft bearing in rear Fig. 73 SHIFT SHAFT housing (Fig. 77). (8) Rotate shift shaft so detent notches in shaft are 1 - SHIFT SHAFT 2 - 3-4 FORK facing the TOP of the transmission housing. 3 - SHAFT DETENT NOTCHES CAUTION: Positioning of the shift shaft detent (4) Assemble shift shaft shift lever and bushing notch is important. Both of the shaft roll pins can (Fig. 74). Slot in bushing must face up and roll pin be installed even when the shaft is 180° off. If this hole for lever to align with hole in shaft. occurs, transmission will have to be disassembled to correct shaft alignment. 21 - 24 MANUAL - NV1500 TJ MANUAL - NV1500 (Continued)

(10) Align roll pin holes in shift shaft, lever and bushing, then start roll pin into shaft lever by hand (Fig. 79).

Fig. 76 LEVER OPENING IN HOUSING 1 - SHIFT SHAFT

Fig. 79 STARTING ROLL PIN IN SHIFT SHAFT LEVER 1 - SHAFT LEVER ROLL PIN 2 - LEVER AND BUSHING

(11) Seat shaft lever roll pin with pin punch (Fig. 80).

CAUTION: Shaft lever roll pin must be flush with the surface of the lever. The lever bushing will bind on the roll pin if the pin is not seated flush.

(12) Verify lock pin slot in lever bushing is positioned as shown (Fig. 80).

Fig. 77 SHIFT SOCKET AND SHAFT 1 - SHIFT SOCKET 2 - SHIFT SHAFT

(9) Select correct new roll pin for shift shaft lever (Fig. 78). Shaft lever roll pin is approximately 22 mm (7/8 in.) long. Shift socket roll pin is approximately 33 mm (1-1/4 in.) long.

Fig. 80 SEATING SHIFT SHAFT LEVER ROLL PIN 1 - BUSHING LOCK PIN SLOT 2 - SEAT ROLL PIN FLUSH WITH LEVER

Fig. 78 SHAFT LEVER AND SOCKET ROLL PINS (13) Align roll pin holes in shift socket and shift 1 - SHAFT LEVER ROLL PIN shaft. Then start roll pin into shift shaft by hand 2 - SHIFT SOCKET ROLL PIN (Fig. 81). TJ MANUAL - NV1500 21 - 25 MANUAL - NV1500 (Continued)

and use plastic mallet to seat bearing. Bearing goes in from front side of housing only.

Fig. 81 STARTING ROLL PIN IN SHIFT SOCKET 1 - ROLL PIN 2 - SHIFT SOCKET Fig. 83 INPUT SHAFT AND COUNTERSHAFT 3 - SHIFT SHAFT BEARING (14) Seat roll pin in shift socket with pin punch. 1 - SHIFT SHAFT BUSHING 2 - INPUT SHAFT BEARING Roll pin must be instaled flush with socket (Fig. 82). 3 - COUNTERSHAFT FRONT BEARING RACE

(2) Apply small amount of petroleum jelly to shift shaft bushing in front housing (Fig. 84). (3) Apply 1/8 in. wide bead of Mopar௡ Gasket Maker or equivalent to mating surfaces of front and rear housings (Fig. 84).

Fig. 82 SEATING SHIFT SOCKET ROLL PIN 1 - PIN PUNCH 2 - SHIFT SOCKET 3 - SEAT ROLL PIN FLUSH 4 - SHIFT SOCKET

(15) Verify notches in shift fork arms are aligned. Fig. 84 SEALER TO FRONT/REAR HOUSING 1 - HOUSING FLANGE SURFACE FRONT HOUSING AND INPUT SHAFT BEARING RETAINER 2 - MOPAR GASKET MAKER (OR LOCTITE 518) (1) If previously removed, install input shaft bearing in front housing bore (Fig. 83). Install snap ring 21 - 26 MANUAL - NV1500 TJ MANUAL - NV1500 (Continued)

(4) Have helper hold rear housing and geartrain in upright position. Then install front housing on rear housing and geartrain. (5) Work front housing downward onto geartrain until seated on rear housing.

CAUTION: If the front housing will not seat on the rear housing, the shift components are not in Neu- tral, or one or more components are misaligned. Do not force the front housing into place.

(6) Place transmission in horizontal position. (7) Apply Mopar௡ Gasket Maker or equivalent to housing attaching bolts. Apply sealer material sealer to underside of bolt heads and to bolt shanks and threads (Fig. 85). (8) Install and start housing attaching bolts by hand Fig. 86 SHIFT SHAFT BUSHING LOCK BOLT (Fig. 85). Then tighten bolts to 34 N·m (25 ft. lbs.). 1 - SHIFT SHAFT LOCK BOLT 2 - SHAFT SOCKET

(11) Install the selected shims and the shim cap. Tighten shim cap bolts to 29 N·m (21.4 ft. lbs.). Ver- ify the shim selection by rotating the input shaft by hand with the transmission in neutral. The proper torque required to rotate the input shaft and the countershaft is approximately 5-7 in.lbs.. The input shaft should therefore be easily rotated by hand. If the input shaft cannot be rotated by hand or is not smooth through several rotations, re-check the countershaft pre-load. (12) Lubricate then install shift shaft detent plunger in housing bore. Verify plunger is fully seated in detent notch in shift shaft.

Fig. 85 HOUSING ATTACHING BOLTS NOTE: Lubricate plunger with Valvoline Dura blendா 1 - HOUSING ATTACHING BOLTS (APPLY SEALER Semi-Synthetic or Synthetic grease or equivalent. BEFOREHAND) (13) Install detent plug in end of Installer 8123. (9) Install shift shaft bushing lock bolt (Fig. 86). Position plug on detent spring and compress spring ௡ Apply Mopar Gasket Maker or equivalent to bolt until detent plug pilots in detent plunger bore. Drive threads, shank and underside of bolt head before detent plug into transmission case until plug seats. installation. (14) Install backup light switch (Fig. 87). (15) Install input shaft snap ring (Fig. 88). CAUTION: If the lock bolt cannot be fully installed, (16) Install new oil seal in front bearing retainer do not try to force it into place. Either the shift with Installer 6448 (Fig. 89). shaft is not in Neutral, or the shaft bushing (or (17) Apply bead of Mopar௡ Silicone Sealer or lever) is misaligned. equivalent to flange surface of front bearing retainer. (10) Remove countershaft bearing shim cap and shim. Attach a dial indicator and move countershaft front and back to measure shaft end play. The required countershaft pre-load 0.001-0.003 inches. Add this amount to the measured amount of countershaft end-play. This gives the amount of shims necessary to correctly pre-load the front and rear countershaft bearings. TJ MANUAL - NV1500 21 - 27 MANUAL - NV1500 (Continued)

(18) Align and install front bearing retainer over input shaft and onto housing mounting surface (Fig. 90). Although retainer is one-way fit on housing, be sure bolt holes are aligned before seating retainer.

NOTE: Be sure that no sealer gets into the oil feed hole in the transmission case or bearing retainer.

Fig. 87 BACKUP LIGHT SWITCH 1 - BACKUP LAMP SWITCH

Fig. 90 INPUT SHAFT BEARING RETAINER 1 - BEARING RETAINER 2 - OIL FEED

(19) Install and tighten bearing retainer bolts to Fig. 88 INPUT SHAFT SNAP RING 29 N·m (21.4 ft. lbs.) (Fig. 91). 1 - INPUT SHAFT SNAP RING

Fig. 91 INPUT SHAFT BEARING RETAINER BOLTS Fig. 89 BEARING RETAINER OIL SEAL 1 - BOLTS (5) 1 - INSTALLER 2 - BEARING RETAINER 2 - FRONT BEARING RETAINER 21 - 28 MANUAL - NV1500 TJ MANUAL - NV1500 (Continued)

SHIFT TOWER AND LEVER (5) Fill transmission to bottom edge of fill plug (1) Apply petroleum jelly to ball end of shift lever hole with Mopar௡ Transmission. and interior of shift socket. (6) Install and tighten fill plug to 34 N·m (25 ft. (2) Shift the transmission into third gear. lbs.). (3) Align and install shift tower and lever assem- (7) Check transmission vent. Be sure vent is open bly (Fig. 92). Verify shift ball is seated in socket and and not restricted. offset in the tower is toward the passenger side of the vehicle before installing tower bolts. INSTALLATION (4) Install shift tower bolts (Fig. 93) and tighten (1) Install clutch housing on transmission and bolts to 8.5 N·m (75.2 in. lbs.). tighten housing bolts to 46 N·m (34 ft. lbs.). (2) Lubricate contact surfaces of release fork pivot ball stud and release fork with high temp grease. (3) Install release bearing, fork and retainer clip. (4) Position and secure transmission on transmission jack. (5) Lightly lubricate pilot bearing and transmission input shaft splines with Mopar high temp grease. (6) Raise transmission and align transmission input shaft and clutch disc splines. Then slide transmission into place. (7) Install clutch housing-to-engine bolts and tighten to 75 N·m (55 ft.lbs.).

NOTE: Be sure the housing is properly seated on engine block before tightening bolts. Fig. 92 SHIFT TOWER (8) Install shift tower and bolts. Tighten bolts to 1 - SHIFT TOWER AND LEVER ASSEMBLY 11 N·m (8 ft.lbs.). 2 - SHIFT SOCKET 3 - SEAL (9) Install transmission mount and tighten bolts to 54 N·m (40 ft. lbs.). (10) Install transfer case, shift linkage and vent hose. (11) Install wire connectors to transmission and transfer case. (12) Install skid plate/crossmember and tighten bolts to 41 N·m (31 ft. lbs.). (13) Remove support stands from engine and transmission. (14) Install propeller shafts. (15) Install slave cylinder in clutch housing. (16) Install starter motor. (17) Install transmission dust shield. (18) Fill transmission and transfer case.

Fig. 93 SHIFT TOWER BOLT 1 - SHIFT TOWER AND LEVER ASSEMBLY TJ MANUAL - NV1500 21 - 29 MANUAL - NV1500 (Continued) SPECIFICATIONS

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. lbs. Back up Lamp Switch 41 30 - Coutershaft Bearing Shim 41 30 - Cap Bearing Retainer - Front 41 30 - Bearing Retainer - Rear 34 25 - Drain/Fill Plug 34 25 - Shift Shaft Lock Bolt 27 20 - Idler Shaft Bolts - M8 27 20 - Idler Shaft Bolts - M10 52 40 - Shift Tower Bolts 11 8 100 Clutch Housing Bolts 46 34 - Transmission Bolts 75 55 - Skid Plate Bolts 41 31 - Transmission mount bolts 54 40 -

SPECIAL TOOLS

INSTALLER C-4656

HANDLE C-4171

INSTALLER 8123

SUPPORT STAND 8355 INSTALLER 6448 21 - 30 MANUAL - NV1500 TJ MANUAL - NV1500 (Continued)

STUD ALIGNMENT 8120

REMOVER 8117A

REMOVER 8356

REMOVER L-4454

SPLITTER BEARING 1130

CUP 6310-1 TJ MANUAL - NV3550 21 - 31

MANUAL - NV3550

TABLE OF CONTENTS

page page

MANUAL - NV3550 INSTALLATION ...... 64 DESCRIPTION ...... 31 SPECIFICATIONS ...... 65 OPERATION ...... 31 SPECIAL TOOLS ...... 65 DIAGNOSIS AND TESTING ...... 31 VEHICLE SPEED SENSOR REMOVAL ...... 32 DESCRIPTION ...... 66 DISASSEMBLY ...... 33 OPERATION ...... 66 CLEANING ...... 42 REMOVAL ...... 67 INSPECTION ...... 42 INSTALLATION ...... 67 ASSEMBLY ...... 45 MANUAL - NV3550 DESCRIPTION The NV3550 is a medium-duty, 5-speed, constant mesh, fully synchronized manual transmission. The transmission is a four-wheel drive configurations. The transmission gear case consists of two aluminum housings. The clutch housing is a removable component. It is not an integral part of the transmission front housing. A combination of roller and ball bearings are used to support the transmission shafts in the two housings. The transmission gears all rotate on caged type needle bearings. A roller bearing is used between the input and output shaft. The NV3550 has a single shaft shift mechanism with three shift forks all mounted on the shaft. The Fig. 1 NV3550 Identification shaft is supported in the front and rear housings by 1 - PART NUMBER TAG bushings and one linear ball bearing. Internal shift 2 - IDENTIFICATION TAG components consist of the forks, shaft, shift lever 3 - FRONT OF REAR HOUSING socket and detent components. up-shifting or down-shifting). The synchronizer does The transmission drain plug is located on the bot- this by having the synchronizer hub splined to the tom and fill plug on the side. mainshaft and moving the blocker ring into contact The NV3550 identification and part number bar with the gear’s friction cone. As the blocker ring and code tags (Fig. 1) are located on the top of the trans- friction cone come together, the gear speed is brought mission, forward of the shift tower. up or down to the speed of the synchronizer. As the OPERATION two speeds match, the splines on the inside of the synchronizer sleeve become aligned with the teeth on The driver selects a particular gear by moving the the blocker ring and the friction cone and eventually shift lever to the desired gear position. This move- will slide over the teeth, locking the gear to the ment moves the internal transmission shift compo- mainshaft through the synchronizer. nents to begin the shift sequence. As the shift lever moves the selected shift rail, the shift fork attached DIAGNOSIS AND TESTING to that rail begins to move. The fork is positioned in a groove in the outer circumference of the synchro- LOW LUBRICANT LEVEL nizer sleeve. As the shift fork moves the synchronizer A low transmission lubricant level is generally the sleeve, the synchronizer begins to speed-up or slow result of a leak, inadequate lubricant fill, or an incor- down the selected gear (depending on whether we are rect lubricant level check. 21 - 32 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued) Leaks can occur at the mating surfaces of the gear REMOVAL case and adaptor or from the front/rear seals. A sus- (1) Shift transmission into first or third gear. pected leak could also be the result of an overfill con- (2) Remove the floor console and shift boot as nec- dition. essary to access the bottom of the shift lever at the Leaks at the rear of the extension or adapter hous- shift tower attachment. ing will be from the housing oil seals. Leaks at com- (3) Remove shift tower bolts and remove shift ponent mating surfaces will probably be the result of tower and shift lever assembly. inadequate sealer, gaps in the sealer, incorrect bolt (4) Raise and support vehicle on suitable safety tightening, or use of a non–recommended sealer. stands. A leak at the front of the transmission will be from (5) Support engine with adjustable jack stand. either the front bearing retainer or retainer seal. Position wood block between jack and oil pan to Lubricant may be seen dripping from the clutch avoid damaging pan. housing after extended operation. If the leak is (6) Remove skid plate, if equipped. severe, it may also contaminate the clutch disc caus- (7) Remove crossmember. ing the disc to slip, grab, and/or chatter. (8) Disconnect necessary exhaust system compo- A correct lubricant level check can only be made nents. when the vehicle is level. Also allow the lubricant to (9) Remove slave cylinder (Fig. 2) from clutch settle for a minute or so before checking. These rec- housing. ommendations will ensure an accurate check and avoid an underfill or overfill condition. Always check the lubricant level after any addition of fluid to avoid an incorrect lubricant level condition. HARD SHIFTING Hard shifting is usually caused by a low lubricant level, improper, or contaminated lubricants. The conse- quence of using non–recommended lubricants is noise, excessive wear, internal bind, and hard shifting. Sub- stantial lubricant leaks can result in gear, shift rail, synchro, and bearing damage. If a leak goes undetected for an extended period, the first indications of component damage are usually hard shifting and noise. Shift component damage, incorrect clutch adjustment, or a damaged clutch pressure plate or disc are additional probable causes of increased shift effort. Incorrect adjustment or a worn/damaged pressure plate or disc can cause incorrect release. If the clutch problem is advanced, gear clash during shifts can result. Worn or damaged synchro rings can cause Fig. 2 Slave Cylinder gear clash when shifting into any forward gear. In some new or rebuilt transmissions, new synchro 1 - CLUTCH SLAVE CYLINDER rings may tend to stick slightly causing hard or noisy (10) Mark rear propeller shaft and rear axle yokes shifts. In most cases, this condition will decline as for installation alignment (Fig. 3). the rings wear-in. (11) Mark front propeller shaft, axle and transfer case yokes for installation alignment. TRANSMISSION NOISE (12) Remove propeller shafts. Most manual transmissions make some noise dur- (13) Unclip wire harnesses from transmission and ing normal operation. Rotating gears generate a mild transfer case. whine that is audible, but generally only at extreme (14) Disconnect transfer case shift linkage at speeds. transfer case. Severe, highly audible transmission noise is gener- (15) Remove nuts attaching transfer case to trans- ally the initial indicator of a lubricant problem. Insuf- mission. ficient, improper, or contaminated lubricant will (16) Remove transfer case. promote rapid wear of gears, synchros, shift rails, forks and bearings. The overheating caused by a lubricant problem, can also lead to gear and bearing damage. TJ MANUAL - NV3550 21 - 33 MANUAL - NV3550 (Continued)

(24) Pull transmission jack rearward until input shaft clears clutch. Then slide transmission out from under vehicle. (25) Remove clutch release bearing, release fork and retainer clip. (26) Remove clutch housing from transmission. DISASSEMBLY

FRONT HOUSING (1) Shift transmission into Neutral. (2) Remove drain plug and drain lubricant. (3) Inspect drain plug magnet for debris. (4) Remove backup light switch. Switch is located on passenger side of rear housing (Fig. 5).

Fig. 3 Propeller Shaft And Axle Yokes 1 - REFERENCE MARKS

(17) Remove crankshaft position sensor (Fig. 4).

Fig. 5 BACKUP LIGHT SWITCH 1 - BACKUP LIGHT SWITCH

(5) Remove shift tower bolts and remove tower and lever assembly (Fig. 6).

Fig. 4 Crankshaft Position Sensor 1 - CRANKSHAFT POSITION SENSOR 2 - GROMMET 3 - MOUNTING BOLT(S) 4 - LEFT REAR OF ENGINE 5 - TRANSMISSION

CAUTION: It is important that the crankshaft position sensor be removed prior to transmission removal. The sensor can easily be damaged if left in place during removal operations.

(18) Support engine with adjustable jack stand. Position wood block between jack and oil pan to Fig. 6 SHIFT TOWER avoid damaging pan. 1 - SHIFT TOWER AND LEVER ASSEMBLY (19) Support transmission with transmission jack. 2 - SHIFT SOCKET (20) Secure transmission to jack with safety 3 - SEAL chains. (21) Disconnect rear cushion and bracket from (6) Remove shift shaft lock bolt (Fig. 7) located on transmission. top of the housing just forward of shift tower. (22) Remove rear crossmember. (23) Remove clutch housing-to-engine bolts. 21 - 34 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued)

Fig. 7 SHAFT LOCK BOLT Fig. 9 PULL DETENT PLUG 1 - SHIFT SHAFT LOCK BOLT 1 - NUT 2 - SHAFT SOCKET 2 - REMOVER

(7) Remove shift shaft detent plug with Remover 8117A. Attach the fingers of the remover to the detent plug (Fig. 8). Then push the cup down till it contacts the trans. Tighten the nut (Fig. 9) till it pulls the plug from the trans case.

Fig. 10 BEARING RETAINER 1-PRYTOOL 2 - BEARING RETAINER

Fig. 8 DETENT PULLER 1 - REMOVER 2 - DETENT PLUG

(8) Remove shift shaft detent plunger and spring. Remove spring and plunger with a pencil magnet. (9) Remove bolts attaching input shaft bearing retainer to front housing and remove retainer.

NOTE: Use pry tool to carefully lift retainer and break sealer bead (Fig. 10). Fig. 11 INPUT SHAFT BEARING RETAINER 1 - SHAFT BEARING (10) Remove bearing retainer from input shaft 2 - BEARING RETAINER (Fig. 11). 3 - INPUT SHAFT TJ MANUAL - NV3550 21 - 35 MANUAL - NV3550 (Continued)

(11) Remove snap ring that secures input shaft in front bearing (Fig. 12).

Fig. 12 INPUT SHAFT SNAP RING 1 - INPUT SHAFT SNAP RING Fig. 14 INPUT AND COUNTERSHAFT BEARING 2 - OIL FEED RACE 1 - INPUT SHAFT BEARING (12) Remove bolts that attach front housing to rear 2 - FRONT HOUSING housing. 3 - COUNTERSHAFT FRONT BEARING (13) Separate front housing from rear housing (Fig. 13). With a plastic mallet tap the front housing (15) Remove screw from reverse blocker and off the alignment dowels. remove blocker (Fig. 15) from case. NOTE: The reverse blocker is only used on RHD vehicles.

Fig. 13 FRONT HOUSING 1 - FRONT HOUSING 2 - REAR HOUSING Fig. 15 REVERSE BLOCKER (RHD) 3 - DOWELS (2) 4 - PLASTIC MALLET 1 - REVERSE BLOCKER 2 - SHIFTER SHAFT BUSHING (14) Remove and inspect input shaft bearing and 3 - VENT countershaft front bearing (Fig. 14). 21 - 36 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued)

(16) Note the location of the input shaft, shift shaft, shift forks and geartrain (Fig. 16).

Fig. 17 SHIFT SOCKET ROLL PIN 1 - REMOVER 2 - SHIFT SOCKET

NOTE: Place shop towel over shaft to contain detent ball and spring. Fig. 16 GEARTRAIN AND SHIFT COMPONENTS 1 - SHIFT SHAFT 2 - BUSHING 3 - REAR HOUSING 4 - REVERSE IDLER ANSD SUPPORT 5 - OUTPUT SHAFT AND GEARS 6 - COUNTERSHAFT 7 - 1-2 SHIFT FORK 8 - INPUT SHAFT 9 - 3-4 SHIFT FORK

SHIFT/FORK SHAFTS AND REVERSE IDLER SEGMENT (1) Unseat the roll pin that secures the shift socket to the shift shaft with Remover 6858 as follows: (a) Position remover on the shift shaft. Center the tool over the roll pin and verify that the tool legs are firmly seated on the shift socket (Fig. 17). Fig. 18 DETENT SPRING AND BALL (b) Tilt the socket toward the side of the case. 1 - SHAFT LEVER This positions the roll pin at a slight angle to avoid 2 - SPRING AND BALL trapping the pin between the gear teeth. 3 - MAGNET (c) Tighten the tool to press the roll pin down- (3) With a hammer and punch drive out roll pin ward and out of the shift socket (Fig. 17). that secures shift bushing and lever to shift shaft NOTE: Press the roll pin just enough to clear the (Fig. 19). shift shaft. Be careful not to push the pin into the CAUTION: Use proper size punch to avoid bending geartrain. the shift shaft. (2) Rotate lever and bushing upward and out of the shift forks and catch detent ball and spring (Fig. 18) as they exit the shaft lever. TJ MANUAL - NV3550 21 - 37 MANUAL - NV3550 (Continued)

Fig. 21 SHIFT SOCKET AND ROLL PIN 1 - SHAFT BORE 2 - ROLL PIN 3 - SHIFT SOCKET

Fig. 19 SHIFT SHAFT LEVER AND BUSHING ROLL PIN 1 - LEVER AND BUSHING 2 - SHIFT SHAFT

(4) Pull shift shaft straight (Fig. 20) out of rear housing.

Fig. 22 SHIFT SHAFT LEVER AND BUSHING 1 - SHAFT LEVER AND BUSHING 2 - 3-4 FORK

Fig. 20 SHIFT SHAFT 1 - SHIFTER SHAFT 2 - SHIFTER SHAFT DETENT 3 - 3-4 SHIFT FORK

(5) Remove shift socket from rear housing (Fig. 21). Fig. 23 3-4 SHIFT FORK (6) Remove lever and bushing (Fig. 22). 1 - 3-4 FORK (7) Rotate 3-4 fork around synchro sleeve until 2 - 1-2 AND 5TH-REVERSE FORK ARMS fork clears shift arms on 1-2 and fifth-reverse forks, 3 - 3-4 SYNCHRO SLEEVE then remove 3-4 fork (Fig. 23). 21 - 38 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued)

(8) Remove the reverse idler shaft support bolt (d) Stand geartrain and rear housing upright on (front bolt) (Fig. 24). fixture (Fig. 27). Have helper hold fixture tool in (9) Loosen rear reverse idler shaft bolt (rear bolt) place while housing and geartrain is being rotated (Fig. 24). into upright position.

Fig. 24 REVERSE IDLER SHAFT/SUPPORT BOLT Fig. 26 FIXTURE ASSEMBLY 1 - SUPPORT BOLT 1 - FIXTURE 2 - SHAFT BOLT 2 - ADAPTER 6747-1A 3 - CUP ADAPTER (10) Remove reverse idler shaft support (Fig. 25) 4 - REVERSE IDLER PEDESTAL 5 - ADAPTER 6747-2A segment by sliding it straight out of housing.

Fig. 25 IDLER SHAFT SUPPORT 1 - IDLER SHAFT 2 - IDLER SHAFT SUPPORT

(11) Support geartrain and rear housing on Fix- ture 6747 as follows: (a) Adjust height of reverse idler pedestal rod Fig. 27 GEARTRAIN/HOUSING FIXTURE until the reverse idle shaft bottoms in Cup 8115. 1 - INPUT SHAFT 2 - COUNTERSHAFT (b) Position Adapters 6747-1A and 6747-2A on 3 - FIXTURE Fixture 6747. (c) Slide fixture tool onto input shaft, counter- (12) Remove rear bolt holding reverse idler shaft shaft and idler gear (Fig. 26). in housing. TJ MANUAL - NV3550 21 - 39 MANUAL - NV3550 (Continued) REAR ADAPTER HOUSING (1) Locate rear seal dimples (Fig. 28). With slide hammer mounted screw, remove rear seal by inserting screw into one of the seal dimples (Fig. 29).

Fig. 30 REAR BEARING SNAP RING 1 - SNAP RING PLIERS 2 - REAR BEARING SNAP RING 3 - OUTPUT SHAFT Fig. 28 SEAL DIMPLES 1 - LOCATION OF DIMPLES 2 - SEAL FACE

Fig. 31 REAR ADAPTER HOUSING 1 - REAR ADAPTER HOUSING 2 - OUTPUT SHAFT

(5) Examine condition of bearing bore, countershaft rear bearing race and idler shaft notch in rear housing. Replace housing if race, bore or notch are worn or damaged. Fig. 29 REAR SEAL 1 - SLIDE HAMMER GEARTRAIN FROM FIXTURE 2 - REMOVER 3 - REAR SEAL (1) Remove reverse idler gear assembly from assembly fixture cup. (2) Remove rear bearing snap ring from output (2) Remove 1-2 and fifth-reverse forks from syn- shaft with snap ring pliers (Fig. 30). chro sleeves. (3) Lift rear adapter housing upward and off (3) Slide countershaft out of fixture tool. geartrain (Fig. 31). (4) Lift and remove output shaft and gears off (4) Remove bearing retainer bolts and remove rear input shaft. bearing retainer and rear bearing (Fig. 32). If needed (5) Lift and remove input shaft, pilot bearing and push or tap bearing out of the housing with a ham- fourth gear synchro ring from assembly fixture tool. mer. 21 - 40 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued)

(4) Remove retaining ring that secures two-piece thrust washer on shaft (Fig. 34). Use a small pry tool to remove retaining ring.

Fig. 34 THRUST WASHER Fig. 32 REAR ADAPTER HOUSING COMPONENTS 1-PRYTOOL 1 - BEARING RETAINER 2 - THRUST WASHER RETAINING RING 2 - RETAINER BOLTS (3) 3 - IDLER SHAFT NOTCH (5) Remove two-piece thrust washer (Fig. 35). Note 4 - COUNTERSHAFT REAR BEARING RACE position of washer locating lugs in shaft notches for 5 - REAR BEARING installation reference. OUTPUT SHAFT

NOTE: The synchronizer hubs and sleeves are different and must not be intermixed. Remove each synchronizer unit as an assembly to avoid intermixing parts. Reference mark or tag each synchro hub and sleeve for correct assembly.

(1) Remove snap ring that secures 3-4 synchro hub on output shaft. (2) Remove 3-4 synchro assembly, third gear synchro ring and third gear with shop press and Bearing Splitter 1130. Position splitter between second and third gears. (3) Remove third gear needle bearing (Fig. 33).

Fig. 35 TWO-PIECE THRUST WASHER 1 - SECOND GEAR 2 - THRUST WASHER (2-PIECE) 3 - WASHER LOCATING LUG

(6) Remove second gear and needle bearing (Fig. 36). (7) Remove second gear synchro ring, synchro friction cone and synchro cone (Fig. 37). (8) Remove interim ring. (9) Remove 1-2 synchro hub snap ring. (10) Remove 1-2 synchro hub and sleeve and first Fig. 33 THIRD GEAR NEEDLE BEARING gear from output shaft with press and Bearing Split- 1 - THIRD GEAR NEEDLE BEARING ter 1130 (Fig. 38). Position splitter between first and reverse gears. TJ MANUAL - NV3550 21 - 41 MANUAL - NV3550 (Continued)

(11) Remove first gear needle bearing (Fig. 39).

Fig. 36 SECOND GEAR AND NEEDLE BEARING 1 - SECOND GEAR 2 - SECOND GEAR NEEDLE BEARING Fig. 39 FIRST GEAR NEEDLE BEARING 1 - FIRST GEAR NEEDLE BEARING

(12) Remove fifth gear (Fig. 40).

Fig. 40 FIFTH GEAR 1 - FIFTH GEAR AND SYNCHRO RING

Fig. 37 SECOND GEAR SYNCHRO RING AND (13) Remove fifth gear needle bearing. CONES 1 - 1-2 SYNCHRO HUB AND SLEEVE NOTE: Spread bearing apart just enough to clear 2 - INTERM RING shoulder on output shaft (Fig. 41). 3 - SYNCHRO FRICTION CONE 4 - SYNCHRO CONE 5 - SYNCHRO RING

Fig. 38 HUB SLEEVE AND 1-2 SYNCHRO Fig. 41 FIFTH GEAR NEEDLE BEARING 1 - 1-2 SYNCHRO HUB AND SLEEVE 2 - SPLITTER 1 - FIFTH GEAR NEEDLE BEARING 21 - 42 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued)

(14) Remove fifth-reverse synchro hub snap ring (16) Remove reverse gear and needle bearing (Fig. (Fig. 42). 44).

Fig. 44 REVERSE GEAR AND NEEDLE BEARING 1 - REVERSE GEAR AND NEEDLE BEARING

REVERSE IDLER (1) Remove idler gear snap rings (Fig. 45). Fig. 42 FIFTH-REVERSE SYNCHRO HUB SNAP (2) Remove thrust washer, wave washer, thrust RING plate and idler gear from shaft. 1 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE (3) Remove idler gear needle bearing from shaft. 2 - SYNCHRO HUB SNAP RING 3 - SNAP RING PLIERS CLEANING (15) Remove fifth-reverse synchro hub and sleeve Clean the gears, shafts, shift components and with a press (Fig. 43). transmission housings with a standard parts cleaning solvent. Do not use acid or corrosive base sol- vents. Dry all parts except bearings with compressed air. Clean the shaft bearings with a mild solvent such as Mopar௡ degreasing solvent, Gunk, or similar sol- vents. Do not dry the bearings with compressed air. Allow the bearings to either air dry, or wipe them dry with clean shop towels. INSPECTION

NOTE: Minor nicks on component surfaces can be smoothed with 320/420 grit emery soaked in oil and final polished with crocus cloth.

SHIFT LEVER ASSEMBLY The shift lever assembly is not serviceable. Replace the lever and shift tower as an assembly if the tower, lever, lever ball, or internal components are worn, or damaged.

Fig. 43 FIFTH-REVERSE SYNCHRO HUB AND SLEEVE 1 - PRESS 2 - FIFTH-REVERSE SYNCHRO HUB AND SLEEVE 3 - REVERSE GEAR 4 - OUTPUT SHAFT TJ MANUAL - NV3550 21 - 43 MANUAL - NV3550 (Continued)

Fig. 45 REVERSE IDLER COMPONENTS 1 - SNAP RING 6 - IDLER GEAR BEARING 2 - FLAT WASHER 7 - IDLER SHAFT 3 - WAVE WASHER 8 - THRUST WASHER 4 - THRUST WASHER 9 - SNAP RING 5 - REVERSE IDLER GEAR 10 - THRUST WASHER LOCKBALLS

SHIFT SHAFT AND FORKS tershaft bearing race is loose, worn, or damaged. Inspect the shift fork interlock arms and synchro The rear housing will have to be replaced if the sleeve contact surfaces (Fig. 46). Replace any fork countershaft rear bearing race is loose, worn, or exhibiting wear or damage in these areas. Do not damaged. attempt to salvage shift forks. Inspect the input shaft bearing retainer. Be sure Check condition of the shift shaft detent plunger the release bearing slide surface of the retainer is in and spring. The plunger should be smooth and free of good condition. Replace the retainer seal if necessary. nicks, or scores. The plunger spring should be Inspect the output shaft bearing retainer. Be sure straight and not collapsed, or distorted. Replace the the U-shaped retainer is flat and free of distortion. plunger and spring if in doubt about condition. Check Replace the retainer if the threads are damaged, or if condition of detent plunger bushings. Replace if dam- the retainer is bent, or cracked. aged. Inspect the shift shaft, shift shaft bushing and COUNTERSHAFT BEARINGS AND RACES bearing, the shaft lever, and the lever bushing that The countershaft bearings and races are machine fits over the lever. Replace the shaft if bent, cracked, lapped during manufacture to form matched sets. or severely scored. Replace the shift shaft bushing or The bearings and races should not be interchanged. bearing if damaged. Replace the shaft lever and bushing if either part NOTE: The bearing races are a permanent press fit is deformed, or worn. Do not attempt to salvage these in the housings and are NOT serviceable. If a bear- parts as shift fork binding will occur. Replace the roll ing race becomes damaged, it will be necessary to pin that secures the lever to the shaft. replace the front or rear housing as necessary. A new countershaft bearing will be supplied with each FRONT/REAR HOUSINGS AND BEARING new housing for service use. RETAINERS The countershaft bearings can be installed back- Inspect the housings carefully. Look for cracks, wards if care is not exercised. The bearing roller cage stripped threads, scored mating surfaces, damaged is a different diameter on each side. Be sure the bearing bores, or worn dowel pin holes. Minor nicks bearing is installed so the large diameter side of the on mating surfaces can be dressed off with a fine file, cage is facing the countershaft gear (Fig. 47). The or emery cloth. small diameter side goes in the bearing race. NOTE: The front housing contains the countershaft REVERSE IDLER COMPONENTS front bearing race. The rear housing contains the Inspect the idler gear, bearing, shaft, thrust countershaft rear bearing race. Be advised that washer, wave washer and thrust plate. Replace the these components are NOT serviceable items. The bearing if any of the needle bearing rollers are worn, front housing will have to be replaced if the coun- 21 - 44 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued)

Fig. 46 SHIFT FORKS & SHAFT 1 - SHIFT SHAFT 4 - 3-4 SHIFT FORK 2 - SHAFT LEVER 5 - 1-2 SHIFT FORK 3 - SHAFT LEVER BUSHING 6 - FIFTH-REVERSE SHIFT FORK

Replace the thrust washer, wave washer, or thrust plate if cracked, chipped, or worn. Replace the idler gear if the teeth are chipped, cracked or worn thin. Replace the shaft if worn, scored, or the bolt threads are damaged beyond repair. Replace the support segment if cracked, or chipped and replace the idler attaching bolts if the threads are damaged. Shift Socket Inspect the shift socket for wear or damage. Replace the socket if the roll pin, or shift shaft bores are damaged. Replace the socket if the ball seat is worn, or cracked. Do not reuse the original shift socket roll pin. Install a new pin during reassembly. The socket roll pin is approximately 33 mm (1-1/4 in.) long. Output Shaft And Geartrain Inspect all of the gears for worn, cracked, chipped, or broken teeth. Also check condition of the bearing bore in each gear. The bores should be smooth and Fig. 47 COUNTERSHAFT & BEARINGS free of surface damage. Discoloration of the gear bores is a normal occurrence and is not a reason for 1 - COUNTERSHAFT 2 - BEARING CAGE replacement. Replace gears only when tooth damage has occurred, or if the bores are brinnelled or chipped, cracked, flat-spotted, or brinnelled. Also severely scored. replace the bearing if the plastic bearing cage is Inspect the shaft splines and bearings surfaces. damaged or distorted. Replace the shaft if the splines are damaged or bearing surfaces are deeply scored, worn, or brinnelled. TJ MANUAL - NV3550 21 - 45 MANUAL - NV3550 (Continued) ASSEMBLY Sealers are used at all case joints. Usea Mopar Gasket Maker for all case joints and Mopar silicone sealer or equivalent, for the input shaft bearing retainer. Apply these products as indicated in the assembly procedures.

CAUTION: The transmission shift components must be in the Neutral position during assembly. This prevents damage to the synchro and shift components when the housings are installed.

SYNCHRONIZER

WARNING: WEAR SAFETY GLASSES WHILE ASSEMBLING THE SYNCHRONIZER. A BALL COULD JUMP OUT AND CAUSE INJURY.

To assemble each synchro install the springs, struts and detent balls one at a time as follows: (1) Lubricate synchronizer components with Mopar Fig. 48 SYNCHRONIZER COMPONENTS Manual Transmission lubricant or equivalent. 1 - SLEEVE (2) Slide the sleeve part way onto the hub. Leave 2 - HUB SHOULDER enough room to install the spring in the hub and the 3 - SPRING (3) 4 - STRUT (3) strut in the hub groove. 5 - DETENT BALL (3) (3) Install the first spring in the hub. Then install 6 - HUB a strut over the spring. Be sure the spring is seated in the spring bore in the strut. (4) Slide the sleeve onto the hub just far enough to hold the first strut and spring in place. (5) Place the detent ball in the top of the strut. Then carefully work the sleeve over the ball to hold it in place. Use a small flat blade screwdriver to press the ball into place while moving the sleeve over it. (6) Repeat the procedure for the remaining springs, struts and balls. Tape or rubber band each strut and ball to temporarily secure as they are installed. Fig. 49 REVERSE GEAR BEARING (7) Verify synchro springs, struts and detent balls 1 - REVERSE GEAR BEARING are all in place (Fig. 48). 2 - SHOULDER OUTPUT SHAFT

NOTE: Lubricate all components with recommended lubricant during assembly. Petroleum jelly can be used to hold parts in place.

(1) Lubricate and install reverse gear needle bearing on shaft (Fig. 49). Slide bearing up against shoulder on output shaft. (2) Install reverse gear over needle bearing (Fig. 50). (3) Install brass synchro ring on reverse gear (Fig. 51). Fig. 50 REVERSE GEAR 1 - REVERSE GEAR 21 - 46 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued)

(6) Install new fifth-reverse hub snap ring (Fig. 53) and verify the snap ring is seated.

Fig. 51 REVERSE SYNCHRO 1 - REVERSE GEAR 2 - SYNCHRO RING

(4) Assemble fifth-reverse synchro hub, sleeve, struts, springs and detent balls, if not previously done.

CAUTION: One side of the hub has shoulders around the hub bore, this side of the hub faces the Fig. 53 FIFTH/REVERSE SYNCHRO HUB SNAP RING front of the shaft. One side of the sleeve is tapered. 1 - FIFTH-REVERSE SYNCHRO ASSEMBLY The tapered side faces the front of the shaft. 2 - SNAP RING 3 - PRESS BED (5) Start fifth-reverse synchro assembly on output 4 - PRESS BLOCKS shaft splines by hand. Then seat synchro onto shaft with a press and Cup 6310-1 (Fig. 52). (7) Install fifth gear synchro ring in synchro hub and sleeve (Fig. 54). NOTE: Lugs on the synchro ring must be aligned with the sleeve notches for installation.

Fig. 54 FIFTH GEAR SYNCHRO RING 1 - FIFTH-SPEED SYNCHRO RING 2 - FIFTH-REVERSE SYNCHRO ASSEMBLY

(8) Install fifth gear bearing, spreading bearing only enough to clear shoulder on output shaft (Fig. 55). Verify bearing is properly seated. Fig. 52 FIFTH-REVERSE SYNCHRO ASSEMBLY (9) Install fifth gear on shaft and onto bearing (Fig. 56). 1 - SPACER 2 - PRESS RAM (10) Invert output shaft and set the shaft in Cup 3 - REVERSE GEAR 6310-1 so that fifth gear is seated on the tool (Fig. 4 - FIFTH-REVERSE SYNCHRO ASSEMBLY 57). 5 - CUP 6 - PRESS BLOCKS 7 - OUTPUT SHAFT TJ MANUAL - NV3550 21 - 47 MANUAL - NV3550 (Continued)

Fig. 55 FIFTH GEAR BEARING 1 - SHAFT SHOULDER 2 - FIFTH GEAR BEARING

Fig. 57 FIRST GEAR BEARING 1 - FIRST GEAR BEARING 2 - SHAFT SHOULDER 3 - CUP 4 - PRESS BLOCKS

Fig. 56 FIFTH GEAR 1 - FIFTH GEAR 2 - BEARING

(11) Install first gear bearing on output shaft (Fig. 57). Verify bearing is seated on shaft shoulder and is properly joined. (12) Install first gear on shaft and over bearing Fig. 58 FIRST GEAR with synchro cone facing up (Fig. 58). 1 - FIRST GEAR 2 - CUP 3 - BEARING 21 - 48 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued)

(13) Install first gear synchro ring (Fig. 59). (16) Press 1-2 synchro onto output shaft using suitable size pipe tool and shop press (Fig. 61).

CAUTION: Align the synchro ring and sleeve as hub the is being pressed onto the shaft. The synchro ring can crack if not aligned.

Fig. 59 FIRST GEAR SYNCHRO RING 1 - FIRST GEAR SYNCHRO RING 2 - CUP 3 - FIRST GEAR

(14) Assemble 1-2 synchro hub sleeve, springs, struts and detent balls.

CAUTION: The 1-2 synchro hub and sleeve can be installed backwards. One side of the synchro sleeve is marked First Gear Side. Verify this side of the sleeve is facing first gear.

(15) Start 1-2 synchro assembly on shaft by hand (Fig. 60). Verify synchro sleeve is properly positioned. Fig. 61 PRESS 1-2 SYNCHRO 1 - SUITABLE SIZE PIPE TOOL 2 - SYNCHRO RING 3 - CUP 4 - 1-2 SYNCHRO ASSEMBLY 5 - PRESS RAM

Fig. 60 STARTING 1-2 SYNCHRO 1 - 1–2 SYNCHRO ASSEMBLY 2 - CUP 3 - FIRST GEAR SIDE OF SYNCHRO SLEEVE TJ MANUAL - NV3550 21 - 49 MANUAL - NV3550 (Continued)

(17) Install interm ring. (21) Install second gear needle bearing on shaft (18) Install new 1-2 synchro hub snap ring (Fig. (Fig. 64). 62) and verfiy the snap ring is seated.

Fig. 64 SECOND GEAR BEARING Fig. 62 1-2 SYNCHRO HUB SNAP RING 1 - SECOND GEAR BEARING 1 - 1-2 SYNCHRO 2 - CUP 2 - CUP 3 - SYNCHRO SNAP RING (22) Install second gear onto shaft and bearing (19) Install second gear synchro ring in 1-2 syn- (Fig. 65). Verify second gear is fully seated on synchro hub and sleeve (Fig. 63). Verify synchro ring is chro components. properly seated. (20) Install synchro friction cone and synchro cone in synchro ring.

Fig. 65 SECOND GEAR 1 - CUP 2 - 1-2 SYNCHRO ASSEMBLY 3 - BEARING Fig. 63 SECOND GEAR SYNCHRO RING 4 - SECOND GEAR 1 - SECOND GEAR SYNCHRO RING 2 - 1-2 SYNCHRO 3 - CUP 21 - 50 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued)

(23) Install two-piece thrust washer (Fig. 66). Ensure washer halves are seated in shaft groove and that washer lugs are seated in shaft lug bores.

NOTE: Dot or markings on the two-piece thrust washer go toward 3rd gear.

Fig. 67 RETAINING RING 1 - THRUST WASHER RETAINING RING 2 - THRUST WASHER HALVES 3 - SECOND GEAR 4 - LOCATING DIMPLE

Fig. 66 TWO-PIECE THRUST WASH 1 - WASHER GROOVE IN SHAFT 2 - LUG BORE 3 - THRUST WASHER LUGS Fig. 68 THRUST RETAINER 4 - LUG BORE 5 - LUG 1 - PLASTIC MALLET 6 - WASHER HALF 2 - THRUST WASHER RETAINING RING

(24) Start retaining ring around two-piece thrust (28) Install third speed synchro ring on third gear washer (Fig. 67). Ensure locating dimple is between (Fig. 71). the thrust washer halves. (29) Assemble 3-4 synchro hub, sleeve, springs, (25) Seat thrust washer retaining ring with plastic struts and detent balls. mallet (Fig. 68). (30) Start 3-4 synchro hub on output shaft splines (26) Install third gear needle bearing on shaft (Fig. by hand (Fig. 72). 69). (27) Install third gear on shaft and bearing (Fig. CAUTION: The 3-4 synchro hub and sleeve can be 70). installed backwards. One side of the sleeve has grooves in it. This side of sleeve faces the front of the shaft. TJ MANUAL - NV3550 21 - 51 MANUAL - NV3550 (Continued)

Fig. 69 THIRD GEAR BEARING Fig. 72 3-4 SYNCHRO HUB ON OUTPUT SHAFT 1 - THIRD GEAR BEARING 1 - GROOVED SIDE OF SLEEVE (TO FRONT) 2 - 3-4 SYNCHRO ASSEMBLY

(31) With the lug on the ring aligned with the slot on the synchro, press 3-4 synchro assembly onto output shaft with shop press and suitable size pipe tool (Fig. 73).

NOTE: Place the pipe on hub as close to output shaft as possible without contacting the shaft splines.

Fig. 70 THIRD GEAR 1 - THIRD GEAR 2 - BEARING

Fig. 73 3-4 SYNCHRO ON OUTPUT SHAFT 1 - PRESS RAM 2 - PIPE TOOL 3 - 3-4 SYNCHRO Fig. 71 THIRD SPEED SYNCHRO RING 4 - THIRD SPEED SYNCHRO RING 1 - THIRD SPEED SYNCHRO RING (32) Install new 3-4 synchro hub snap ring (Fig. 2 - THIRD GEAR 74) and verify snap ring is seated. 21 - 52 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued) REVERSE IDLER ASSEMBLY (1) Lubricate idler components with Mopar Man- ual Transmission lubricant or equivalent. (2) Slide idler gear bearing on shaft (Fig. 76). Bearing fits either way on shaft. (3) Slide gear onto shaft. Side of gear with recess goes to rear (Fig. 76). (4) Place first lock ball in dimple at rear end of idler shaft (Fig. 76). Hold ball in place with petroleum jelly. (5) Slide rear thrust washer onto shaft and over lock ball (Fig. 77). (6) Install snap ring in groove at rear of shaft (Fig. 77). Fig. 74 3-4 SYNCHRO HUB SNAP RING (7) Install lock ball in dimple at front of shaft. 1 - 3-4 SYNCHRO HUB SNAP RING Hold ball in place with petroleum jelly. 2 - HEAVY DUTY SNAP RING PLIERS (8) Install front thrust washer on shaft and slide washer up against gear and over lock ball (Fig. 78). (33) Verify position of synchro sleeves before pro- (9) Install wave washer, flat washer and remain- ceeding with assembly operations (Fig. 75). Grooved ing snap ring on idler shaft (Fig. 78). Verify snap side of 3-4 sleeve should be facing forward. First gear ring is seated. side of 1-2 sleeve should be facing first gear. Tapered side of fifth-reverse sleeve should be facing forward.

Fig. 75 SYNCHRO SLEEVE LOCATIONS 1 - DOUBLE GROOVE FORWARD 5 - GROOVE FORWARD 2 - GROOVE FORWARD 6 - 5TH-REV SYNCHRO SLEEVE 3 - FIRST GEAR SIDE MARKING TOWARD FIRST GEAR 7 - 1-2 SYNCHRO SLEEVE 4 - TAPER FORWARD 8 - 3-4 SYNCHRO SLEEVE TJ MANUAL - NV3550 21 - 53 MANUAL - NV3550 (Continued)

Fig. 76 IDLER GEAR AND BEARING 1 - IDLER GEAR 2 - BEARING 3 - LOCK BALL 4 - REAR OF SHAFT

Fig. 78 IDLER GEAR AND SHAFT ASSEMBLY 1 - REAR OF SHAFT 2 - GEAR 3 - THRUST WASHER AND BALL 4 - WAVE WASHER 5 - FLAT WASHER 6 - FRONT OF SHAFT 7 - SNAP RING 8 - SNAP RING

(7) Thread the bolt into the bearing as much as possible. (8) Attach a slide hammer or suitable puller to the bolt and remove the bearing. (9) Use the short end of Installer 8119 to install the new bearing. (10) The bearing is correctly installed if the bear- Fig. 77 IDLER GEAR REAR THRUST WASHER ing is flush with the transmission case. 1 - LOCK BALL 2 - SNAP RING GROOVE 3 - THRUST WASHER DETENT PLUNGER BUSHING Inspect detent plunger bushings for damage and SHIFT SHAFT AND BUSHINGS/BEARINGS replace if necessary. Inspect shift shaft bushing and bearing for damage and replace if necessary. NOTE: The detent plunger bushings are installed to (1) Locate a bolt that will thread into the bushing a specific depth. The space between the two bush- without great effort. ings when correctly installed contain an oil feed (2) Thread the bolt into the bushing, allowing the hole. Do not attempt to install the bushings with bolt to make its own threads in the bushing. anything other than the specified tool or this oil (3) Attach a slide hammer or suitable puller to the hole may become restricted. bolt and remove bushing. (1) Using the long end of Installer 8119, drive the (4) Use the short end of Installer 8119 to install detent bushings through the outer case and into the the new bushing. shift shaft bore. (5) The bushing is correctly installed if the bush- (2) Remove the bushings from the shift shaft bore. ing is flush with the transmission case. (3) Install a new detent plunger bushing on the (6) To replace the bearing locate a bolt that will long end of Installer 8118. thread into the bearing without great effort. 21 - 54 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued)

(4) Start the bushing in the detent plunger bore in the case. (5) Drive the bushing into the bore until the tool contacts the transmission case. (6) Install a new detent plunger bushing on the short end of Installer 8118. (7) Start the bushing in the detent plunger bore in the case. (8) Drive the bushing into the bore until the tool contacts the transmission case. GEARTRAIN ASSEMBLY (1) Install Adapter 6747-1A on input shaft hub of Fixture 6747 (Fig. 79).

Fig. 80 PILOT BEARING AND INPUT SHAFT 1 - PILOT BEARING 2 - INPUT SHAFT

(4) Install fourth gear synchro ring on input shaft (Fig. 81).

Fig. 79 ASSEMBLY FIXTURE 1 - ADAPTER 6747-2A (INSTALL ON COUNTERSHAFT FRONT Fig. 81 FOURTH GEAR SYNCHRO HUB) 1 - FOURTH GEAR SYNCHRO RING 2 - CUP ADAPTER 8115 2 - INPUT SHAFT 3 - ADAPTER 6747-A 4 - FIXTURE 6747 (5) Adjust height of idler gear pedestal on assem- (2) Install input shaft in fixture tool. Make sure bly fixture (Fig. 82). Start with a basic height of 18.4 Adapter 6747-1A is positioned under shaft as shown cm (7-1/4 in.). Final adjustment can be made after (Fig. 80). gear is positioned on pedestal. (3) Install pilot bearing in input shaft (Fig. 80). (6) Install assembled output shaft and geartrain in input shaft (Fig. 83). Carefully rotate output shaft NOTE: The side of the pilot bearing with the small until the 3-4 synchro ring seats in synchro hub and diameter goes toward the input shaft. sleeve. TJ MANUAL - NV3550 21 - 55 MANUAL - NV3550 (Continued)

(7) Install Adapter 6747-2A on front bearing hub of countershaft. The adapter has a shoulder on one side that goes towards the countershaft. (8) Slide countershaft (and adapter) into fixture slot. Verify countershaft and output shaft gears are fully meshed with the mainshaft gears (Fig. 84). (9) Check alignment of countershaft and output shaft gear teeth. Note that gears may not align per- fectly. A difference in height of 1.57 to 3.18 mm (1/16 to 1/8 in.) will probably exist. This difference will not interfere with assembly.

Fig. 82 IDLER PEDESTAL BASIC HEIGHT 1 - REVERSE IDLER PEDESTAL

Fig. 84 COUNTERSHAFT ON FIXTURE 1 - OUTPUT SHAFT AND GEARTRAIN 2 - COUNTERSHAFT (SLIDE INTO PLACE ON FIXTURE TOOL)

(10) Position reverse idler in support cup of assembly fixture (Fig. 85). Ensure idler gear is properly meshed and aligned with shaft gear teeth and that Fig. 83 OUTPUT SHAFT AND GEARTRAIN bolt holes are facing out and not toward geartrain. 1 - OUTPUT SHAFT AND GEARTRAIN Adjust pedestal up or down if necessary. Also be sure 2 - INPUT SHAFT that short end of idler shaft is facing up as shown. 3 - FIXTURE 6747 21 - 56 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued)

Fig. 87 SHIFT FORKS IN SYNCHRO 1 - SYNCHRO SLEEVES 2 - FORK ARMS 3 - SHIFT FORKS

ADAPTER HOUSING (1) Install rear bearing in adapter housing. Use Fig. 85 REVERSE IDLER ASSEMBLY POSITION wood hammer handle or wood dowel to tap bearing 1 - OUTPUT SHAFT AND GEARTRAIN into place. 2 - COUNTERSHAFT (2) Position rear bearing retainer in adapter hous- 3 - REVERSE IDLER ASSEMBLY ing (Fig. 88). 4 - TOOL PEDESTAL

(11) Assemble 1-2 and fifth reverse-shift forks (Fig. 86). Arm of fifth-reverse fork goes through slot in 1-2 fork.

Fig. 86 1-2 AND FIFTH-REVERSE 1 - FIFTH-REVERSE FORK ARM Fig. 88 ADAPTER HOUSING 2 - 1-2 FORK 1 - BEARING RETAINER 3 - FIFTH-REVERSE FORK 2 - RETAINER BOLT 3 - IDLER SHAFT NOTCH (12) Install assembled shift forks in synchro 4 - COUNTERSHAFT BEARING RACE 5 - REAR BEARING sleeves (Fig. 87). Verify forks are properly seated in sleeves. (3) Apply Mopar Gasket Maker or equivalent, to threads, bolt shanks and under hex heads of bearing retainer bolts. TJ MANUAL - NV3550 21 - 57 MANUAL - NV3550 (Continued)

(4) Apply liberal quantity of petroleum jelly to countershaft rear bearing and bearing race. (5) Install countershaft rear bearing in bearing race (Fig. 88).

CAUTION: Be sure the large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing.

(6) Apply extra petroleum jelly to hold countershaft rear bearing in place when housing is installed. (7) Apply light coat of petroleum jelly to shift shaft bushing/bearing in adapter housing. (8) Install adapter housing on geartrain. (9) Install rear bearing snap ring on output shaft (Fig. 89). Fig. 90 REAR SEAL 1 - REAR SEAL 2 - SEAL LIP 3 - OUTPUT SHAFT

Fig. 89 REAR BEARING SNAP RING 1 - SNAP RING PLIERS 2 - SNAP RING 3 - OUTPUT SHAFT

(10) Lubricate lip of new rear seal (Fig. 90) with Fig. 91 REVERSE IDLER SHAFT/SUPPORT BOLT Mopar Door Ease or transmission fluid. 1 - SUPPORT BOLT (11) Install new rear seal in adapter housing bore 2 - SHAFT BOLT with Installer C-3860-A. Verify seal is seated in housing bore (Fig. 90). (12) Slide reverse idler shaft support straight into the housing. (13) Install reverse idler shaft support bolt and idler shaft bolt (Fig. 91). Tighten bolts to 19-25 N·m (14-18 ft. lbs.). 21 - 58 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued) SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET (1) Verify that all synchro sleeves are in Neutral position (centered on hub).

CAUTION: The transmission synchros must all be in Neutral position for assembly. Otherwise the housings, shift forks and gears can be damaged during installation of the two housings.

(2) Install 3-4 shift fork in synchro sleeve (Fig. 92). Verify that groove in fork arm is aligned with grooves in 1-2 and fifth-reverse fork arms as shown.

Fig. 93 LEVER AND BUSHING 1 - SHAFT LEVER 2 - LEVER BUSHING 3 - BUSHING LOCK PIN SLOT

Fig. 92 3-4 SHIFT FORK 1 - 3-4 FORK 2 - ALIGN GROOVES IN FORK ARMS

(3) Slide the end of shift shaft with shaft detent notches through 3-4 shift fork. (4) Assemble shift shaft shift lever and bushing (Fig. 93). Be sure slot in bushing is facing up and roll Fig. 94 LEVER AND BUSHING ASSENBLY pin hole for lever is aligned with hole in shaft. (5) Install assembled lever and bushing on shift 1 - SHIFT SHAFT 2 - SHAFT LEVER AND BUSHING shaft (Fig. 94). 3 - 3-4 FORK (6) Slide shift shaft through shift forks (Fig. 95) and into shift lever opening in rear housing (Fig. 96). (7) Align shift socket with shaft and slide shaft through socket and into shift shaft bearing in rear housing (Fig. 97). TJ MANUAL - NV3550 21 - 59 MANUAL - NV3550 (Continued)

Fig. 95 SHIFT SHAFT Fig. 97 SHIFT SOCKET 1 - SHIFT SHAFT 1 - SHIFT SOCKET 2 - 3-4 SHIFT FORK 2 - SHIFT SHAFT

Fig. 98 ROLL PIN IDENTIFICATION 1 - SHAFT LEVER ROLL PIN 2 - SHIFT SOCKET ROLL PIN

Fig. 96 SHAFT IN LEVER OPENING 1 - SHIFT SHAFT

(8) Rotate shift shaft so detent notches in shaft are facing the TOP of the transmission housing.

CAUTION: Positioning of the shift shaft detent notch is important. Both of the shaft roll pins can be installed even when the shaft is 180° off. If this occurs, the transmission will have to be disassembled again to correct shaft alignment.

(9) Select correct new roll pin for shift shaft lever (Fig. 98). Shaft lever roll pin is approximately 22 mm (7/8 in.) long. Shift socket roll pin is approximately Fig. 99 ROLL PIN IN SHIFT SHAFT 33 mm (1-1/4 in.) long. 1 - SHAFT LEVER ROLL PIN 22 mm (7/8 in.) (10) Align roll pin holes in shift shaft, lever and 2 - LEVER AND BUSHING bushing. Then start roll pin into shaft lever by hand CAUTION: The shaft lever roll pin must be flush (Fig. 99). with the surface of the lever. The lever bushing will (11) Seat shaft lever roll pin with pin punch (Fig. bind on the roll pin if the pin is not seated flush. 100). 21 - 60 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued)

(12) Verify that lock pin slot in lever bushing is positioned as shown (Fig. 100).

Fig. 100 SHIFT SHAFT LEVER ROLL 1 - BUSHING LOCK PIN SLOT 2 - ROLL PIN FLUSH WITH LEVER

(13) Align roll pin holes in shift socket and shift Fig. 102 SEATING SHIFT SOCKET ROLL PIN shaft. Then start roll pin into shift shaft by hand 1 - PIN PUNCH 2 - SHIFT SOCKET (Fig. 101). 3 - SEAT ROLL PIN FLUSH 4 - SHIFT SOCKET

Fig. 101 ROLL PIN IN SHIFT SOCKET 1 - ROLL PIN 33 mm (1 1/4 in.) Fig. 103 SHIFT LEVER POSITION 2 - SHIFT SOCKET 3 - SHIFT SHAFT 1 - SHIFT FORK ARMS 2 - DETENT BORE (14) Seat roll pin in shift socket with pin punch. Roll pin must be flush with socket (Fig. 102). (17) Install detent spring then the ball into the (15) Verify that notches in shift fork arms are detent bore (Fig. 104) and hold the ball in the lever. aligned (Fig. 103). Realign arms if necessary. Then rotate the lever upward into the fork arm (16) Rotate shift lever and bushing downward to notches. expose detent bore in the lever. NOTE: Verify detent ball is seated in the fork arms before proceeding. TJ MANUAL - NV3550 21 - 61 MANUAL - NV3550 (Continued)

(4) Reach into countershaft front bearing with finger, and push each bearing roller outward against race. Then apply extra petroleum jelly to hold rollers in place. This avoids having rollers becoming displaced during housing installation.

Fig. 104 DETENT SPRING AND BALL 1 - SHAFT LEVER 2 - SPRING AND BALL 3 - MAGNET

FRONT HOUSING AND INPUT SHAFT BEARING RETAINER Fig. 106 COUNTERSHAFT FRONT BEARING (1) Install reverse blocker, retainter and retainer 1 - BEARING RACE 2 - PETROLEUM JELLY bolt in front housing. 3 - COUNTERSHAFT FRONT BEARING (2) If previously removed, input shaft bearing in front housing (Fig. 105). Install snap ring and use (5) Apply small amount of petroleum jelly to shift plastic mallet to seat bearing. Bearing goes in from shaft bushing in front housing. front side of housing only. (6) Apply 1/8 in. wide bead of Mopar Gasket Maker or equivalent, to mating surfaces of front and rear housings (Fig. 107).

Fig. 105 INPUT SHAFT AND COUNTERSHAFT FRONT BEARING 1 - INPUT SHAFT BEARING 2 - COUNTERSHAFT FRONT BEARING 3 - SHIFT SHAFT BUSHING

(3) Apply liberal quantity of petroleum jelly to countershaft front bearing. Then insert bearing in front housing race (Fig. 105). Large diameter side of Fig. 107 SEAL FRONT/REAR HOUSINGS bearing cage goes toward countershaft (Fig. 106). 1 - HOUSING FLANGE SURFACE Small diameter side goes toward bearing race in 2 - GASKET MAKER housing. 21 - 62 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued)

(7) Have helper hold rear housing and geartrain in CAUTION: If the lock bolt cannot be fully installed, upright position. Then install front housing on rear do not try to force it into place. Either the shift housing and geartrain. shaft is not in Neutral or the shaft bushing (or (8) Work front housing downward onto geartrain lever) is misaligned. until seated on rear housing.

CAUTION: If the front housing will not seat on the rear housing, either the shift components are not in Neutral, or one or more components are misaligned. Do not force the front housing into place. This will only result in damaged components.

(9) Tap rear housing alignment dowels back into place with hammer and pin punch. Both dowels should be flush fit in each housing. Have helper hold transmission upright while dowels are tapped back into place. (10) Place transmission in horizontal position. (11) Apply Mopar Gasket Maker or equivalent to housing attaching bolts. Apply sealer material sealer to underside of bolt heads and to bolt shanks and threads (Fig. 108). Fig. 109 SHAFT LOCK BOLT (12) Install and start housing attaching bolts by 1 - SHIFT SHAFT LOCK BOLT hand (Fig. 108). Then tighten bolts to 34 N·m (25 ft. 2 - SHAFT SOCKET lbs.). (14) Lubricate then install shift shaft detent plunger in housing bore. Lubricate plunger with Val- voline Dura Blend௡ semi-synthetic/synthetic grease or equivalent. Verify plunger is fully seated in detent notch in shift shaft. (15) Install detent spring inside plunger. (16) Install plug on detent spring and compress spring. Then drive detent plug with Installer 8123 into transmission case until plug seats. (17) Install backup light switch (Fig. 110).

Fig. 108 HOUSING BOLTS 1 - HOUSING BOLTS

(13) Install shift shaft bushing lock bolt (Fig. 109). Apply Mopar Gasket Maker or equivalent, to bolt threads, shank and underside of bolt head before installation. Fig. 110 BACKUP LIGHT SWITCH NOTE: This is a special bolt and can not be substi- 1 - BACKUP LIGHT SWITCH tuted with any other bolt. (18) Install input shaft snap ring (Fig. 111). TJ MANUAL - NV3550 21 - 63 MANUAL - NV3550 (Continued)

(21) Align and install front bearing retainer over input shaft and onto housing mounting surface (Fig. 114). Although retainer is one-way fit on housing, be sure bolt holes are aligned before seating retainer.

NOTE: Ensure no sealer gets in the transmission case oil feed hole and slot in bearing retainer is aligned with oil feed hole.

Fig. 111 SHAFT SNAP RING - TYPICAL 1 - INPUT SHAFT SNAP RING

(19) Install new oil seal in front bearing retainer with Installer 6448 (Fig. 112).

Fig. 114 INPUT SHAFT BEARING RETAINER 1 - INPUT SHAFT 2 - OIL FEED 3 - BEARING RETAINER

(22) Install and tighten bearing retainer bolts to 9-14 N·m (7-10 ft. lbs.) (Fig. 115).

Fig. 112 OIL SEAL IN FRONT BEARING RETAINER 1 - INSTALLER 2 - FRONT BEARING RETAINER

(20) Apply bead of Mopar silicone sealer or equivalent to flange surface of front bearing retainer (Fig. 113).

Fig. 115 BEARING RETAINER BOLTS 1 - RETAINER BOLTS

Fig. 113 SEAL BEARING RETAINER AND HOUSING 1 - APPLY SEALER BEAD 2 - INPUT SHAFT BEARING RETAINER 21 - 64 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued) SHIFT TOWER AND LEVER INSTALLATION (1) Apply petroleum jelly to ball end of shift lever (1) Install clutch housing on transmission and and interior of shift socket. tighten housing bolts to 46 N·m (34 ft. lbs.). (2) Shift the transmission into third gear. (2) Lubricate contact surfaces of release fork pivot (3) Align and install shift tower and lever assem- ball stud and release fork with high temp grease. bly (Fig. 116). Be sure shift ball is seated in socket (3) Install release bearing, fork and retainer clip. and the offset in the tower is toward the passenger (4) Position and secure transmission on transmis- side of the vehicle before installing tower bolts. sion jack. (4) Install shift tower bolts (Fig. 117). Tighten (5) Lightly lubricate pilot bearing and transmission bolts to 8.5 N·m (75.2 in. lbs.). input shaft splines with Mopar high temp grease. (6) Raise transmission and align transmission input shaft and clutch disc splines. Then slide transmission into place. (7) Install and tighten clutch housing-to-engine bolts to:Be sure the housing is properly seated on engine block before tightening bolts. • Tighten 3/8” diameter bolts to 37 N·m (27 ft.lbs.). • Tighten 7/16” diameter bolts to 58 N·m (43 ft.lbs.). • Tighten M12 bolts to 75 N·m (55 ft.lbs.). (8) Be sure transmission is in first or third gear. (9) Install crossmember and tighten crossmember- to-frame bolts to 41 N·m (31 ft. lbs.). (10) Install fasteners to hold rear cushion and bracket to transmission. Then tighten transmission- Fig. 116 SHIFT TOWER to-rear support bolts/nuts to 54 N·m (40 ft. lbs.). 1 - SHIFT TOWER (11) Remove support stands from engine and transmission. (12) Install and connect crankshaft position sensor. (13) Install transfer case. (14) Install rear propeller shaft slip yoke to transmission or transfer case output shaft if equipped. (15) Install rear propeller shaft with reference marks aligned (Fig. 118).

Fig. 117 SHIFT TOWER BOLTS 1 - SHIFT TOWER AND LEVER ASSEMBLY

(5) Fill transmission to bottom edge of fill plug hole with Mopar Transmission Lubricant. (6) Install and tighten fill plug to 34 N·m (25 ft. lbs.). Fig. 118 Propeller Shaft (7) Check transmission vent. Be sure vent is open and not restricted. 1 - REFERENCE MARKS (16) Install and tighten propeller shaft U-joint clamp bolts to 19 N·m (170 in. lbs.). TJ MANUAL - NV3550 21 - 65 MANUAL - NV3550 (Continued)

(17) Align marks on front propeller shaft, axle and Lubricant Recommendation sections of the appropri- transfer case yokes. ate component for correct fluid. (18) Install and tighten propeller shaft U-joint (22) Lower vehicle. clamp bolts to 19 N·m (170 in. lbs.). (23) Install nuts on two M6X1.0 bolts and thread (19) Install slave cylinder in clutch housing. the bolts into the threaded holes at the base of the (20) Install skid plate, if equipped and tighten shift lever. bolts to 42 N·m (31 ft. lbs.). Tighten stud nuts to 17 (24) Tighten the nuts equally until the shift lever N·m (150 in. lbs.). will slide over the shift tower stub shaft. (21) Fill transmission and transfer case if (25) Install the floor console and shift boot. equipped, with recommended lubricants. Refer to the

SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Clutch Housing Bolts 54-61 40-45 - Crossmember To Frame Bolts 61-75 44-55 - Crossmember To Insulator Nuts 54-61 40-45 - Drain/Fill Plug 9-27 14-20 - Front To Rear Housing Bolts 30-35 22-26 - Front Bearing Retainer Bolts 9-14 7-8 80-124 Idler Shaft Bolts 19-25 14-18 - Rear Bearing Retainer Bolts 30-35 22-26 - Shift Tower Bolts 7-10 5-7 62-88 Slave Cylinder Nuts 23 17 - Transfer Case Nuts 47 35 - U-Joint Clamp Bolts 19 14 -

SPECIAL TOOLS

ADAPTER 6747-1A

REMOVER/INSTALLER 6858

ADAPTER 6747-2A

FIXTURE 6747 21 - 66 MANUAL - NV3550 TJ MANUAL - NV3550 (Continued)

CUP 8115

REMOVER 8117A

SPLITTER 1130

INSTALLER 8123 TUBE 6310-1

INSTALLER 8118 INSTALLER 6448 VEHICLE SPEED SENSOR DESCRIPTION The 3-wire Vehicle Speed Sensor (VSS) is located on the speedometer pinion gear adapter. If equipped with 4WD, this adapter is located on the extension housing of the transfer case (drivers side). If REMOVER/INSTALLER 8119 equipped with 2WD, this adapter is located on the left side of the transmission extension housing. OPERATION The VSS is a 3-circuit (3–wire), magnetic, hall-ef- fect sensor. The 3 circuits are: • A 5-volt power supply from the Powertrain Con- trol Module (PCM). PIN ALIGNMENT 8120 • A ground is provided for the sensor though a low-noise sensor return circuit in the PCM. • An input to the PCM is used to determine vehicle speed and distance traveled. TJ MANUAL - NV3550 21 - 67 VEHICLE SPEED SENSOR (Continued)

The speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a closed throttle signal from the throttle position sensor, indicate a closed throttle deceleration to the PCM. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. REMOVAL The Vehicle Speed Sensor (VSS) is located on the speedometer pinion gear adapter. If equipped with 4WD, this adapter is located on the transfer case extension (left side) (Fig. 119). If equipped with 2WD, this adapter is located on the extension housing of the transmission (left side).

Fig. 120 VSS Removal/Installation 1 - ELECTRICAL CONNECTOR 2 - SENSOR MOUNTING BOLT 3 - O-RING 4 - SPEEDOMETER PINION GEAR 5 - SPEEDOMETER PINION GEAR ADAPTER 6 - O-RING 7 - VEHICLE SPEED SENSOR

(1) Raise and support vehicle. (2) Disconnect electrical connector from sensor by pushing slide tab (Fig. 119). After slide tab has been positioned, push in on secondary release lock (Fig. 119) on side of connector and pull connector from sensor. (3) Remove sensor mounting bolt (Fig. 120). (4) Remove sensor (pull straight out) from speedometer pinion gear adapter (Fig. 120). Do not remove gear adapter from transmission. INSTALLATION (1) Clean inside of speedometer pinion gear Fig. 119 VSS Location adapter before installing speed sensor. 1 - SENSOR ELECTRICAL CONNECTOR (2) Install sensor into speedometer gear adapter 2 - SLIDE TAB and install mounting bolt. Before tightening bolt, ver- 3 - 4WD TRANSFER CASE EXTENSION 4 - VEHICLE SPEED SENSOR ify speed sensor is fully seated (mounted flush) to 5 - RELEASE LOCK speedometer pinion gear adapter. (3) Tighten sensor mounting bolt to 2.2 N·m (20 in. lbs.) torque. (4) Connect electrical connector to sensor. 21 - 68 AUTOMATIC TRANSMISSION - 42RLE TJ

AUTOMATIC TRANSMISSION - 42RLE

TABLE OF CONTENTS

page page

AUTOMATIC TRANSMISSION - 42RLE FLUID AND FILTER DESCRIPTION ...... 69 DIAGNOSIS AND TESTING OPERATION ...... 71 DIAGNOSIS AND TESTING - CAUSES OF DIAGNOSIS AND TESTING BURNT FLUID ...... 141 DIAGNOSIS AND TESTING - AUTOMATIC DIAGNOSIS AND TESTING - EFFECTS OF TRANSMISSION ...... 76 INCORRECT FLUID LEVEL ...... 141 DIAGNOSIS AND TESTING - ROAD TEST . . . 77 DIAGNOSIS AND TESTING - FLUID DIAGNOSIS AND TESTING - HYDRAULIC CONTAMINATION ...... 141 PRESSURE TESTS ...... 78 STANDARD PROCEDURE DIAGNOSIS AND TESTING - CLUTCH AIR STANDARD PROCEDURE - FLUID LEVEL PRESSURE TESTS ...... 80 CHECK ...... 141 DIAGNOSIS AND TESTING - FLUID STANDARD PROCEDURE - FLUID/FILTER LEAKAGE ...... 81 SERVICE ...... 142 STANDARD PROCEDURE - ALUMINUM STANDARD PROCEDURE - TRANSMISSION THREAD REPAIR ...... 82 FILL ...... 142 REMOVAL ...... 82 GEARSHIFT CABLE DISASSEMBLY ...... 83 REMOVAL ...... 143 ASSEMBLY ...... 100 INSTALLATION ...... 143 INSTALLATION ...... 115 HOLDING CLUTCHES SCHEMATICS AND DIAGRAMS - 42RLE DESCRIPTION ...... 144 TRANSMISSION ...... 118 OPERATION ...... 144 SPECIFICATIONS INPUT CLUTCH ASSEMBLY 42RLE AUTOMATIC TRANSMISSION ...... 131 DISASSEMBLY ...... 144 SPECIAL TOOLS ASSEMBLY ...... 151 42RLE AUTOMATIC TRANSMISSION ...... 133 INPUT SPEED SENSOR ACCUMULATOR DESCRIPTION ...... 161 DESCRIPTION ...... 136 OPERATION ...... 161 OPERATION ...... 137 REMOVAL ...... 161 ADAPTER HOUSING SEAL INSTALLATION ...... 161 REMOVAL ...... 137 OIL PUMP INSTALLATION ...... 137 DESCRIPTION ...... 161 BEARINGS OPERATION ...... 161 ADJUSTMENTS DISASSEMBLY ...... 162 BEARING ADJUSTMENT PROCEDURES . . . 137 ASSEMBLY ...... 163 BRAKE TRANSMISSION SHIFT INTERLOCK OUTPUT SPEED SENSOR MECHANISM DESCRIPTION ...... 163 DESCRIPTION ...... 137 OPERATION ...... 163 OPERATION ...... 137 REMOVAL ...... 163 REMOVAL ...... 138 INSTALLATION ...... 164 INSTALLATION ...... 139 OVERDRIVE SWITCH ADJUSTMENTS DESCRIPTION ...... 164 ADJUSTMENT - BRAKE TRANSMISSION OPERATION ...... 164 SHIFT INTERLOCK CABLE ...... 140 REMOVAL ...... 164 DRIVING CLUTCHES INSTALLATION ...... 165 DESCRIPTION ...... 140 PLANETARY GEARTRAIN OPERATION ...... 140 DESCRIPTION ...... 165 OPERATION ...... 165 SEAL - OIL PUMP REMOVAL ...... 165 TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 69

INSTALLATION ...... 165 INSTALLATION ...... 174 SHIFT MECHANISM TRANSMISSION CONTROL RELAY DESCRIPTION ...... 165 DESCRIPTION ...... 174 OPERATION ...... 165 OPERATION ...... 174 DIAGNOSIS AND TESTING - SHIFT TRANSMISSION RANGE SENSOR MECHANISM ...... 165 DESCRIPTION ...... 175 ADJUSTMENTS - SHIFT MECHANISM ...... 166 OPERATION ...... 175 SOLENOID REMOVAL ...... 175 DESCRIPTION ...... 166 INSTALLATION ...... 176 OPERATION ...... 167 TRANSMISSION TEMPERATURE SENSOR SOLENOID/PRESSURE SWITCH ASSY DESCRIPTION ...... 176 DESCRIPTION ...... 167 OPERATION ...... 176 OPERATION ...... 167 VALVE BODY REMOVAL ...... 168 DESCRIPTION ...... 177 INSTALLATION ...... 169 OPERATION ...... 177 TORQUE CONVERTER REMOVAL ...... 180 DESCRIPTION ...... 169 DISASSEMBLY ...... 182 OPERATION ...... 172 ASSEMBLY ...... 188 REMOVAL ...... 174 INSTALLATION ...... 193

AUTOMATIC TRANSMISSION - • Valve body • Solenoid/Pressure switch assembly 42RLE Control of the transmission is accomplished by fully adaptive electronics. Optimum shift scheduling DESCRIPTION is accomplished through continuous real-time sensor The 42RLE (Fig. 1) is a four-speed transmission feedback information provided to the Powertrain that is a conventional hydraulic/mechanical assembly Control Module (PCM). controlled with adaptive electronic controls and mon- The PCM is the heart of the electronic control sys- itors. The hydraulic system of the transmission con- tem and relies on information from various direct sists of the transmission fluid, fluid passages, and indirect inputs (sensors, switches, etc.) to deter- hydraulic valves, and various line pressure control mine driver demand and vehicle operating condi- components. An input clutch assembly which houses tions. With this information, the PCM can calculate the underdrive, overdrive, and reverse clutches is and perform timely and quality shifts through vari- used. It also utilizes separate holding clutches: 2nd/ ous output or control devices (solenoid pack, trans- 4th gear and Low/Reverse. The primary mechanical mission control relay, etc.). components of the transmission consist of the follow- The PCM also performs certain self-diagnostic ing: functions and provides comprehensive information • Three multiple disc input clutches (sensor data, DTC’s, etc.) which is helpful in proper • Two multiple disc holding clutches diagnosis and repair. This information can be viewed • Four hydraulic accumulators with the DRB௡ scan tool. • Two planetary gear sets • Hydraulic oil pump 21 - 70 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

Fig. 1 42RLE Automatic Transmission TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 71 AUTOMATIC TRANSMISSION - 42RLE (Continued)

1 - DRIVEPLATE 6 - REVERSE CLUTCH 11 - STUB SHAFT 2 - TORQUE CONVERTER 7 - FRONT PLANET CARRIER 12 - LOW/REVERSE CLUTCH 3 - INPUT SHAFT 8 - REAR PLANET CARRIER 13 - 2/4 CLUTCH 4 - UNDERDRIVE CLUTCH 9 - OUTPUT SHAFT 14 - OIL PUMP 5 - OVERDRIVE CLUTCH 10 - SNAP RING

TRANSMISSION IDENTIFICATION If the tag is not legible or is missing, the “PK” The 42RLE transmission can be identified by a number, which is stamped into the left rear flange of barcode label that is affixed to the upper left area of the transmission case, can be referred to for identifi- the bellhousing. cation. The entire part number, build code, and The label contains a series of digits that can be sequence number are stamped into the flange. translated into useful information such as transmission part number, date of manufacture, manufactur- OPERATION ing origin, assembly line identifier, build sequence The 42RLE transmission ratios are: number, etc. Refer to (Fig. 2) for identification label breakdown. First 2.84 : 1 Second 1.57 : 1 Third 1.00 : 1 Overdrive 0.69 : 1 Reverse 2.21 : 1

Fig. 2 Identification Label Breakdown 1 - T=TRACEABILITY 2 - SUPPLIER CODE (PK=KOKOMO) 3 - COMPONENT CODE (TK=KOKOMO TRANSMISSION) 4 - BUILD DAY (350=DEC. 15) 5 - BUILD YEAR (1=2001) 6 - ASSEMBLY LINE CODE 7 - BUILD SEQUENCE NUMBER 8 - LAST THREE OF P/N 9 - CHANGE LEVEL 10 - TRANSMISSION PART NUMBER 11 - P=PART NUMBER 21 - 72 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued) FIRST GEAR POWERFLOW gears are forced to walk around the inside of the sta- In first gear range, torque input is through the tionary rear annulus gear. The pinions are pinned to underdrive clutch to the underdrive hub assembly the rear carrier and cause the rear carrier assembly (Fig. 3). The underdrive hub is splined to the rear to rotate as they walk around the annulus gear. This sun gear. When the underdrive clutch is applied, it provides the torque output for first gear. The other rotates the underdrive hub and rear sun gear. The planetary gearset components are freewheeling. The L/R clutch is applied to hold the front carrier/rear first gear ratio is 2.84:1. annulus assembly. The rear sun gear drives the rear planetary pinion gears. The rear planetary pinion

Fig. 3 First Gear Powerflow 1 - UNDERDRIVE CLUTCH APPLIED (Turns Rear Sun) 2 - LOW-REVERSE CLUTCH APPLIED (Holds Rear Annulus/Front Carrier) TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 73 AUTOMATIC TRANSMISSION - 42RLE (Continued) SECOND GEAR POWERFLOW ions. The rear pinions rotate the rear annulus/front Second gear is achieved by having both planetary carrier assembly. The pinions of the front carrier gear sets contribute to torque multiplication (Fig. 4). walk around the stationary front sun gear. This As in first gear, torque input is through the under- transmits torque to the front annulus/rear carrier drive clutch to the rear sun gear. The 2/4 clutch is assembly, which provides output torque and a gear applied to hold the front sun gear stationary. The ratio of 1.57:1. rotating rear sun gear turns the rear planetary pin-

Fig. 4 Second Gear Powerflow 1 - UNDERDRIVE CLUTCH APPLIED (Turns Rear Sun) 2 - 2-4 CLUTCH APPLIED (Holds Front Sun) 21 - 74 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued) THIRD GEAR POWERFLOW two components (rear sun gear and rear annulus In third gear, two input clutches are applied to pro- gear) rotating at the same speed and in the same vide torque input: the underdrive clutch and over- direction. This effectively locks the entire planetary drive clutch (Fig. 5). The underdrive clutch rotates gearset together and is rotated as one unit. The gear the rear sun gear, while the overdrive clutch rotates ratio in third is 1:1. the front carrier/rear annulus assembly. The result is

Fig. 5 Third Gear Powerflow 1 - UNDERDRIVE CLUTCH APPLIED (Turns Rear Sun) 2 - OVERDRIVE CLUTCH APPLIED (Turns Front Carrier/Rear Annulus) TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 75 AUTOMATIC TRANSMISSION - 42RLE (Continued) FOURTH GEAR POWERFLOW carrier pinions to turn the front annulus/rear carrier In fourth gear input torque is through the over- assembly which provides output torque. In fourth drive clutch which drives the front carrier (Fig. 6). gear, transmission output speed is more than engine The 2/4 clutch is applied to hold the front sun gear. input speed. This situation is called overdrive and As the overdrive clutch rotates the front carrier, it the gear ratio is 0.69:1. causes the pinions of the front carrier to walk around the stationary front sun gear. This causes the front

Fig. 6 Fourth Gear Powerflow 1 - OVERDRIVE CLUTCH APPLIED (Turns Rear Sun) 2 - 2-4 CLUTCH APPLIED (Holds Front Sun) 21 - 76 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued) REVERSE GEAR POWERFLOW DIAGNOSIS AND TESTING In reverse, input power is through the reverse clutch (Fig. 7). When applied, the reverse clutch DIAGNOSIS AND TESTING - AUTOMATIC drives the front sun gear through the overdrive hub TRANSMISSION and shaft. The L/R clutch is applied to hold the front carrier/rear annulus assembly stationary. The front CAUTION: Before attempting any repair on the carrier is being held by the L/R clutch so the pinions 42RLE Four Speed Automatic Transmission, always are forced to rotate the front annulus/rear carrier check for proper shift linkage adjustment. Also assembly in the reverse direction. Output torque is check for diagnostic trouble codes with the DRBா provided, in reverse, with a gear ratio of 2.21:1. scan tool and the 42RLE Transmission Diagnostic Procedure Manual.

Fig. 7 Reverse Gear Powerflow 1 - LOW-REVERSE CLUTCH APPLIED (Holds Rear Annulus Front Carrier) 2 - REVERSE CLUTCH APPLIED (Turns Front Sun) TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 77 AUTOMATIC TRANSMISSION - 42RLE (Continued) 42RLE automatic transmission malfunctions may DIAGNOSIS AND TESTING - ROAD TEST be caused by these general conditions: Prior to performing a road test, verify that the • Poor engine performance fluid level, fluid condition, and linkage adjustment • Improper adjustments have been approved. • Hydraulic malfunctions During the road test, the transmission should be • Mechanical malfunctions operated in each position to check for slipping and • Electronic malfunctions any variation in shifting. When diagnosing a problem always begin with record- If the vehicle operates properly at highway speeds, ing the complaint. The complaint should be defined as but has poor acceleration, the converter stator over- specific as possible. Include the following checks: running clutch may be slipping. If acceleration is nor- • Temperature at occurrence (cold, hot, both) mal, but high throttle opening is needed to maintain • Dynamic conditions (acceleration, deceleration, highway speeds, the converter stator clutch may upshift, cornering) have seized. Both of these stator defects require • Elements in use when condition occurs (what replacement of the torque converter and thorough gear is transmission in during condition) transmission cleaning. • Road and weather conditions Slipping clutches can be isolated by comparing the • Any other useful diagnostic information. “Elements in Use” chart with clutch operation encoun- After noting all conditions, check the easily acces- tered on a road test. This chart identifies which clutches sible variables: are applied at each position of the selector lever. • Fluid level and condition A slipping clutch may also set a DTC and can be • Shift linkage adjustment determined by operating the transmission in all • Diagnostic trouble code inspection selector positions. Then perform a road test to determine if the problem has been corrected or that more diagnosis is necessary. If the problem exists after the preliminary tests and corrections are completed, hydraulic pressure checks should be performed.

ELEMENTS IN USE AT EACH POSITION OF SELECTOR LEVER

Shift Lever INPUT CLUTCHES HOLDING CLUTCHES Position Underdrive Overdrive Reverse 2/4 Low/Reverse P - PARK X R - REVERSE X X N - NEUTRAL X OD - OVERDRIVE First X X Second X X Direct X X Overdrive X X D - DRIVE* First X X Second X X Direct X X L - LOW* First X X Second X X Direct X X * Vehicle upshift and downshift speeds are increased when in these selector positions. 21 - 78 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued) The process of elimination can be used to detect any TEST ONE-SELECTOR IN L (1st Gear) unit which slips and to confirm proper operation of good units. Road test analysis can diagnose slipping NOTE: This test checks pump output, pressure reg- units, but the cause of the malfunction cannot be ulation and condition of the low/reverse clutch determined. Practically any condition can be caused by hydraulic circuit and shift schedule. leaking hydraulic circuits or sticking valves. (1) Attach pressure gauge to the low/reverse clutch DIAGNOSIS AND TESTING - HYDRAULIC tap. PRESSURE TESTS (2) Move selector lever to the L position. (3) Allow vehicle wheels to turn and increase throttle Pressure testing is a very important step in the opening to achieve an indicated vehicle speed to 20 mph. diagnostic procedure. These tests usually reveal the (4) Low/reverse clutch pressure should read 115 to cause of most transmission problems. 145 psi. Before performing pressure tests, be certain that fluid level and condition, and shift cable adjustments TEST TWO-SELECTOR IN DRIVE (Second Gear) have been checked and approved. Fluid must be at operating temperature (150 to 200 degrees F.). NOTE: This test checks the underdrive clutch Install an engine tachometer, raise vehicle on hoist hydraulic circuit as well as the shift schedule. which allows the wheels to turn, and position tachometer so it can be read. (1) Attach gauge to the underdrive clutch tap. Using special adapters L-4559, attach 300 psi (2) Move selector lever to the 3 position. gauge(s) C-3293SP to the port(s) required for test (3) Allow vehicle wheels to turn and increase being conducted. throttle opening to achieve an indicated vehicle speed Test port locations are shown in (Fig. 8). of 30 mph. (4) In second gear the underdrive clutch pressure should read 110 to 145 psi. TEST TWO A–SELECTOR IN OD (Fourth Gear)

NOTE: This test checks the underdrive clutch hydraulic circuit as well as the shift schedule.

(1) Attach gauge to the underdrive clutch tap. (2) Move selector lever to the OD position. (3) Allow wheels to rotate freely and increase throttle opening to achieve an indicated speed of 40 mph. (4) Underdrive clutch pressure should read below 5 psi. If not, than either the solenoid assembly or controller is at fault. Fig. 8 Pressure Taps 1 - TORQUE CONVERTER CLUTCH OFF 2 - REVERSE 3 - LOW/REVERSE 4 - 2/4 5 - UNDERDRIVE 6 - TORQUE CONVERTER CLUTCH ON 7 - OVERDRIVE TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 79 AUTOMATIC TRANSMISSION - 42RLE (Continued) TEST THREE-SELECTOR IN OVERDRIVE (Third and (4) Torque converter clutch off pressure should be Second Gear) less than 5 psi. (5) Now attach the gauge to the torque converter NOTE: This test checks the overdrive clutch clutch on pressure tap. hydraulic circuit as well as the shift schedule. (6) Move selector to the overdrive position. (7) Allow vehicle wheels to turn and increase (1) Attach gauge to the overdrive clutch tap. throttle opening to achieve an indicated vehicle speed (2) Move selector lever to the OD position. of 50 mph. (3) Allow vehicle wheels to turn and increase (8) Verify the torque converter clutch is applied throttle opening to achieve an indicated vehicle speed mode using the RPM display of the DRB scan tool. of 20 mph. (9) Torque converter clutch on pressure should be (4) Overdrive clutch pressure should read 74 to 95 60-90 psi. psi. (5) Move selector lever to the 3 position and TEST SIX-SELECTOR IN REVERSE increase indicated vehicle speed to 30 mph. (6) The vehicle should be in second gear and over- NOTE: This test checks the reverse clutch hydraulic drive clutch pressure should be less than 5 psi. circuit. TEST FOUR-SELECTOR IN OD (Fourth Gear) (1) Attach gauge to the reverse and low/reverse clutch tap. NOTE: This test checks the 2/4 clutch hydraulic cir- (2) Move selector lever to the reverse position. cuit. (3) Read reverse clutch pressure with output stationary (foot on brake) and throttle opened to achieve (1) Attach gauge to the 2/4 clutch tap. 1500 rpm. (2) Move selector lever to the OD position. (4) Reverse and low/reverse clutch pressure should (3) Allow vehicle front wheels to turn and increase read 165 to 235 psi. throttle opening to achieve an indicated vehicle speed of 30 mph. Vehicle should be in fourth gear. TEST RESULT INDICATIONS (4) The 2/4 clutch pressure should read 75 to 95 (1) If proper line pressure is found in any one test, psi. the pump and pressure regulator are working properly. TEST FIVE-SELECTOR IN OVERDRIVE (Fourth (2) Low pressure in all positions indicates a defec- Gear, CC on) tive pump, a clogged filter, or a stuck pressure regulator valve. NOTE: These tests check the torque converter (3) Clutch circuit leaks are indicated if pressures clutch hydraulic circuit. do not fall within the specified pressure range. (4) If the overdrive clutch pressure is greater than (1) Attach gauge to the torque converter clutch off 5 psi in Step 6 of Test Three, a worn reaction shaft pressure tap. seal ring or a defective solenoid assembly is indi- (2) Move selector lever to the overdrive position. cated. (3) Allow vehicle wheels to turn and increase (5) If the underdrive clutch pressure is greater throttle opening to achieve an indicated vehicle speed than 5 psi in Step 4 of Test Two-A, a defective sole- of 50 mph. Vehicle should be in 4th gear, CC on. noid/pressure switch assembly or controller is the cause. CAUTION: Both wheels must turn at the same speed. 21 - 80 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

ALL PRESSURE SPECIFICATIONS ARE PSI (ON HOIST, WITH WHEELS FREE TO TURN)

Gear Actual Gear PRESSURE TAPS Selector Under- Overdrive Reverse Torque Torque 2/4 Low/ Position drive Clutch Clutch Converter Converter Clutch Reverse Clutch Clutch Clutch Clutch Off On PARK * PARK 0-2 0-5 0-2 60-110 45-100 0-2 115-145 0 mph REVERSE * REVERSE 0-2 0-7 165-235 50-100 35-85 0-2 165-235 0 mph NEUTRAL * NEUTRAL 0-2 0-5 0-2 60-110 45-100 0-2 115-145 0 mph L # FIRST 110-145 0-5 0-2 60-110 45-100 0-2 115-145 20 mph 3 # SECOND 110-145 0-5 0-2 60-110 45-100 115- 0-2 30 mph 145 3 # DIRECT 75-95 75-95 0-2 60-90 45-80 0-2 0-2 45 mph OD # OVERDRIVE 0-2 75-95 0-2 60-90 45-80 75-95 0-2 30 mph OD # OVERDRIVE 0-2 75-95 0-2 0-5 60-95 75-95 0-2 50 mph WITH TCC * Engine Speed at 1500 rpm # CAUTION: Both wheels must be turning at same speed.

DIAGNOSIS AND TESTING - CLUTCH AIR PRESSURE TESTS Inoperative clutches can be located by substituting air pressure for fluid pressure. The clutches may be tested by applying air pressure to their respective passages after the valve body has been removed. Use Spe- cial Tool 6599-1 and 6599-2 to perform test (Fig. 9). To make air pressure tests, proceed as follows:

NOTE: The compressed air supply must be free of all dirt and moisture. Use a pressure of 30 psi.

Remove oil pan and valve body. See Valve body recondition. Apply air pressure to the holes in the special tool, one at a time. Listen for the clutch to apply. It will give a slight Fig. 9 Air Pressure Test Plate thud sound. If a large amount of air is heard escap- 1 - AIR PRESSURE TEST PLATES ing, the transmission must be removed from vehicle, 2 - 2/4 CLUTCH RETAINER HOLE disassembled and all seals inspected. OVERDRIVE CLUTCH Apply air pressure to the overdrive clutch apply passage and watch for the push/pull piston to move forward. The piston should return to its starting position when the air pressure is removed. TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 81 AUTOMATIC TRANSMISSION - 42RLE (Continued) UNDERDRIVE CLUTCH DIAGNOSIS AND TESTING - FLUID LEAKAGE Because this clutch piston cannot be seen, its operation is checked by function. Air pressure is applied FLUID LEAKAGE - TORQUE CONVERTER HOUSING to the low/reverse or the 2/4 clutches. This locks the AREA output shaft. Use a piece of rubber hose wrapped When diagnosing converter housing fluid leaks, around the input shaft and a pair of clamp-on pliers three actions must be taken before repair: to turn the input shaft. Next apply air pressure to (1) Verify proper transmission fluid level. the underdrive clutch (Fig. 10). The input shaft (2) Verify that the leak originates from the con- should not rotate with hand torque. Release the air verter housing area and is transmission fluid. pressure and confirm that the input shaft will rotate. (3) Determine the true source of the leak. Fluid leakage at or around the torque converter area may originate from an engine oil leak (Fig. 11). The area should be examined closely. Factory fill fluid is red and, therefore, can be distinguished from engine oil.

Fig. 10 Testing Underdrive Clutch 1 - AIR PRESSURE TEST PLATE 6599–1 2 - AIR NOZZLE

REVERSE CLUTCH Apply air pressure to the reverse clutch apply passage and watch for the push/pull piston to move rear- Fig. 11 Converter Housing Leak Paths ward. The piston should return to its starting 1 - PUMP SEAL position when the air pressure is removed. 2 - PUMP VENT 3 - PUMP BOLT 4 - PUMP GASKET 2/4 CLUTCH 5 - CONVERTER HOUSING Apply air pressure to the feed hole located on the 6 - CONVERTER 7 - REAR MAIN SEAL LEAK 2/4 clutch retainer. Look in the area where the 2/4 piston contacts the first separator plate and watch Some suspected converter housing fluid leaks may carefully for the 2/4 piston to move rearward. The not be leaks at all. They may only be the result of piston should return to its original position after the residual fluid in the converter housing, or excess air pressure is removed. fluid spilled during factory fill, or fill after repair. Converter housing leaks have several potential LOW/REVERSE CLUTCH sources. Through careful observation, a leak source Apply air pressure to the low/reverse clutch feed can be identified before removing the transmission hole passage. Look in the area where the low/reverse for repair. piston contacts the first separator plate. Watch care- Pump seal leaks tend to move along the drive hub fully for the piston to move forward. The piston and onto the rear of the converter (Fig. 11). Pump should return to its original position after the air o-ring or pump body leaks follow the same path as a pressure is removed. seal leak. Pump attaching bolt leaks are generally deposited on the inside of the converter housing and not on the converter itself. Pump seal or gasket leaks usually travel down the inside of the converter housing (Fig. 11). 21 - 82 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued) TORQUE CONVERTER LEAKAGE Possible sources of torque converter leakage are: • Torque converter weld leaks at the outside diameter weld (Fig. 12). • Torque converter hub weld (Fig. 12).

Fig. 12 Converter Leak Points - Typical 1 - OUTSIDE DIAMETER WELD 2 - TORQUE CONVERTER HUB WELD 3 - STARTER RING GEAR 4 - LUG Fig. 13 Crankshaft Position Sensor STANDARD PROCEDURE - ALUMINUM 1 - CRANKSHAFT POSITION SENSOR 2 - MOUNTING BOLT THREAD REPAIR 3 - ELECTRICAL CONNECTOR Damaged or worn threads in the aluminum trans- 4 - TRANSMISSION BELLHOUSING mission case and valve body can be repaired by the use of Heli-Coils, or equivalent. This repair consists (7) If transmission is being removed for overhaul, of drilling out the worn-out damaged threads. Then remove transmission oil pan, drain fluid and reinstall tap the hole with a special Heli-Coil tap, or equiva- pan. (Refer to 21 - TRANSMISSION/AUTOMATIC - lent, and installing a Heli-Coil insert, or equivalent, 42RLE/FLUID - STANDARD PROCEDURE) into the hole. This brings the hole back to its original (8) Remove torque converter access cover. thread size. (9) Rotate crankshaft in clockwise direction until Heli-Coil, or equivalent, tools and inserts are converter bolts are accessible. Then remove bolts one readily available from most automotive parts suppli- at a time. Rotate crankshaft with socket wrench on ers. dampener bolt. (10) Mark propeller shaft and axle yokes for REMOVAL assembly alignment. Then disconnect and remove (1) Disconnect battery negative cable. propeller shafts. (Refer to 3 - DIFFERENTIAL & (2) Raise and support vehicle. DRIVELINE/PROPELLER SHAFT/PROPELLER (3) Disconnect and lower or remove necessary SHAFT - REMOVAL) exhaust components. (11) Disconnect wires from the input and output (4) Remove engine-to-transmission bending braces speed sensors (Fig. 14). or engine collar. (12) Disconnect wires from the transmission range (5) Remove starter motor. (Refer to 8 - ELECTRI- sensor (Fig. 14) and the solenoid/pressure switch CAL/STARTING/STARTER MOTOR - REMOVAL) assembly (Fig. 15). (6) On 4.0L engine equipped vehicles, disconnect (13) Disconnect gearshift cable from transmission and remove crankshaft position sensor (Fig. 13). manual valve lever. Retain sensor attaching bolt. (14) Disconnect shift rod from transfer case shift lever or remove shift lever from transfer case. CAUTION: The crankshaft position sensor can be (15) Support rear of engine with safety stand or damaged during transmission removal (or installa- jack. tion) if the sensor is left in place. To avoid damage, (16) Raise transmission slightly with service jack remove the sensor before removing the transmis- to relieve load on skid plate and transmission sup- sion. port. TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 83 AUTOMATIC TRANSMISSION - 42RLE (Continued)

Fig. 14 Input and Output Speed Sensors and Fig. 16 Transmission Mount - Automatic Transmission Range Sensor Transmission 1 - INPUT SPEED SENSOR 1 - TRANSMISSION SUPPORT BRACKET 2 - OUTPUT SPEED SENSOR 2 - AUTOMATIC TRANSMISSION 3 - TRANSMISSION RANGE SENSOR 3 - SKID PLATE 4 - FRAME 5 - TRANSMISSION MOUNT SUPPORT BRACKET 6 - CUSHION

(22) Disconnect fluid cooler lines at transmission. (23) Remove all converter housing bolts. (24) Carefully work transmission and torque converter assembly rearward off engine block dowels. (25) Hold torque converter in place during transmission removal. (26) Lower transmission and remove assembly from under the vehicle. (27) To remove torque converter, carefully slide torque converter out of the transmission. DISASSEMBLY

NOTE: If the transmission is being reconditioned Fig. 15 Solenoid/Pressure Switch Assembly (clutch/seal replacement) or replaced, it is neces- 1 - SOLENOID/PRESSURE SWITCH ASSEMBLY CONNECTOR sary to perform the Quick Learn Procedure using the DRBIIIா Scan Tool (Refer to 8 - ELECTRICAL/ (17) Remove bolts securing rear support (Fig. 16) ELECTRONIC CONTROL MODULES/TRANSMISSION and cushion to transmission and skid plate. Raise CONTROL MODULE - STANDARD PROCEDURE). transmission slightly, slide exhaust hanger arm from bracket and remove rear support. Before disassembling transmission, move the shift (18) Remove bolts attaching skid plate (Fig. 16) to lever clockwise as far as it will go and then remove frame and remove skid plate. (Refer to 13 - FRAME the shift lever. & BUMPERS/FRAME/TRANSFER CASE SKID PLATE - REMOVAL) NOTE: Tag all clutch pack assemblies, as they are (19) Disconnect transfer case vent hose. removed, for reassembly identification. (20) Remove transfer case. (Refer to 21 - TRANS- MISSION/TRANSFER CASE - REMOVAL) CAUTION: Do not intermix clutch discs or plates as (21) Remove fill tube bracket bolts and pull tube the unit might then fail. out of transmission. Retain fill tube seal. Remove the bolt attaching transfer case vent tube to converter housing. 21 - 84 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

(1) Remove the torque converter from the trans- (3) Remove the bolts (Fig. 19) that hold the mission input shaft (Fig. 17). adapter housing onto the transmission case. (2) Measure input shaft end play using Tool 8266. (4) Remove the adapter (Fig. 21) housing from the Set up Tool 8266 and a dial indicator as shown in (Fig. transmission case. There are two pry slots (Fig. 20) 18). Move input shaft in and out to obtain end play located near the bottom corners of the housing for reading. End play specifications are 0.13 to 0.64 mm separating the housing from the transmission case. (0.005 to 0.025 inch). Record indicator reading for reference when reassembling the transmission. If endplay exceeds the specified range, the #4 thrust plate needs to be inspected and changed if necessary.

Fig. 19 Remove Adapter Housing Bolts 1 - TRANSMISSION CASE 2 - ADAPTER HOUSING 3 - BOLTS Fig. 17 Remove Torque Converter 1 - TORQUE CONVERTER 2 - TRANSMISSION 3 - INPUT SHAFT

Fig. 20 Lube Tube Grommet Fig. 18 Measure Input Shaft End Play Using Tool 1 - HOUSING 2 - LUBE TUBE 8266 - Typical 3 - GROMMET 1 - TOOL 8266-8 4 - PRY SLOTS 2 - TOOL 8266-2 3 - TOOL C-3339 TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 85 AUTOMATIC TRANSMISSION - 42RLE (Continued)

Fig. 21 Remove Adapter Housing Fig. 23 Remove 4X4 Stub Shaft 1 - TRANSMISSION CASE 1 - STUB SHAFT 2 - ADAPTER HOUSING 2 - OUTPUT SHAFT

(5) Inspect the lube tube grommet (Fig. 20) for (7) Remove the input speed sensor bolt (Fig. 24). damage. If the grommet lip is damaged, it will need (8) Remove the output speed sensor bolt (Fig. 25). to be replaced. (9) Remove the input and output speed sensors (6) Using a Slide Hammer C-3752 (Fig. 22), (Fig. 26). Identify the speed sensors for re-installa- remove the 4X4 stub shaft (Fig. 23) from the trans- tion since they are not interchangeable. mission output shaft.

Fig. 24 Remove Input Speed Sensor Bolt Fig. 22 Remove the 4X4 Stub shaft Using C-3752 1 - INPUT SPEED SENSOR 1 - 4X4 STUB SHAFT 2 - TRANSMISSION CASE 2 - PULLER C-3752 21 - 86 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

(11) Remove the transmission oil pan (Fig. 28).

Fig. 25 Remove Output Speed Sensor Bolt 1 - OUTPUT SPEED SENSOR Fig. 27 Remove Transmission Oil Pan Bolts 2 - TRANSMISSION CASE 1 - TRANSMISSION OIL PAN 2 - BOLTS

Fig. 26 Remove Output Speed Sensor 1 - OUTPUT SPEED SENSOR Fig. 28 Remove Transmission Oil Pan 2 - TRANSMISSION CASE 1 - TRANSMISSION OIL PAN (10) Remove the transmission oil pan bolts (Fig. 27). TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 87 AUTOMATIC TRANSMISSION - 42RLE (Continued)

(12) Remove the transmission oil filter screws (Fig. 29). (13) Remove transmission oil filter (Fig. 30). (14) Remove the oil filter o-ring from the valve body (Fig. 31).

Fig. 31 Remove Oil Filter O-Ring 1 - VALVE BODY 2 - O-RING

(15) Remove valve body-to-case bolts (Fig. 32). Fig. 29 Remove Oil Filter Screws 1 - OIL FILTER 2 - SCREWS

Fig. 32 Remove Valve Body Bolts 1 - BOLTS

CAUTION: Do not handle the valve body by the Fig. 30 Remove Transmission Filter manual shaft. Damage could result. 1 - TRANSMISSION FILTER 21 - 88 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

(16) Remove valve body from transmission (Fig. (18) Remove overdrive accumulator and springs 33). (Fig. 35) (Fig. 36).

Fig. 33 Remove Valve Body From Transmission Fig. 35 Remove Overdrive Accumulator and Springs 1 - VALVE BODY 1 - OVERDRIVE ACCUMULATOR PISTON 2 - RETURN SPRINGS 3 - SEAL RING (17) Remove underdrive accumulator and spring 4 - SEAL RING (Fig. 34) (Fig. 36).

Fig. 34 Remove Underdrive Accumulator and Fig. 36 Accumulator Location Springs 1 - OVERDRIVE ACCUMULATOR LOCATION 1 - ACCUMULATOR PISTON (UNDERDRIVE) 2 - UNDERDRIVE ACCUMULATOR LOCATION 2 - RETURN SPRINGS 3 - LOW/REVERSE ACCUMULATOR 3 - SEAL RING 4 - SEAL RING TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 89 AUTOMATIC TRANSMISSION - 42RLE (Continued)

(19) Remove the low/reverse accumulator snap (21) Remove low/reverse accumulator piston and ring (Fig. 37). springs (Fig. 39) (Fig. 40).

Fig. 37 Remove Low/Reverse Accumulator Fig. 39 Remove Low/Reverse Accumulator Piston 1 - SNAP RING 1 - SEAL RINGS 2 - LOW/REVERSE ACCUMULATOR 2 - PISTON 3 - PISTON 4 - PETROLATUM (20) Remove the low/reverse accumulator plug 5 - SUITABLE TOOL (Fig. 38).

Fig. 40 Low/Reverse Accumulator Components Fig. 38 Remove Low/Reverse Accumulator Plug 1 - ACCUMULATOR PISTON 1 - ADJUSTABLE PLIERS 2 - SEAL RINGS 2 - PLUG 3 - RETURN SPRINGS 4 - NOTE NOTCH 21 - 90 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

(22) Remove and discard the oil pump-to-case bolts (24) Remove oil pump while pushing in on input (Fig. 41). The oil pump bolts are not to be reused. shaft (Fig. 43).

Fig. 41 Remove Oil Pump Attaching Bolts Fig. 43 Remove Oil Pump 1 - BOLTS 1 - “PUSH IN” ON INPUT SHAFT WHILE REMOVING PUMP 2 - OIL PUMP (25) Remove oil pump gasket (Fig. 44). (23) Remove oil pump using C-3752 Pullers (Fig. 42).

Fig. 44 Remove Oil Pump Gasket Fig. 42 Oil Pump Pullers 1 - BELLHOUSING 2 - OIL PUMP GASKET 1 - OIL PUMP 2 - PULLERS CAUTION: By-pass valve must be replaced if transmission failure occurs. TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 91 AUTOMATIC TRANSMISSION - 42RLE (Continued)

(26) Remove the cooler by-pass valve (Fig. 45).

Fig. 45 Remove By-Pass Valve 1 - BYPASS VALVE

(27) Remove the #1 caged needle bearing (Fig. 46). Fig. 47 Remove Input Clutch Assembly 1 - INPUT CLUTCH ASSEMBLY

Fig. 46 Remove No. 1 Caged Needle Bearing 1 - #1 CAGED NEEDLE BEARING 2 - NOTE: TANGED SIDE OUT Fig. 48 Remove #4 Thrust Plate (28) Remove the input clutch assembly (Fig. 47). 1 - OVERDRIVE SHAFT ASSEMBLY 2 - #4 THRUST PLATE (SELECT) (29) Remove the #4 thrust plate (Fig. 48). 21 - 92 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

(30) Remove the front sun gear assembly and #4 (32) Remove the rear sun gear and #7 needle bear- thrust washer (if still in place) (Fig. 49). ing (Fig. 51) and (Fig. 52).

Fig. 49 Remove Front Sun Gear Assembly Fig. 51 Remove Rear Sun Gear 1 - FRONT SUN GEAR ASSEMBLY 1 - #7 NEEDLE BEARING 2 - #4 THRUST WASHER (FOUR TABS) 2 - REAR SUN GEAR

(31) Remove the front carrier/rear annulus and #6 NOTE: The number seven needle bearing has three needle bearing (Fig. 50). antireversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear (Fig. 52).

Fig. 50 Remove Front Carrier/Rear Annulus 1 - #6 NEEDLE BEARING 2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL). Fig. 52 Number 7 Bearing 1 - #7 BEARING 2 - REAR SUN GEAR TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 93 AUTOMATIC TRANSMISSION - 42RLE (Continued)

(33) Install and load Tool 5058 to remove the 2/4 clutch retainer snap ring (Fig. 53).

Fig. 55 2/4 Clutch Retainer 1 - 2/4 CLUTCH RETAINER 2 - 2/4 CLUTCH RETURN SPRING Fig. 53 Remove 2/4 Clutch Retainer Snap Ring 1 - TOOL 5058 (35) Remove the 2/4 clutch return spring (Fig. 56). 2 - SCREWDRIVER 3 - SNAP RING 4 - 2/4 CLUTCH RETAINER

(34) Remove the 2/4 clutch retainer (Fig. 54) and (Fig. 55).

Fig. 56 Remove 2/4 Clutch Return Spring 1 - 2/4 CLUTCH RETURN SPRING

Fig. 54 Remove 2/4 Clutch Retainer 1 - 2/4 CLUTCH RETAINER 21 - 94 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

(36) Remove the 2/4 clutch pack (Fig. 57). (38) Remove the low/reverse reaction plate (Fig. 59).

Fig. 57 Remove 2/4 Clutch Pack Fig. 59 Remove Low/Reverse Reaction Plate 1 - CLUTCH PLATE (4) 2 - CLUTCH DISC (4) 1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)

(37) Remove the tapered snap ring (Fig. 58). (39) Remove one (1) low/reverse clutch disc to facilitate snap ring removal (Fig. 60).

Fig. 58 Remove Tapered Snap Ring Fig. 60 Remove One Disc 1 - LOW/REVERSE CLUTCH REACTION PLATE 2 - LONG TAB 1 - ONE DISC FROM LOW/REVERSE CLUTCH 3 - SCREWDRIVER 4 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP) 5 - OIL PAN FACE TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 95 AUTOMATIC TRANSMISSION - 42RLE (Continued)

(40) Remove the low/reverse reaction plate snap (42) Using a die grinder or equivalent, grind the ring (Fig. 61). stakes in the shoulder of the shaft nuts as shown in (Fig. 63) (Fig. 64). Do not grind all the way through the nut and into the shaft. There are two stakes on each nut.

Fig. 61 Remove Low/Reverse Reaction Plate Snap Ring 1 - SCREWDRIVER Fig. 63 Grinding Stakes 2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING 3 - DO NOT SCRATCH CLUTCH PLATE 1 - TRANSFER SHAFT 2 - GRIND HERE 3 - GRIND HERE (41) Remove the low/reverse clutch pack (Fig. 62). 4 - NUT STAKE

Fig. 62 Remove Low/Reverse Clutch Pack Fig. 64 Stake Grinding Pattern 1 - TRANSFER SHAFT 1 - CLUTCH PLATES (5) 2 - TRANSFER SHAFT NUT 2 - CLUTCH DISCS (5)

CAUTION: Failure to grind and open stakes of the output shaft nut and transfer shaft nut will result in thread damage to the shafts during nut removal.

WARNING: WEAR SAFETY GOGGLES WHILE GRINDING STAKE NUTS. 21 - 96 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

(43) Using a small chisel, carefully open the stakes on nut (Fig. 65).

Fig. 67 Use Arbor Press to Remove Output Shaft from Case Fig. 65 Opening Nut Stakes 1 - OUTPUT SHAFT 2 - ARBOR PRESS 1 - CHISEL 3 - TRANSMISSION CASE 2 - NUT STAKE

(44) Use special tool 6497 and 6498A to remove the transfer shaft nut or the output shaft nut (Fig. 66).

Fig. 66 Remove Output Shaft Nut 1 - SPECIAL TOOL 6497 2 - SPECIAL TOOL 6498A 3 - BREAKER BAR Fig. 68 Remove Front Bearing Cup - Typical 1 - ARBOR PRESS (45) Remove the output shaft from case using a 2 - SPECIAL TOOL 6596 shop press (Fig. 67). Use special tool 6596 with a shop press to remove (46) Use special tool 6597 and handle C-4171 and the front output shaft bearing cup (Fig. 68). C-4171-2 to press the rear output shaft bearing cup rearward (Fig. 69). TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 97 AUTOMATIC TRANSMISSION - 42RLE (Continued)

(48) Install and load compressor (Fig. 71) as shown in (Fig. 72).

Fig. 71 Low/Reverse Spring Compressor Tool 1 - TOOL 6057 2 - TOOL 5059 3 - TOOL 5058-3 Fig. 69 Remove Rear Bearing Cup 1 - SPECIAL TOOL 4171 AND 4171-2 2 - SPECIAL TOOL 6597

(47) Remove the rear carrier front bearing cone (Fig. 70).

Fig. 72 Compressor Tool in Use 1 - LOW/REVERSE CLUTCH RETURN SPRING 2 - SNAP RING (INSTALL AS SHOWN) 3 - TOOL 5058A-3 4 - TOOL 5059A 5 - SPECIAL TOOL 6057

Fig. 70 Remove Rear Carrier Front Bearing Cone 1 - SPECIAL TOOL 5048-1 2 - SPECIAL TOOL 6545 3 - REAR CARRIER 4 - SPECIAL TOOL 5048 21 - 98 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

(49) Remove the low/reverse belleville spring snap (51) Remove the park sprag pivot retaining screw. ring (Fig. 73). (52) Drive out the anchor shaft using suitable punch (Fig. 75).

Fig. 73 Remove Snap Ring 1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS Fig. 75 Anchor Shaft Removal (AS SHOWN) 1 - PIN PUNCH 2 - SNAP RING PLIERS 2 - GUIDE BRACKET ASSEMBLY 3 - SPECIAL TOOL 5059A (53) Remove the guide bracket pivot shaft (Fig. (50) Remove the low/reverse piston belleville 76). Inspect all components (Fig. 77) for wear and spring (Fig. 74). replace if necessary.

Fig. 74 Low/Reverse Piston Belleville Spring 1 - LOW/REVERSE PISTON RETURN SPRING Fig. 76 Remove Guide Bracket Pivot Shaft 2 - PISTON 1 - PIVOT PIN 2 - GUIDE BRACKET ASSEMBLY TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 99 AUTOMATIC TRANSMISSION - 42RLE (Continued)

(56) Remove low/reverse piston retainer (Fig. 79).

Fig. 77 Guide Bracket Disassembled 1 - GUIDE BRACKET Fig. 79 Remove Piston Retainer 2-PAWL 1 - LOW/REVERSE CLUTCH PISTON RETAINER 3 - SPLIT SLEEVE 2 - GASKET 4 - SPACER 5 - STEPPED SPACER 6 - ANTIRATCHET SPRING (57) Remove the low/reverse piston retainer gasket (Fig. 80). (54) Remove the low/reverse clutch piston (Fig. 78).

Fig. 80 Remove Piston Retainer Gasket 1 - GASKET HOLES MUST LINE UP Fig. 78 Remove Low/Reverse Clutch Piston 2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET 1 - LOW/REVERSE CLUTCH PISTON 2 - D-RING SEAL 3 - D-RING SEAL

(55) Remove the low/reverse piston retainer screws. 21 - 100 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued) ASSEMBLY (3) Install low/reverse piston retainer (Fig. 83).

NOTE: If the transmission assembly is being reconditioned (clutch/seal replacement) or replaced, it is necessary to perform the Quick Learn Procedure using the DRBIIIா Scan Tool (Refer to 8 - ELECTRI- CAL/ELECTRONIC CONTROL MODULES/TRANS- MISSION CONTROL MODULE - STANDARD PROCEDURE).

(1) Install the output bearing cups using Special Tool - 5050A (Fig. 81).

Fig. 83 Install Piston Retainer 1 - LOW/REVERSE CLUTCH PISTON RETAINER 2 - GASKET

(4) Install low/reverse piston retainer-to-case Fig. 81 Bearing Cup Installation Special Tool - screws (Fig. 84) and torque to 5 N·m (45 in. lbs.). 5050A (2) Install low/reverse piston retainer gasket (Fig. 82).

Fig. 84 Install Retainer Attaching Screws 1 - LOW/REVERSE CLUTCH PISTON RETAINER 2 - SCREWDRIVER 3 - TORX-LOC SCREWS Fig. 82 Install Piston Retainer Gasket 1 - GASKET HOLES MUST LINE UP 2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 101 AUTOMATIC TRANSMISSION - 42RLE (Continued)

(5) Install low/reverse clutch piston (Fig. 85).

Fig. 87 Guide Bracket 1 - GUIDE BRACKET Fig. 85 Install Low/Reverse Clutch Piston 2 - ANTIRATCHET SPRING (MUST BE ASSEMBLED AS SHOWN) 1 - LOW/REVERSE CLUTCH PISTON 3-PAWL 2 - D-RING SEAL 3 - D-RING SEAL (7) Install guide bracket pivot shaft (Fig. 88).

(6) Assemble guide bracket assembly as shown in (Fig. 86) (Fig. 87).

Fig. 88 Install Guide Bracket Pivot Shaft 1 - PIVOT PIN 2 - GUIDE BRACKET ASSEMBLY Fig. 86 Guide Bracket Assembly CAUTION: When installing, be sure guide bracket 1 - GUIDE BRACKET 2-PAWL and split sleeve touch the rear of the transmission 3 - SPLIT SLEEVE case. 4 - SPACER 5 - STEPPED SPACER 6 - ANTIRATCHET SPRING (8) Install park sprag pivot retaining screw and torque to 4.5 N·m (40 in. lbs.). 21 - 102 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

(9) Install low/reverse piston belleville spring into position (Fig. 89).

Fig. 91 Compressor Tool in Use 1 - LOW/REVERSE CLUTCH RETURN SPRING Fig. 89 Install Low/Reverse Piston Return Spring 2 - SNAP RING (INSTALL AS SHOWN) 3 - TOOL 5058A-3 1 - LOW/REVERSE PISTON RETURN SPRING 4 - TOOL 5059A 2 - PISTON 5 - SPECIAL TOOL 6057

(10) Install and load low/reverse spring compressor (11) Install snap ring and remove compressor tool tool as shown in (Fig. 90) (Fig. 91) to facilitate snap (Fig. 92). ring installation.

Fig. 92 Install Snap Ring Fig. 90 Low/Reverse Spring Compressor Tool 1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS 1 - TOOL 6057 (AS SHOWN) 2 - TOOL 5059 2 - SNAP RING PLIERS 3 - TOOL 5058-3 3 - TOOL 6057 TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 103 AUTOMATIC TRANSMISSION - 42RLE (Continued)

(12) Install rear carrier front bearing cone (Fig. (d) Install shim on output shaft (Fig. 96). Apply 93). small amount of petrolatum onto the shim to hold it in place. Use the original shim as a starting point. If original shim is not available, use the thickest shim available. (e) Install output shaft/rear carrier into rear bearing. The shaft must be pressed into position. Use special tool MD-998911 (Disc) and C- 4171 and C4171-2 (Handle) to press shaft into rear bearing (Fig. 97). (f) Do not re-use old output shaft nut because the removed stake weakens the nut flange. Using special tools 6497 and 6498-A, install new output shaft nut. Do not reuse old output shaft nut. Tighten new output shaft nut to 271 N·m (200 ft. lbs.). (g) Check the turning torque of the output shaft (Fig. 98). The shaft should have 1 to 8 in. lbs. of turning torque. If the turning torque is higher than 8 in. lbs., install a thicker shim. If turning torque is less than 1 in. lb., install a thinner shim. Make sure there is no end play. (h) The new nut must be staked after the correct turning torque is obtained (Fig. 99) (Fig. 100). Use special tool 6639 to stake output shaft nut. CAU- TION: Failure to stake nut could allow the nut to back-off during use.

Fig. 93 Install Rear Carrier Front Bearing Cone 1 - ARBOR PRESS 2 - SPECIAL TOOL C-4171 3 - SPECIAL TOOL 6052 4 - REAR CARRIER

(13) Check output bearing preload. Output bearing preload must be checked and/or adjusted if any of the following items have been replaced: • Output shaft (rear carrier assembly) • Output shaft bearings • Transmission case (a) PRELOAD CHECK/SHIM SELECTION: Install rear output shaft bearing cone and special tool 6618A (Fig. 94). Fig. 94 Bearing Installation (b) Install special tool 6618A (Fig. 95). Lightly 1 - SPECIAL TOOL 6618-A tighten retaining screws. Screws should be below 2 - REAR OUTPUT SHAFT BEARING the plate surface, but do not snug screws. (c) Turn case over on arbor press so that the plate is resting on the press base. CAUTION: The output shaft will extend through the hole of tool 6618A. Ensure your press table has clearance for the output shaft. 21 - 104 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

Fig. 95 Special Tool Installed 1 - SPECIAL TOOL 6618-A

Fig. 97 Press Shaft Into Case 1 - SPECIAL TOOL C-4171 AND C-4171-2 2 - SPECIAL TOOL MD-998911

Fig. 96 Shim Installation 1 - SHIM 2 - OUTPUT SHAFT

Fig. 98 Checking Turning Torque 1 - TORQUE WRENCH 2 - SPECIAL TOOL 6498-A 3 - OUTPUT SHAFT NUT TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 105 AUTOMATIC TRANSMISSION - 42RLE (Continued)

(14) Install low/reverse clutch pack (Fig. 101). Leave uppermost disc out to facilitate snap ring installation.

Fig. 101 Install Low/Reverse Clutch Pack 1 - CLUTCH PLATES (5) Fig. 99 Staking Output Shaft Nut - Typical 2 - CLUTCH DISCS (5) 1 - ARBOR PRESS 2 - STAKING TOOL - 6639 (15) Install low/reverse reaction plate snap ring 3 - NEW NUT (Fig. 102).

Fig. 102 Install Low/Reverse Reaction Plate Snap Ring 1 - SCREWDRIVER 2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING 3 - DO NOT SCRATCH CLUTCH PLATE Fig. 100 Properly Staked Nut 1 - BOTTOMED IN SLOT 2 - CORRECTLY STAKED NUT 21 - 106 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

(16) Install one low/reverse clutch disc (Fig. 103).

Fig. 105 Snap Ring Installed Fig. 103 Install One Disc 1 - SCREWDRIVER 2 - TAPERED SNAP RING (INSTALL AS SHOWN) 1 - ONE DISC FROM LOW/REVERSE CLUTCH

(17) Install low/reverse reaction plate with flat side up (Fig. 104).

Fig. 104 Install Low/Reverse Reaction Plate 1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)

(18) Install tapered snap ring (tapered side out) (Fig. 105). Make sure that the snap ring ends are ori- ented as shown (Fig. 106) Fig. 106 Tapered Snap Ring Instructions TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 107 AUTOMATIC TRANSMISSION - 42RLE (Continued)

(19) Measure low/reverse clutch pack. Set up dial (22) Install 2/4 clutch belleville spring (Fig. 109) indicator as shown in (Fig. 107). Press down clutch (Fig. 110). pack with finger and zero dial indicator. Record measurement in four (4) places and take average reading. Low/Reverse clutch pack clearance is 0.84 to 1.60 (0.033 to 0.063 inch).

Fig. 109 Install 2/4 Clutch Return Spring 1 - 2/4 CLUTCH RETURN SPRING

Fig. 107 Check Low/Reverse Clutch Clearance 1 - DIAL INDICATOR 2 - DIAL INDICATOR TIP TOOL 6268 3 - HOOK TOOL

(20) Select the proper low/reverse reaction plate to achieve specifications. (21) Install 2/4 clutch pack (Fig. 108).

Fig. 110 Proper Orientation of 2/4 Clutch 1 - NOTE POSITION 2 - RETURN SPRING 3 - 2/4 CLUTCH RETAINER

Fig. 108 Install 2/4 Clutch Pack 1 - CLUTCH PLATE (4) 2 - CLUTCH DISC (4) 21 - 108 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

(23) Install 2/4 clutch retainer (Fig. 111).

Fig. 113 Check 2/4 Clutch Clearance Fig. 111 Install 2/4 Clutch Retainer 1 - DIAL INDICATOR 2 - HOOK TOOL 1 - 2/4 CLUTCH RETAINER 3 - DIAL INDICATOR TIP TOOL 6268

(24) Set up Tool 5058 as shown in (Fig. 112). Com- (26) Install the #7 needle bearing to the rear sun press 2/4 clutch just enough to facilitate snap ring gear (Fig. 114). The number 7 needle bearing has installation. three antireversal tabs and is common with the number 5 and number 2 position. The orientation should allow the bearing to seat flat against the rear sun gear. A small amount of petrolatum can be used to hold the bearing to the rear sun gear.

Fig. 112 Remove 2/4 Clutch Retainer Snap Ring 1 - TOOL 5058 2 - SCREWDRIVER 3 - SNAP RING 4 - 2/4 CLUTCH RETAINER

(25) Measure 2/4 clutch clearance: Set up dial Fig. 114 Number 7 Bearing indicator as shown in (Fig. 113). Press down clutch 1 - #7 BEARING pack with finger and zero dial indicator. Record mea- 2 - REAR SUN GEAR surement in four (4) places and take average reading. The 2/4 clutch pack clearance is 0.76 to 2.64 mm (0.030 to 0.104 inch). If not within specifications, the clutch is not assembled properly. There is no adjustment for the 2/4 clutch clearance. TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 109 AUTOMATIC TRANSMISSION - 42RLE (Continued)

(27) Install rear sun gear and #7 needle bearing (Fig. 115).

Fig. 117 Install Front Sun Gear Assembly 1 - FRONT SUN GEAR ASSEMBLY Fig. 115 Install Rear Sun Gear 2 - #4 THRUST WASHER (FOUR TABS) 1 - #7 NEEDLE BEARING (c) Install input clutch assembly. Ensure the 2 - REAR SUN GEAR input clutch assembly is completely seated by view- (28) Install front carrier/rear annulus assembly ing position through input speed sensor hole. If and #6 needle bearing (Fig. 116). the speed sensor tone wheel is not centered in the opening, the input clutches assembly is not seated properly. (d) Remove the oil pump o-ring (Fig. 119) and install oil pump and gasket to transmission. Tighten the oil pump bolts to 30 N·m (265 in. lbs.). Use screw-in dowels or phillips-head screwdrivers to align pump to case. Be sure to reinstall O-ring on oil pump after selecting the proper No. 4 thrust plate. (e) Measure the input shaft end play with the transmission in the vertical position. This will ensure that the measurement will be accurate. (f) Set up and measure endplay using End Play Set 8266 and Dial Indicator Set C3339 as shown in (Fig. 120). (g) Measure input shaft end play. Input shaft end play must be .005 to .025 inch. For exam- Fig. 116 Install Front Carrier/Rear Annulus ple, if end play reading is 0.055 inch, select No. 4 1 - #6 NEEDLE BEARING Thrust Plate which is 0.071 to 0.074 thick. This 2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL). should provide an input shaft end play reading of 0.020 inch, which is within specifications. (29) Install front sun gear assembly and #4 thrust (h) Remove oil pump, gasket, and input clutch washer (Fig. 117). assembly to gain access to and install proper #4 (30) Determine proper #4 thrust plate thick- thrust plate. ness. (a) Select the thinnest #4 thrust plate thickness. (b) Install #4 thrust plate (Fig. 118) using petrolatum to hold into position. 21 - 110 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

Fig. 118 Install #4 Thrust Plate 1 - OVERDRIVE SHAFT ASSEMBLY 2 - #4 THRUST PLATE (SELECT) 3 - PETROLATUM FOR RETENTION

Fig. 120 Measure Input Shaft End Play Using Tool 8266 - Typical 1 - TOOL 8266-8 2 - TOOL 8266-2 3 - TOOL C-3339

Fig. 119 Remove Oil Pump O-Ring 1 - OIL PUMP ASSEMBLY 2 - O-RING

(31) Install input clutch assembly with proper thrust plate (Fig. 121).

Fig. 121 Install Input Clutch Assembly 1 - INPUT CLUTCH ASSEMBLY TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 111 AUTOMATIC TRANSMISSION - 42RLE (Continued)

(32) Install #1 caged needle bearing (Fig. 122). (34) Install oil pump gasket (Fig. 124).

Fig. 122 Install No. 1 Caged Needle Bearing Fig. 124 Install Oil Pump Gasket 1 - #1 CAGED NEEDLE BEARING 1 - BELLHOUSING 2 - NOTE: TANGED SIDE OUT 2 - OIL PUMP GASKET

(33) Replace cooler by-pass valve if transmission (35) Install oil pump and torque the new oil pump- failure has occurred (Fig. 123). to-case bolts to 30 N·m (265 in. lbs.) (Fig. 125). Do not reuse original oil pump bolts. CAUTION: By-pass valve MUST be replaced if transmission failure occurs.

Fig. 125 Install Oil Pump Attaching Bolts 1 - BOLTS Fig. 123 Install By-Pass Valve 2 - OIL PUMP 1 - BYPASS VALVE

NOTE: To align oil pump, gasket, and case during installation, use threaded dowels or phillips screwdrivers. 21 - 112 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

(36) Install low/reverse accumulator as shown in (38) Install low/reverse accumulator snap ring (Fig. 126). (Fig. 128).

Fig. 126 Low/Reverse Accumulator Components Fig. 128 Install Low/Reverse Accumulator Snap 1 - ACCUMULATOR PISTON 2 - SEAL RINGS Ring 3 - RETURN SPRINGS 1 - SNAP RING 4 - NOTE NOTCH 2 - LOW/REVERSE ACCUMULATOR

(37) Install low/reverse accumulator plug (Fig. (39) Install underdrive and overdrive accumulators 127). as shown in (Fig. 129) (Fig. 130) (Fig. 131).

Fig. 127 Install Low/Reverse Accumulator Plug Fig. 129 Accumulator Location 1 - ADJUSTABLE PLIERS 1 - OVERDRIVE ACCUMULATOR LOCATION 2 - PLUG 2 - UNDERDRIVE ACCUMULATOR LOCATION 3 - LOW/REVERSE ACCUMULATOR

CAUTION: Do not handle the valve body by the manual shaft. Damage could result. TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 113 AUTOMATIC TRANSMISSION - 42RLE (Continued)

(40) Install valve body into place as shown in (Fig. 132).

Fig. 130 Install Underdrive Accumulator and Springs 1 - ACCUMULATOR PISTON (UNDERDRIVE) 2 - RETURN SPRINGS 3 - SEAL RING Fig. 132 Install Valve Body Onto Transmission 4 - SEAL RING 1 - VALVE BODY

(41) Install seven (7) valve body-to-case bolts (Fig. 133) and torque to 12 N·m (105 in. lbs.).

Fig. 131 Install Overdrive Accumulator and Springs 1 - OVERDRIVE ACCUMULATOR PISTON 2 - RETURN SPRINGS 3 - SEAL RING 4 - SEAL RING Fig. 133 Install Valve Body Bolts (7) 1 - BOLTS 21 - 114 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

(42) Install transmission oil filter (Fig. 134). Tighten the bolts to 5 N·m (45 in. lbs.)

Fig. 136 Input and Output Speed Sensors and Transmission Range Sensor Fig. 134 Install Transmission Filter 1 - INPUT SPEED SENSOR 2 - OUTPUT SPEED SENSOR 1 - TRANSMISSION FILTER 3 - TRANSMISSION RANGE SENSOR

(43) Install transmission oil pan (Fig. 135) with a bead of Mopar௡ ATF RTV (MS-GF41). Torque oil pan- to-case bolts to 20 N·m (14.5 ft. lbs.).

Fig. 135 Install Transmission Oil Pan 1 - TRANSMISSION OIL PAN Fig. 137 Measure Input Shaft End Play Using Tool 8266 - Typical (44) Install both speed sensors into transmission 1 - TOOL 8266-8 case (Fig. 136). Torque the speed sensor bolts to 9 2 - TOOL 8266-2 N·m (80 in. lbs.). 3 - TOOL C-3339 (45) As a final check of the transmission, measure the input shaft end play. This will indicate when a #4 (46) Inspect the lube tube grommet (Fig. 138) for thrust plate change is required. The #4 thrust plate damage. If the grommet lip is damaged, it will need is located behind the overdrive clutch hub. Attach a to be replaced. dial indicator to transmission bell housing with its (47) Install the 4X4 stub shaft onto the transmis- plunger seated against end of input shaft (Fig. 137). sion output shaft. Move input shaft in and out to obtain end play read- (48) Place a bead of Mopar௡ ATF RTV (MS-GF41) ing. End play specifications are 0.13 to 0.64 mm on the rear surface of the transmission case for the (0.005 to 0.025 inch). If not within specifications, adapter housing. make the necessary thrust plate adjustment. TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 115 AUTOMATIC TRANSMISSION - 42RLE (Continued)

(50) Install the bolts (Fig. 140) that hold the adapter housing onto the transmission case. Be sure to install any stud bolts to their original locations. Tighten the bolts to 54 N·m (40 ft.lbs.).

Fig. 140 Install Adapter Housing Bolts 1 - TRANSMISSION CASE Fig. 138 Lube Tube Grommet 2 - ADAPTER HOUSING 1 - HOUSING 3 - BOLTS 2 - LUBE TUBE 3 - GROMMET 4 - PRY SLOTS INSTALLATION (1) Check torque converter hub and hub drive (49) Install the adapter (Fig. 139) housing onto the notches for sharp edges burrs, scratches, or nicks. transmission case. Polish the hub and notches with 320/400 grit paper and crocus cloth if necessary. The hub must be smooth to avoid damaging pump seal at installation. (2) Lubricate converter drive hub and oil pump seal lip with transmission fluid. (3) Align converter and oil pump. (4) Carefully insert converter in oil pump. Then rotate converter back and forth until fully seated in pump gears. (5) Check converter seating with steel scale and straightedge (Fig. 141). Surface of converter lugs should be 1/2 in. to rear of straightedge when converter is fully seated. (6) Temporarily secure converter with C-clamp. (7) Lightly grease crankshaft flange hole. (8) Position transmission on jack and secure it with safety chains. Fig. 139 Install Adapter Housing 1 - TRANSMISSION CASE 2 - ADAPTER HOUSING 21 - 116 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

Fig. 141 Checking Converter Seating - Typical 1 - SCALE 2 - STRAIGHTEDGE Fig. 142 Crankshaft Position Sensor (9) Check condition of converter driveplate. 1 - CRANKSHAFT POSITION SENSOR Replace the plate if cracked, distorted or damaged. 2 - MOUNTING BOLT Also be sure transmission dowel pins are seated 3 - ELECTRICAL CONNECTOR in engine block and protrude far enough to 4 - TRANSMISSION BELLHOUSING hold transmission in alignment. (19) Install skid plate (Fig. 143) and attach trans- (10) Raise transmission and align converter with mission rear support to skid plate. (Refer to 13 - drive plate and converter housing with engine block. FRAME & BUMPERS/FRAME/TRANSFER CASE (11) Move transmission forward. Then raise, lower SKID PLATE - INSTALLATION) or tilt transmission to align converter housing with engine block dowels. (12) Carefully work transmission forward and over engine block dowels until converter hub is seated in crankshaft. (13) Install and tighten bolts that attach transmission converter housing to engine block.

CAUTION: Be sure the converter housing is fully seated on the engine block dowels before tightening any bolts.

(14) Install torque converter attaching bolts. Tighten bolts to 88 N·m (65 ft. lbs.). (15) On 4.0L engine equipped vehicles, install the crankshaft position sensor (Fig. 142). (16) Install transmission fill tube and seal. Install new fill tube seal in transmission before installation. Fig. 143 Transmission Mount - Automatic (17) Connect transmission cooler lines to transmis- Transmission sion. 1 - TRANSMISSION SUPPORT BRACKET (18) Install transfer case onto transmission. (Refer 2 - AUTOMATIC TRANSMISSION to 21 - TRANSMISSION/TRANSFER CASE - 3 - SKID PLATE 4 - FRAME INSTALLATION) 5 - TRANSMISSION MOUNT SUPPORT BRACKET 6 - CUSHION TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 117 AUTOMATIC TRANSMISSION - 42RLE (Continued)

(20) Remove engine support fixture. (21) Remove transmission jack. (22) Connect input and output speed sensor wires (Fig. 144).

Fig. 145 Solenoid/Pressure Switch Assembly 1 - SOLENOID/PRESSURE SWITCH ASSEMBLY CONNECTOR

Grommets should not be reused. Use pry tool to Fig. 144 Input and Output Speed Sensors and remove rod from grommet and cut away old grom- Transmission Range Sensor met. Use pliers to snap new grommet into lever and to snap rod into grommet at assembly. 1 - INPUT SPEED SENSOR 2 - OUTPUT SPEED SENSOR (28) Connect gearshift cable. 3 - TRANSMISSION RANGE SENSOR (29) Connect transfer case shift linkage. (30) Adjust gearshift linkage, if necessary. (23) Connect wires to the transmission range sen- (31) Align and connect propeller shaft(s). (Refer to sor (Fig. 144) and the solenoid/pressure switch 3 - DIFFERENTIAL & DRIVELINE/PROPELLER assembly (Fig. 145). SHAFT/PROPELLER SHAFT - INSTALLATION) (24) Install converter housing access cover. (32) Fill transfer case to bottom edge of fill plug (25) Install exhaust pipes and support brackets, if hole. removed. (33) Lower vehicle and connect battery negative (26) Install starter motor (Refer to 8 - ELECTRI- cable. CAL/STARTING/STARTER MOTOR - INSTALLA- (34) Fill transmission to correct level with Mopar௡ TION) and cooler line bracket. ATF +4. (27) Install new plastic retainer grommet on any shift linkage rod or lever that was disconnected. 21 - 118 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued) SCHEMATICS AND DIAGRAMS - 42RLE TRANSMISSION

Park/Neutral (Speed Under 8 mph) TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 119 AUTOMATIC TRANSMISSION - 42RLE (Continued)

Neutral (Speed Over 8 mph) 21 - 120 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

Reverse TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 121 AUTOMATIC TRANSMISSION - 42RLE (Continued)

Reverse Block (Shift to Reverse w/Speed Over 8 mph) 21 - 122 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

First Gear TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 123 AUTOMATIC TRANSMISSION - 42RLE (Continued)

Second Gear 21 - 124 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

Second Gear (EMCC) TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 125 AUTOMATIC TRANSMISSION - 42RLE (Continued)

Direct Gear 21 - 126 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

Direct Gear (EMCC) TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 127 AUTOMATIC TRANSMISSION - 42RLE (Continued)

Direct Gear (CC On) 21 - 128 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

Overdrive TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 129 AUTOMATIC TRANSMISSION - 42RLE (Continued)

Overdrive (EMCC) 21 - 130 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

Overdrive (CC On) TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 131 AUTOMATIC TRANSMISSION - 42RLE (Continued) SPECIFICATIONS 42RLE AUTOMATIC TRANSMISSION

GENERAL SPECIFICATIONS

Four-Speed Automatic, Electronically Controlled, Fully Transmission Type Adaptive, Electronically Modulated Torque Converter Lubrication Method Pump (internal - external gear-type) Water Heat Exchanger and/or Air-to-Oil Heat Cooling Method Exchanger

GEAR RATIOS

1st Gear 2.84:1 2nd Gear 1.57:1 3rd Gear (Direct) 1.00:1 4th Gear (Overdrive) 0.69:1 Reverse Gear 2.21:1

BEARING PRELOAD (DRAG TORQUE)

Description Metric Standard Output Shaft 0.22-0.903 N·m 1-8 in. lbs.

CLUTCH PACK

Description Metric Standard Low/Reverse Clutch (Select 0.84-1.60 mm 0.033-0.063 in. Reaction Plate) Two/Four Clutch (No Select) 0.76-2.64 mm 0.030-0.104 in. Reverse Clutch (Select Snap Ring) 0.89-1.37 mm 0.035-0.054 in. Overdrive Clutch (No Select) 1.07-3.25 mm 0.042-0.128 in. Underdrive Clutch (Select Reaction 0.94-1.50 mm 0.037-0.059 in. Plate)

INPUT SHAFT

Description Metric Standard End Play 0.12-0.63 mm 0.005-0.025 in. 21 - 132 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

OIL PUMP CLEARANCES

DESCRIPTION METRIC STANDARD Outer Gear-to-Crescent 0.060-0.298 mm 0.0023-0.0117 in. Inner Gear-to-Crescent 0.093-0.385 mm 0.0036-0.0151 in. Outer Gear-to-Pocket 0.089-0.202 mm 0.0035-0.0079 in. Outer Gear Side Clearance 0.020-0.046 mm 0.0008-0.0018 in. Inner Gear Side Clearance 0.020-0.046 mm 0.0008-0.0018 in.

TORQUE SPECIFICATIONS

Description N·m Ft. Lbs. In. Lbs. Bolt, Converter-to-Driveplate 88 65 - Bolt, Fluid Filter-to-Valve Body 5 - 45 Bolt, L/R Clutch Retainer-to-Case 5 - 45 Bolt, Adapter/Extension Housing 54 40 - Bolt, Manual Valve Lever-to-Manual Valve 5 - 45 Bolt, Oil Pan-to-Case 20 14.5 - Bolt, Oil Pump-to-Case 30 - 265 Bolt, Park Sprag Retainer 4.5 - 40 Bolt, Reaction Shaft Support Halves 28 - 250 Bolt, Solenoid/Pressure Switch Assy-to- 5.5 - 50 Valve Body Bolt, Valve Body-to-Case 12 - 105 Bolt, Valve Body-to-Transfer Plate 5 - 45 Fitting, Cooler Line 47.5 35 - Nut, Output Shaft 271 200 - Plug, Pressure Tap 5 - 45 Bolt, Input Speed-to-Case Sensor 9 - 80 Bolt, Output Speed-to-Case Sensor 9 - 80 TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 133 AUTOMATIC TRANSMISSION - 42RLE (Continued) SPECIAL TOOLS 42RLE AUTOMATIC TRANSMISSION

Pressure Gauge (High) C-3293SP Universal Handle C-4171

Handle Extension C-4171-2 Dial Indicator C-3339

Adapter Set L-4559 Slide Hammer C-3752

Puller Set 5048 Seal Puller C-3981B 21 - 134 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

Installer 5050A Installer 6052

Compressor 5058A Disk 6057

Compressor 5059-A Tip 6268

Installer 5067 Remover/Installer 6301 TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 135 AUTOMATIC TRANSMISSION - 42RLE (Continued)

Remover 6596 Remover/Installer 6302

Remover 6597

Remover 6310

Plate Set 6599

Wrench 6497

Support Plate 6618A

Wrench 6498-A

Staking Tool 6639

Puller Jaws 6545 21 - 136 AUTOMATIC TRANSMISSION - 42RLE TJ AUTOMATIC TRANSMISSION - 42RLE (Continued)

End Play Set 8266

Fig. 146 Accumulator Assembly - Typical 1 - ACCUMULATOR PISTON (UNDERDRIVE) 2 - RETURN SPRINGS 3 - SEAL RING 4 - SEAL RING

Pressure Fixture 8391 ACCUMULATOR DESCRIPTION The 42RLE underdrive, overdrive, low/reverse, and 2/4 clutch hydraulic circuits each contain an accumulator. An accumulator assembly typically consists of a piston, seals, return spring), and a cover or plug (Fig. 146). Fig. 147 Accumulator Location The overdrive and underdrive accumulators are 1 - OVERDRIVE ACCUMULATOR LOCATION located within the transmission case, and are 2 - UNDERDRIVE ACCUMULATOR LOCATION retained by the valve body (Fig. 147). 3 - LOW/REVERSE ACCUMULATOR The low reverse accumulator (Fig. 147) is also located within the transmission case, but the assembly is retained by a cover and a snap-ring. TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 137 ACCUMULATOR (Continued) The 2/4 accumulator is located in the valve body. It BEARINGS is retained by a cover and retaining screws (Fig. 148). ADJUSTMENTS BEARING ADJUSTMENT PROCEDURES Take extreme care when removing and installing bearing cups and cones. Use only an arbor press for installation, as a hammer may not properly align the bearing cup or cone. Burrs or nicks on the bearing seat will give a false end play reading, while gauging for proper shims. Improperly seated bearing cup and cones are subject to low-mileage failure. Bearing cups and cones should be replaced if they show signs of pitting or heat distress. If distress is seen on either the cup or bearing rollers, both cup and cone must be replaced.

NOTE: Bearing drag torque specifications must be maintained to avoid premature bearing failures. Fig. 148 2/4 Accumulator Assembly Used (original) bearing may lose up to 50 percent 1 - VALVE BODY 2 - RETAINER PLATE of the original drag torque after break-in. 3 - DETENT SPRING 4 - SPRINGS NOTE: All bearing adjustments must be made with 5 - SEALS no other component interference or gear inter- 6 - PISTON mesh.

OPERATION Oil all bearings before checking turning torque. The function of an accumulator is to cushion the application of a frictional clutch element. When pressurized fluid is applied to a clutch circuit, the appli- BRAKE TRANSMISSION SHIFT cation force is dampened by fluid collecting in the respective accumulator chamber against the piston INTERLOCK MECHANISM and springs. The intended result is a smooth, firm clutch application. DESCRIPTION The Brake Transmission Shifter/Ignition Interlock (BTSI), is a cable and solenoid operated system. It ADAPTER HOUSING SEAL interconnects the automatic transmission floor mounted shifter to the steering column ignition switch (Fig. 149). REMOVAL (1) Remove the transfer case (Refer to 21 - OPERATION TRANSMISSION/TRANSFER CASE - REMOVAL). The system locks the shifter into the PARK posi- (2) Using a screw mounted in a slide hammer, tion. The Interlock system is engaged whenever the remove the adapter housing seal. ignition switch is in the LOCK or ACCESSORY position. An additional electrically activated feature will INSTALLATION prevent shifting out of the PARK position unless the (1) Install a new adapter housing seal with Tool brake pedal is depressed at least one-half an inch. A Handle C-4171 and Installer C-3860-A. magnetic holding device in line with the park/brake (2) Install the transfer case (Refer to 21 - TRANS- interlock cable is energized when the ignition is in MISSION/TRANSFER CASE - INSTALLATION). the RUN position. When the key is in the RUN position and the brake pedal is depressed, the shifter is unlocked and will move into any position. The interlock system also prevents the ignition switch from being turned to the LOCK or ACCESSORY position (Fig. 150) unless the shifter is fully locked into the PARK position. 21 - 138 AUTOMATIC TRANSMISSION - 42RLE TJ BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM (Continued)

Fig. 149 Ignition Interlock Cable Routing 1 - SHIFT MECHANISM 5 - SOLENOID 2 - LOCK-TAB 6 - WIRE CONNECTOR 3 - IGNITION LOCK INTERLOCK 7 - TIE STRAP 4 - STEERING COLUMN 8 - PARK/BRAKE INTERLOCK CABLE

REMOVAL (1) Remove lower steering column cover. (Refer to 23 - BODY/INSTRUMENT PANEL/STEERING COL- UMN OPENING COVER - REMOVAL) (2) Remove lower steering column shroud. (3) Remove tie strap near the solenoid retaining the brake transmission interlock cable to the steering column. (4) Disengage wire connector from solenoid. (5) With the ignition removed or in the unlocked position, disengage lock tab holding cable end to Fig. 150 Ignition Key Cylinder Actuation steering column (Fig. 151). 1 - SLIDER LOCKED (6) Pull cable end from steering column. 2 - CAM RETURN SPRING (7) Remove the floor console and related trim. 3 - INTERLOCK CABLE (Refer to 23 - BODY/INTERIOR/FLOOR CONSOLE - 4 - CAM 5 - SLIDER REMOVAL) (8) Disconnect the cable from the bellcrank (Fig. 152). (9) Disconnect and remove the cable from the shift bracket. TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 139 BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM (Continued) INSTALLATION (1) Route replacement cable behind instrument panel and under floor console area to shift mechanism. (2) Insert cable end into opening in steering column hub under ignition lock. Push cable inward until lock tab engages. (3) Insert the cable end into the shifter bellcrank. (4) Place gear selector in PARK. (5) Push the spring-loaded cable adjuster forward and snap cable into bracket. (6) Adjust the brake transmission shifter interlock cable. (7) Verify that the cable adjuster lock clamp is pushed downward to the locked position. (8) Test the park-lock cable operation. (9) Install the floor console and related trim. Fig. 151 Brake/Park Interlock Cable (10) Install tie strap to hold cable to base of steer- 1 - IGNITION LOCK ing column. 2 - LOCK TAB (11) Install lower steering column shroud and igni- 3 - CABLE END tion lock. (12) Install lower steering column cover.

Fig. 152 Cable and Shifter 1 - SHIFT MECHANISM 5 - SOLENOID 2 - LOCK-TAB 6 - WIRE CONNECTOR 3 - IGNITION LOCK INTERLOCK 7 - TIE STRAP 4 - STEERING COLUMN 8 - PARK/BRAKE INTERLOCK CABLE 21 - 140 AUTOMATIC TRANSMISSION - 42RLE TJ BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM (Continued) ADJUSTMENTS ADJUSTMENT - BRAKE TRANSMISSION SHIFT INTERLOCK CABLE (1) Shift transmission into PARK. (2) Remove shift lever bezel and console screws. Raise bezel and console for access to cable. (3) Pull cable lock button up to release cable. (4) Turn ignition switch to LOCK position. (5) Use a spacer to create a one millimeter gap between the shifter pawl and top of the shift gate. (6) Pull the cable forward and release.Ensure the cable end is seated in the bellcrank and press cable lock button down until it snaps in place. (7) Check adjustment as follows: (a) Check movement of release shift handle button (floor shift) or release lever (column shift). You should not be able to press button inward or move column lever. (b) Turn ignition switch to RUN position. (c) Shifting out of park should not be possible. (d) Apply the brake and attempt to shift out of PARK. Shifting should be possible. (e) While the transmission is shifted out of Fig. 153 Input Clutch Assembly PARK, release the brake and attempt to shift through all gears. Release the shift button at least 1 - INPUT SHAFT 2 - UNDERDRIVE CLUTCH once during this procedure. The ignition key should 3 - OVERDRIVE CLUTCH not go to the LOCK position. 4 - REVERSE CLUTCH (f) Return transmission to the PARK position 5 - OVERDRIVE SHAFT 6 - UNDERDRIVE SHAFT without applying the brake. (8) Move shift lever back to PARK and check igni- NOTE: (Refer to 21 - TRANSMISSION/AUTOMATIC - tion switch operation. You should be able to turn 42RLE - DIAGNOSIS AND TESTING) for a collective switch to LOCK position and shift lever release but- view of which clutch elements are applied at each ton/lever should not move. position of the selector lever.

DRIVING CLUTCHES UNDERDRIVE CLUTCH The underdrive clutch is hydraulically applied in DESCRIPTION first, second, and third (direct) gears by pressurized Three hydraulically applied input clutches are used fluid against the underdrive piston. When the under- to drive planetary components. The underdrive, overdrive clutch is applied, the underdrive hub drives the drive, and reverse clutches are considered input rear sun gear. clutches and are contained within the input clutch assembly (Fig. 153). The input clutch assembly also OVERDRIVE CLUTCH contains: The overdrive clutch is hydraulically applied in • Input shaft third (direct) and overdrive gears by pressurized fluid • Input hub against the overdrive/reverse piston. When the over- • Clutch retainer drive clutch is applied, the overdrive hub drives the • Underdrive piston front planet carrier. • Overdrive/reverse piston • Overdrive hub REVERSE CLUTCH • Underdrive hub The reverse clutch is hydraulically applied in reverse gear only by pressurized fluid against the OPERATION overdrive/reverse piston. When the reverse clutch is The three input clutches are responsible for driving applied, the front sun gear assembly is driven. different components of the planetary geartrain. TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 141

FLUID AND FILTER The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall DIAGNOSIS AND TESTING into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdraw- DIAGNOSIS AND TESTING - CAUSES OF ing the dipstick. BURNT FLUID Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy Burnt, discolored fluid is a result of overheating is to replace the radiator as the cooler in the radiator which has two primary causes. is not a serviceable part. If coolant has circulated (1) A result of restricted fluid flow through the through the transmission, an overhaul is necessary. main and/or auxiliary cooler. This condition is usu- The torque converter should be replaced whenever ally the result of a damaged main cooler, or severe a failure generates sludge and debris. This is neces- restrictions in the coolers and lines caused by debris sary because normal converter flushing procedures or kinked lines. will not remove all contaminants. (2) Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer tow- ing or similar high load operation will overheat the STANDARD PROCEDURE transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary STANDARD PROCEDURE - FLUID LEVEL transmission fluid cooler, a heavy duty cooling sys- CHECK tem, and the engine/axle ratio combination needed to handle heavy loads. FLUID LEVEL CHECK DIAGNOSIS AND TESTING - EFFECTS OF The transmission sump has a dipstick to check oil similar to most automatic transmissions. It is located INCORRECT FLUID LEVEL on the left side of the engine. Be sure to wipe all dirt A low fluid level allows the pump to take in air from dipstick handle before removing. along with the fluid. Air in the fluid will cause fluid The torque converter fills in both the PARK and pressures to be low and develop slower than normal. NEUTRAL positions. Place the selector lever in If the transmission is overfilled, the gears churn the PARK to be sure that the fluid level check is accu- fluid into foam. This aerates the fluid and causing rate. The engine should be running at idle the same conditions occurring with a low level. In speed for at least one minute, with the vehicle either case, air bubbles cause fluid overheating, oxi- on level ground. At normal operating temperature dation and varnish buildup which interferes with (approximately 82 C. or 180 F.), the fluid level is cor- valve and clutch operation. Foaming also causes fluid rect if it is in the HOT region (cross-hatched area) on expansion which can result in fluid overflow from the the oil level indicator. The fluid level should be in transmission vent or fill tube. Fluid overflow can eas- COLD region at 70° F fluid temperature. Adjust fluid ily be mistaken for a leak if inspection is not careful. level as necessary. Use only Mopar௡ ATF+4, Auto- matic Transmission Fluid. DIAGNOSIS AND TESTING - FLUID CONTAMINATION FLUID LEVEL CHECK USING DRB Transmission fluid contamination is generally a result of: NOTE: Engine and Transmission should be at nor- • adding incorrect fluid mal operating temperature before performing this • failure to clean dipstick and fill tube when procedure. checking level (1) Start engine and apply parking brake. • engine coolant entering the fluid (2) Connect DRBIII௡ scan tool and select transmis- • internal failure that generates debris • overheat that generates sludge (fluid breakdown) sion. • failure to replace contaminated converter after (3) Select sensors. repair (4) Read the transmission temperature value. The use of non-recommended fluids can result in (5) Compare the fluid temperature value with the transmission failure. The usual results are erratic chart. shifts, slippage, abnormal wear and eventual failure (6) Adjust transmission fluid level shown on the dipstick according to the chart (Fig. 154). Use only due to fluid breakdown and sludge formation. Avoid ௡ this condition by using recommended fluids only. Mopar ATF+4, Automatic Transmission Fluid. (7) Check transmission for leaks. 21 - 142 AUTOMATIC TRANSMISSION - 42RLE TJ FLUID AND FILTER (Continued)

Fig. 154 42RLE Fluid Temperature Chart STANDARD PROCEDURE - FLUID/FILTER (7) Check the transmission fluid level and add an SERVICE appropriate amount to bring the transmission fluid level to 3mm (1/8 in.) below the lowest mark on the NOTE: Only fluids of the type labeled Moparா dipstick. ATF+4, Automatic Transmission Fluid, should be (8) Recheck the fluid level after the transmission used in the transmission sump. A filter change has reached normal operating temperature (180°F.). should be made at the time of the transmission oil (9) To prevent dirt from entering transmission, change. The magnet (on the inside of the oil pan) make certain that dipstick is fully seated into the should also be cleaned with a clean, dry cloth. dipstick opening. STANDARD PROCEDURE - TRANSMISSION NOTE: If the transmission is disassembled for any FILL reason, the fluid and filter should be changed. To avoid overfilling transmission after a fluid change or overhaul, perform the following procedure: (1) Raise vehicle on a hoist. Place a drain con- (1) Remove dipstick and insert clean funnel in tainer with a large opening, under transmission oil transmission fill tube. pan. (2) Add following initial quantity of Mopar௡ ATF (2) Loosen pan bolts and tap the pan at one corner +4, Automatic Transmission Fluid, to transmission: to break it loose allowing fluid to drain, then remove (a) If only fluid and filter were changed, add 6 the oil pan. pints (3 quarts) of ATF +4 to transmission. (3) Install a new filter and o-ring on bottom of the (b) If transmission was completely overhauled, valve body and tighten retaining screws to 5 N·m (40 or torque converter was replaced or drained, add in. lbs.). 10 pints (5 quarts) of ATF +4 to transmission. (4) Clean the oil pan and magnet. Reinstall pan (3) Apply parking brakes. using new Mopar௡ Silicone Adhesive sealant. Tighten (4) Start and run engine at normal curb idle speed. oil pan bolts to 19 N·m (165 in. lbs.). (5) Apply service brakes, shift transmission through (5) Pour four quarts of Mopar௡ ATF+4, Automatic all gear ranges then back to NEUTRAL, set parking Transmission Fluid, through the dipstick opening. brake, and leave engine running at curb idle speed. (6) Start engine and allow to idle for at least one (6) Remove funnel, insert dipstick and check fluid minute. Then, with parking and service brakes level. If level is low, add fluid to bring level to applied, move selector lever momentarily to each MIN mark on dipstick. Check to see if the oil level position, ending in the park or neutral position. is equal on both sides of the dipstick. If one side is noticably higher than the other, the dipstick has TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 143 FLUID AND FILTER (Continued) picked up some oil from the dipstick tube. Allow the (3) Disconnect cable at shift lever (Fig. 155) and oil to drain down the dipstick tube and re-check. feed cable through dash panel opening to underside (7) Drive vehicle until transmission fluid is at nor- of vehicle. mal operating temperature. (4) Raise vehicle. (8) With the engine running at curb idle speed, the (5) Disengage cable eyelet at transmission shift gear selector in NEUTRAL, and the parking brake lever and removel cable from the mounting bracket. applied, check the transmission fluid level. Then remove old cable from vehicle. CAUTION: Do not overfill transmission, fluid foam- INSTALLATION ing and shifting problems can result. (1) Route cable through hole in dash panel. Fully seat cable grommet into dash panel. (9) Add fluid to bring level up to MAX arrow (2) Place the auto transmission manual shift con- mark. trol lever in “PARK” detent (rearmost) position and When fluid level is correct, shut engine off, release rotate prop shaft to ensure transmission is in PARK. park brake, remove funnel, and install dipstick in fill (3) Snap the cable into the transmission bracket so tube. the retaining clip is engaged and connect cable end fitting onto the manual control lever ball stud. GEARSHIFT CABLE (4) Place the floor shifter lever in PARK position. (5) Connect shift cable to shifter mechanism by REMOVAL snapping cable retaining ears into shifter bracket and press cable end fitting onto lever ball stud. (1) Shift transmission into PARK. (6) Snap the cable into the transmission bracket so (2) Remove shift lever bezel and necessary console the retaining ears are engaged and connect cable end parts for access to shift lever assembly. (Refer to 23 - fitting onto the manual control lever ball stud. BODY/INTERIOR/FLOOR CONSOLE - REMOVAL) (7) Adjust the shift mechanism.

Fig. 155 Shifter Cable Routing 1 - SHIFT MECHANISM 7 - MANUAL LEVER 2 - LOCK-TAB 8 - CABLE BRACKET 3 - IGNITION LOCK INTERLOCK 9 - SHIFTER CABLE 4 - STEERING COLUMN 10 - BELLHOUSING 5 - SOLENOID 11 - TIE STRAP 6 - WIRE CONNECTOR 12 - PARK/BRAKE INTERLOCK CABLE 21 - 144 AUTOMATIC TRANSMISSION - 42RLE TJ GEARSHIFT CABLE (Continued) (8) Install any floor console components removed 2/4 CLUTCH previously. (Refer to 23 - BODY/INTERIOR/FLOOR The 2/4 clutch is hydraulically applied in second CONSOLE - INSTALLATION) and fourth gears by pressurized fluid against the 2/4 clutch piston. When the 2/4 clutch is applied, the front sun gear assembly is held or grounded to the HOLDING CLUTCHES transmission case. DESCRIPTION LOW/REVERSE CLUTCH Two hydraulically applied multi-disc clutches are The Low/Reverse clutch is hydraulically applied in used to hold planetary geartrain components station- park, reverse, neutral, and first gears by pressurized ary while the input clutches drive others. The 2/4 fluid against the Low/Reverse clutch piston. When and Low/Reverse clutches are considered holding the Low/Reverse clutch is applied, the front planet clutches and are contained at the rear of the trans- carrier/rear annulus assembly is held or grounded to mission case (Fig. 156). the transmission case.

INPUT CLUTCH ASSEMBLY DISASSEMBLY (1) Mount input clutch assembly to Input Clutch Pressure Fixture (Tool 8391). (2) Tap down reverse clutch reaction plate to release pressure from snap ring (Fig. 157).

Fig. 156 2/4 and Low/Reverse Clutches Fig. 157 Tapping Reaction Plate 1 - FRONT PLANET CARRIER/REAR ANNULUS 1 - #4 THRUST PLATE (SELECT) 2 - 2/4 CLUTCH 2 - TAP DOWN REVERSE CLUTCH REACTION PLATE TO 3 - L/R CLUTCH REMOVE OR INSTALL SNAP RING 4 - REAR PLANET CARRIER/FRONT ANNULUS 3 - INPUT CLUTCH RETAINER 5 - REAR SUN GEAR 4 - REVERSE CLUTCH REACTION PLATE 6 - FRONT SUN GEAR ASSEMBLY OPERATION

NOTE: (Refer to 21 - TRANSMISSION/AUTOMATIC - 42RLE - DIAGNOSIS AND TESTING) for a collective view of which clutch elements are applied at each position of the selector lever. TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 145 INPUT CLUTCH ASSEMBLY (Continued)

(3) Remove reverse clutch snap ring (Fig. 158).

Fig. 160 Reverse Clutch Reaction Plate Fig. 158 Reverse Clutch Snap Ring 1 - REVERSE CLUTCH REACTION PLATE (INSTALL FLAT SIDE DOWN) 1 - REACTION PLATE 2 - SCREWDRIVER (5) Remove the reverse clutch pack (two fibers/one 3 - REVERSE CLUTCH SNAP RING (SELECT) steel) (Fig. 161). (4) Pry up and remove reverse clutch reaction plate (Fig. 159) (Fig. 160). NOTE: Tag reverse clutch pack for reassembly identification.

Fig. 159 Pry Reverse Clutch Reaction Plate Fig. 161 Reverse Clutch Pack 1 - REVERSE CLUTCH REACTION PLATE 2 - SCREWDRIVER 1 - REVERSE CLUTCH PLATE 3 - SCREWDRIVER 2 - REVERSE CLUTCH DISC 21 - 146 AUTOMATIC TRANSMISSION - 42RLE TJ INPUT CLUTCH ASSEMBLY (Continued)

(6) Remove the OD/Reverse reaction plate snap (8) Remove OD/Reverse reaction plate wave snap ring (Fig. 162). ring (Fig. 164).

Fig. 162 OD/Reverse Pressure Plate Snap Ring Fig. 164 Waved Snap Ring 1 - OD/REVERSE PRESSURE PLATE 1 - OVERDRIVE SHAFT ASSEMBLY 2 - SCREWDRIVER 2 - OD/REVERSE CLUTCH WAVED SNAP RING 3 - OD/REVERSE PRESSURE PLATE SNAP RING 3 - SCREWDRIVER

(7) Remove OD/Reverse pressure plate (Fig. 163). (9) Remove OD shaft/hub and OD clutch pack (Fig. 165), (Fig. 166).

NOTE: Tag overdrive clutch pack for reassembly identification.

Fig. 163 OD/Reverse Reaction Plate 1 - OD/REVERSE PRESSURE PLATE (STEP SIDE DOWN) 2 - (STEP SIDE DOWN)

Fig. 165 Remove OD Clutch Pack 1 - OVERDRIVE SHAFT ASSEMBLY AND OD CLUTCH PACK 2 - #3 THRUST PLATE 3 - #3 THRUST WASHER 4 - UNDERDRIVE SHAFT ASSEMBLY TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 147 INPUT CLUTCH ASSEMBLY (Continued)

(11) Remove the underdrive shaft assembly (Fig. 168).

Fig. 166 Overdrive Clutch Pack 1 - OVERDRIVE CLUTCH PLATE 2 - OVERDRIVE SHAFT ASSEMBLY 3 - OVERDRIVE CLUTCH DISC Fig. 168 Underdrive Shaft Assembly 1 - #3 THRUST WASHER (5 TABS) (10) Remove and inspect #3 & #4 thrust washers 2 - UNDERDRIVE SHAFT ASSEMBLY (Fig. 167). (12) Remove the #2 needle bearing (Fig. 169).

Fig. 167 #3 and #4 Thrust Washers 1 - #3 THRUST PLATE (3 TABS) Fig. 169 No 2 Needle Bearing 2 - OD SHAFT ASSEMBLY 1 - #2 NEEDLE BEARING (NOTE 3 TABS) 3 - #4 THRUST PLATE (3 SLOTS) 21 - 148 AUTOMATIC TRANSMISSION - 42RLE TJ INPUT CLUTCH ASSEMBLY (Continued)

(13) Remove the OD/UD reaction plate tapered snap ring (Fig. 170).

Fig. 172 Remove Last UD Clutch Disc 1 - ONE UNDERDRIVE CLUTCH DISC Fig. 170 Tapered Snap Ring 1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING 2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)

NOTE: The OD/UD clutch reaction plate has a step on both sides. The OD/UD clutches reaction plate goes tapered step side up.

(14) Remove the OD/UD reaction plate (Fig. 171).

Fig. 173 UD Clutch Flat Snap Ring 1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING 2 - SCREWDRIVER

Fig. 171 OD/UD Reaction Plate 1 - OD/UD CLUTCH REACTION PLATE (STEP SIDE DOWN)

(15) Remove the first UD clutch disc (Fig. 172). (16) Remove the UD clutch flat snap ring (Fig. 173).

NOTE: Tag underdrive clutch pack for reassembly identification.

(17) Remove the UD clutch pack (Fig. 174). Fig. 174 Underdrive Clutch Pack 1 - CLUTCH PLATE CAUTION: Compress return spring just enough to 2 - ONE UD CLUTCH DISC remove or install snap ring. 3 - CLUTCH DISC TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 149 INPUT CLUTCH ASSEMBLY (Continued)

(18) Using Tool 5059A and an arbor press, com- (20) Remove UD clutch piston (Fig. 177). press UD clutch piston enough to remove snap ring (Fig. 175), (Fig. 176).

Fig. 177 Underdrive Clutch Piston 1 - PISTON Fig. 175 UD Spring Retainer Snap Ring (21) Remove input hub tapered snap ring (Fig. 1 - SNAP RING PLIERS 2 - ARBOR PRESS RAM 178). 3 - SNAP RING 4 - SPECIAL TOOL 5059A

(19) Remove spring retainer (Fig. 176).

Fig. 178 Input Hub Tapered Snap Ring 1 - INPUT SHAFT 2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN CAVITY) Fig. 176 UD Return Spring and Retainer 3 - SNAP RING PLIERS 1 - UNDERDRIVE SPRING RETAINER 2 - SNAP RING 3 - SEAL 4 - PISTON RETURN SPRING 21 - 150 AUTOMATIC TRANSMISSION - 42RLE TJ INPUT CLUTCH ASSEMBLY (Continued)

(22) Tap on input hub with soft faced hammer and (23) Separate clutch retainer from OD/Reverse pis- separate input hub from OD/Reverse piston and ton (Fig. 181). clutch retainer (Fig. 179), (Fig. 180).

Fig. 181 Pull Retainer from Piston Fig. 179 Tap on Input Hub 1 - OVERDRIVE/REVERSE PISTON 2 - INPUT CLUTCH RETAINER 1 - INPUT SHAFT AND HUB ASSEMBLY 2 - PLASTIC HAMMER (24) Using Tool 6057 and an arbor press, compress return OD/Reverse piston return spring just enough to remove snap ring (Fig. 182), (Fig. 183).

Fig. 180 Input Hub Removed 1 - INPUT SHAFT AND HUB ASSEMBLY 2 - INPUT CLUTCH RETAINER Fig. 182 Remove Snap Ring 3 - O-RING 1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST 4 - SEAL ENOUGH TO REMOVE OR INSTALL SNAP RING) 5 - OVERDRIVE/REVERSE PISTON 2 - SCREWDRIVER 3 - SNAP RING 4 - SPECIAL TOOL 6057 5 - OD/REVERSE PISTON 6 - RETURN SPRING TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 151 INPUT CLUTCH ASSEMBLY (Continued)

Fig. 183 Return Spring and Snap Ring Fig. 185 Remove Input Shaft 1 - OD/REVERSE PISTON 1 - ARBOR PRESS RAM 2 - RETURN SPRING 2 - SOCKET 3 - SNAP RING 3 - SEAL 4 - O-RING 4 - O-RINGS 5 - INPUT SHAFT (25) Remove input shaft to input clutch hub snap 6 - SEAL 7 - INPUT CLUTCH HUB ring (Fig. 184). ASSEMBLY Use petrolatum on all seals to ease assembly of components. (1) Using an arbor press, install input shaft to input shaft hub (Fig. 186).

Fig. 184 Remove Input Shaft Snap Ring 1 - INPUT SHAFT 2 - SHARP-POINTED TOOL 3 - SNAP RING 4 - O-RINGS 5 - SEALS Fig. 186 Install Input Shaft (26) Using a suitably sized socket and an arbor 1 - INPUT SHAFT press, remove input shaft from input shaft hub (Fig. 2 - ARBOR PRESS RAM 185). 3 - INPUT CLUTCH HUB 21 - 152 AUTOMATIC TRANSMISSION - 42RLE TJ INPUT CLUTCH ASSEMBLY (Continued)

(2) Install input shaft snap ring (Fig. 187).

Fig. 189 Install Snap Ring Fig. 187 Install Input Shaft Snap Ring 1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST ENOUGH TO REMOVE OR INSTALL SNAP RING) 1 - INPUT SHAFT 2 - SCREWDRIVER 2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE) 3 - SNAP RING 3 - SNAP RING 4 - SPECIAL TOOL 6057 4 - O-RINGS 5 - OD/REVERSE PISTON 5 - SEALS 6 - RETURN SPRING

(3) Using an arbor press and Tool 6057, Install (4) Install the OD/Reverse piston assembly to the OD/Reverse piston return spring and snap ring (Fig. input clutch retainer as shown in (Fig. 190). 188), (Fig. 189).

Fig. 190 Install OD/Reverse Piston Fig. 188 Return Spring and Snap Ring 1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON 1 - OD/REVERSE PISTON 2 - INPUT CLUTCHES RETAINER 2 - RETURN SPRING 3 - SNAP RING 4 - O-RING TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 153 INPUT CLUTCH ASSEMBLY (Continued)

(5) Install the input hub/shaft assembly to the (7) Install UD clutch piston (Fig. 193). OD/Reverse piston/clutch retainer assembly (Fig. 191).

Fig. 193 Underdrive Clutch Piston 1 - PISTON Fig. 191 Install Input Shaft Hub Assembly (8) Install UD piston return spring and Tool 5067 1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY (ROTATE TO ALIGN SPLINES) as shown in (Fig. 194). 2 - OD/REV. PISTON

(6) Install input hub tapered snap ring (Fig. 192). Make sure snap ring is fully seated.

Fig. 194 Seal Compressor Special Tool 5067 1 - PISTON RETURN SPRING 2 - SPECIAL TOOL 5067 3 - INPUT CLUTCH RETAINER Fig. 192 Install Input Hub Tapered Snap Ring 1 - INPUT SHAFT 2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN CAVITY) 3 - SNAP RING PLIERS 21 - 154 AUTOMATIC TRANSMISSION - 42RLE TJ INPUT CLUTCH ASSEMBLY (Continued)

(9) Using Tool 5059A and an arbor press, install (10) Install the UD clutch pack (four fibers/four the UD spring retainer and snap ring. (Fig. 195), steels) (Fig. 197). Leave the top disc out until after (Fig. 196) Compress just enough to install snap ring. the snap ring is installed.

CAUTION: Compress return spring just enough to install snap ring.

Fig. 197 Underdrive Clutch Pack 1 - CLUTCH PLATE 2 - ONE UD CLUTCH DISC Fig. 195 UD Return Spring and Retainer 3 - CLUTCH DISC 1 - UNDERDRIVE SPRING RETAINER 2 - SNAP RING (11) Install the UD clutch flat snap ring (Fig. 198). 3 - SEAL 4 - PISTON RETURN SPRING

Fig. 198 UD Clutch Flat Snap Ring 1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING 2 - SCREWDRIVER Fig. 196 Install UD Spring Retainer and Snap Ring 1 - ARBOR PRESS RAM 2 - SNAP RING PLIERS 3 - SNAP RING 4 - OD/REVERSE PISTON 5 - TOOL 5067 6 - TOOL 5059A TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 155 INPUT CLUTCH ASSEMBLY (Continued)

(12) Install the last UD clutch disc (Fig. 199).

Fig. 201 Tapered Snap Ring Fig. 199 Install Last UD Clutch Disc 1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE TAPERED SNAP RING 1 - ONE UNDERDRIVE CLUTCH DISC 2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)

(13) Install the OD/UD clutch reaction plate and (14) Seat tapered snap ring to ensure proper snap ring (Fig. 200), (Fig. 201). The OD/UD clutches installation (Fig. 202). reaction plate has a step on both sides. Install the OD/UD clutches reaction plate tapered step side up.

Fig. 202 Seating Tapered Snap Ring 1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE Fig. 200 OD/UD Reaction Plate TAPERED SNAP RING 2 - SCREWDRIVER 1 - OD/UD CLUTCH REACTION PLATE (STEP SIDE DOWN)

NOTE: Snap ring ends must be located within one finger of the input clutch hub. Be sure that snap ring is fully seated, by pushing with screwdriver, into snap ring groove all the way around. 21 - 156 AUTOMATIC TRANSMISSION - 42RLE TJ INPUT CLUTCH ASSEMBLY (Continued)

(15) Install input clutch assembly to the Input (17) Using moderate pressure, press down and Clutch Pressure Fixture - Tool 8391 (Fig. 203). hold (near indicator) the UD clutch pack with screwdriver or suitable tool and zero dial indicator (Fig. 205). When releasing pressure on clutch pack, indicator reading should advance 0.005–0.010.

Fig. 203 Input Clutch Assembly on Pressure Fixture Tool - 8391 1 - INPUT CLUTCH ASSEMBLY 2 - INPUT CLUTCH PRESSURE FIXTURE - 8391 Fig. 205 Press Down on UD Clutch Pack and Zero (16) Set up dial indicator on the UD clutch pack as Dial Indicator shown in (Fig. 204). 1 - DIAL INDICATOR 2 - UNDERDRIVE CLUTCH

CAUTION: Do not apply more than 30 psi (206 kPa) to the underdrive clutch pack.

(18) Apply 30 psi (206 kPa) to the underdrive hose on Tool 8391 and measure UD clutch clearance. Mea- sure and record UD clutch pack measurement in four (4) places, 90° apart. (19) Take average of four measurements and compare with UD clutch pack clearance specification. Underdrive clutch pack clearance must be 0.94- 1.50 mm (0.037-0.059 in.). (20) If necessary, select the proper reaction plate to achieve specifications: (21) Install the OD clutch pack (four fibers/three steels) (Fig. 206). (22) Install OD reaction plate waved snap ring (Fig. 207). (23) Install the OD/Reverse reaction plate with large step down (towards OD clutch pack) (Fig. 208). Fig. 204 Set Up Dial Indicator to Measure UD Clutch (24) Install OD reaction plate flat snap ring (Fig. Clearance 209). (25) Measure OD clutch pack clearance. Set up 1 - DIAL INDICATOR 2 - UNDERDRIVE CLUTCH dial indicator on top of the OD/Reverse reaction plate as shown in (Fig. 210). TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 157 INPUT CLUTCH ASSEMBLY (Continued)

Fig. 206 Install OD Clutch Pack Fig. 209 Install Flat Snap Ring 1 - OVERDRIVE CLUTCH PACK 1 - ARBOR PRESS RAM 2 - TOOL 5059A 3 - FLAT SNAP RING

Fig. 207 Install Waved Snap Ring 1 - OVERDRIVE REACTION PLATE WAVED SNAP RING 2 - SCREWDRIVER

Fig. 210 Measure OD Clutch Pack Clearance 1 - DIAL INDICATOR 2 - OD/REVERSE PRESSURE PLATE

(26) Zero dial indicator and apply 30 psi (206 kPa) air pressure to the overdrive clutch hose on Tool 8391. Measure and record OD clutch pack measurement in four (4) places, 90° apart. (27) Take average of four measurements and compare with OD clutch pack clearance specification. The overdrive (OD) clutch pack clearance is Fig. 208 OD/Reverse Reaction Plate 1.07-3.25 mm (0.042-0.128 in.). 1 - OVERDRIVE/REVERSE PRESSURE PLATE If not within specifications, the clutch is not 2 - (STEP SIDE DOWN) assembled properly. There is no adjustment for the OD clutch clearance. 21 - 158 AUTOMATIC TRANSMISSION - 42RLE TJ INPUT CLUTCH ASSEMBLY (Continued)

(28) Install reverse clutch pack (two fibers/one steel) (Fig. 211).

Fig. 213 Install Reverse Clutch Snap Ring 1 - REVERSE CLUTCH SNAP RING (SELECT) Fig. 211 Install Reverse Clutch Pack 2 - SCREWDRIVER 1 - REVERSE CLUTCH PLATE 3 - REVERSE CLUTCH REACTION PLATE 2 - REVERSE CLUTCH DISCS

(29) Install reverse clutch reaction plate with the flat side down towards reverse clutch (Fig. 212).

Fig. 214 Pry Up Reaction Plate 1 - SCREWDRIVER 2 - SNAP RING Fig. 212 Install Reaction Plate 3 - SCREWDRIVER 4 - MUST RAISE REVERSE REACTION PLATE TO RAISE SNAP 1 - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN) RING

(30) Tap reaction plate down to allow installation (32) Set up a dial indicator on the reverse clutch of the reverse clutch snap ring. Install reverse clutch pack as shown in (Fig. 215). snap ring (Fig. 213). (33) Using moderate pressure, press down and (31) Pry up reverse reaction plate to seat against hold (near indicator) reverse clutch disc with screw- snap ring (Fig. 214). driver or suitable tool and zero dial indicator (Fig. 216). When releasing pressure, indicator should advance 0.005-0.010. as clutch pack relaxes. TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 159 INPUT CLUTCH ASSEMBLY (Continued)

(34) Apply 30 psi (206 kPa) air pressure to the reverse clutch hose on Tool 8391. Measure and record reverse clutch pack measurement in four (4) places, 90° apart. (35) Take average of four measurements and compare with reverse clutch pack clearance specification. The reverse clutch pack clearance is 0.89-1.37 mm (0.035-0.054 in.). Select the proper reverse clutch snap ring to achieve specifications: (36) To complete the assembly, reverse clutch and overdrive clutch must be removed. (37) Install the #2 needle bearing (Fig. 217).

Fig. 215 Measure Reverse Clutch Pack Clearance 1 - DIAL INDICATOR 2 - REVERSE CLUTCH

Fig. 217 Install No. 2 Needle Bearing 1 - #2 NEEDLE BEARING (NOTE 3 SMALL TABS) 2 - TABS UP

(38) Install the underdrive shaft assembly (Fig. 218).

Fig. 216 Press Down on Reverse Clutch and Zero Indicator 1 - DIAL INDICATOR Fig. 218 Install Underdrive Shaft Assembly 2 - REVERSE CLUTCH 1 - UNDERDRIVE SHAFT ASSEMBLY 2 - #2 NEEDLE BEARING 21 - 160 AUTOMATIC TRANSMISSION - 42RLE TJ INPUT CLUTCH ASSEMBLY (Continued)

(39) Install the #3 thrust washer to the underdrive shaft assembly. Be sure five tabs are seated properly (Fig. 219).

Fig. 221 Install Overdrive Shaft Assembly 1 - OVERDRIVE SHAFT ASSEMBLY 2 - #3 THRUST PLATE 3 - #3 THRUST WASHER Fig. 219 Install No. 3 Thrust Washer 1 - #3 THRUST WASHER (NOTE 5 TABS) (42) Reinstall overdrive and reverse clutch as 2 - UNDERDRIVE SHAFT ASSEMBLY shown (Fig. 222). Rechecking these clutch clearances is not necessary. (40) Install the #3 thrust plate to the bottom of the overdrive shaft assembly. Retain with petrolatum or transmission assembly gel (Fig. 220).

Fig. 222 Input Clutch Assembly 1 - INPUT CLUTCH ASSEMBLY 2 - OVERDRIVE SHAFT ASSEMBLY Fig. 220 Install No. 3 Thrust Plate 1 - OVERDRIVE SHAFT ASSEMBLY 2 - DABS OF PETROLATUM (FOR RETENTION) 3 - #3 THRUST PLATE (NOTE 3 TABS)

(41) Install the overdrive shaft assembly (Fig. 221). TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 161

INPUT SPEED SENSOR (3) Remove the wiring connector from the input speed sensor (Fig. 224). DESCRIPTION (4) Remove the bolt holding the input speed sensor to the transmission case. The Input and Output Speed Sensors (Fig. 223) are (5) Remove the input speed sensor from the trans- two-wire magnetic pickup devices that generate AC mission case. signals as rotation occurs. They are mounted in the left side of the transmission case and are considered primary inputs to the Transmission Control Module (TCM).

Fig. 224 Input Speed Sensor 1 - INPUT SPEED SENSOR 2 - OUTPUT SPEED SENSOR 3 - TRANSMISSION RANGE SENSOR Fig. 223 Input and Output Speed Sensors and Transmission Range Sensor INSTALLATION 1 - INPUT SPEED SENSOR (1) Install the input speed sensor into the trans- 2 - OUTPUT SPEED SENSOR mission case. 3 - TRANSMISSION RANGE SENSOR (2) Install the bolt to hold the input speed sensor OPERATION into the transmission case. Tighten the bolt to 9 N·m (80 in.lbs.). The Input Speed Sensor provides information on (3) Install the wiring connector onto the input how fast the input shaft is rotating. As the teeth of speed sensor the input clutch hub pass by the sensor coil, an AC (4) Verify the transmission fluid level. Add fluid as voltage is generated and sent to the TCM. The TCM necessary. interprets this information as input shaft rpm. (5) Lower vehicle. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM OIL PUMP interprets this information as output shaft rpm. The TCM compares the input and output speed DESCRIPTION signals to determine the following: The oil pump is located in the pump housing inside • Transmission gear ratio the bell housing of the transmission case. The oil • Speed ratio error detection pump assembly (Fig. 225) consists of an inner and • CVI calculation outer gear, a housing, and a cover that also serves as The TCM also compares the input speed signal and the reaction shaft support. the engine speed signal to determine the following: • Torque converter clutch slippage OPERATION • Torque converter element speed ratio As the torque converter rotates, the converter hub REMOVAL rotates the inner and outer gears. As the gears rotate, the clearance between the gear teeth (1) Raise vehicle. increases in the crescent area, and creates a suction (2) Place a suitable fluid catch pan under the at the inlet side of the pump. This suction draws transmission. fluid through the pump inlet from the oil pan. As the 21 - 162 AUTOMATIC TRANSMISSION - 42RLE TJ OIL PUMP (Continued)

(3) Remove the pump gears (Fig. 227) and check for wear and damage on pump housing and gears.

Fig. 225 Oil Pump Assembly 1 - PUMP HOUSING 2 - OUTER PUMP GEAR 3 - INNER PUMP GEAR Fig. 227 Oil Pump Assembly 4 - REACTION SHAFT SUPPORT 1 - PUMP HOUSING 5 - SEAL RINGS (4) 2 - OUTER PUMP GEAR 6 - REACTION SHAFT 3 - INNER PUMP GEAR 7 - CRESCENT 4 - REACTION SHAFT SUPPORT 5 - SEAL RINGS (4) clearance between the gear teeth in the crescent area 6 - REACTION SHAFT decreases, it forces pressurized fluid into the pump 7 - CRESCENT outlet and to the valve body. (4) Re-install the gears and check clearances. (5) Measure the clearance between the outer gear DISASSEMBLY and the pump pocket (Fig. 228). Clearance should be (1) Remove the reaction shaft support bolts. 0.089-0.202 mm (0.0035-0.0079 in.). (2) Remove reaction shaft support from pump housing (Fig. 226).

Fig. 228 Measure Outer Gear to Pocket 1 - OUTER GEAR Fig. 226 Reaction Shaft Support 2 - POCKET 1 - PUMP HOUSING 2 - REACTION SHAFT SUPPORT (6) Measure clearance between outer gear and 3 - PUMP GEARS crescent. Clearance should be 0.060-0.298 mm (0.0023-0.0117 in.). TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 163 OIL PUMP (Continued) (7) Measure clearance between inner gear and OUTPUT SPEED SENSOR crescent. Clearance should be 0.093-0.385 mm (0.0036-0.0151 in.). DESCRIPTION (8) Position an appropriate piece of Plastigage The Input and Output Speed Sensors (Fig. 230) are across both pump gears. two-wire magnetic pickup devices that generate AC (9) Align the Plastigage to a flat area on the reac- signals as rotation occurs. They are mounted in the tion shaft support housing. left side of the transmission case and are considered (10) Install the reaction shaft to the pump hous- primary inputs to the Transmission Control Module ing. Tighten the bolts to 27 N·m (20 ft. lbs.). (TCM). (11) Remove bolts and carefully separate the housings. Measure the Plastigage following the instructions supplied. (12) Clearance between outer gear side and the reaction shaft support should be 0.020-0.046 mm (0.0008-0.0018 in.). Clearance between inner gear side and the reaction shaft support should be 0.020- 0.046 mm (0.0008-0.0018 in.). ASSEMBLY (1) Assemble oil pump as shown in (Fig. 229) (2) Install and torque reaction shaft support-to-oil pump housing bolts to 28 N·m (20 ft. lbs.) torque.

Fig. 230 Input and Output Speed Sensors and Transmission Range Sensor 1 - INPUT SPEED SENSOR 2 - OUTPUT SPEED SENSOR 3 - TRANSMISSION RANGE SENSOR OPERATION The Input Speed Sensor provides information on how fast the input shaft is rotating. As the teeth of the input clutch hub pass by the sensor coil, an AC voltage is generated and sent to the TCM. The TCM interprets this information as input shaft rpm. The Output Speed Sensor generates an AC signal in a similar fashion, though its coil is excited by rotation of the rear planetary carrier lugs. The TCM interprets this information as output shaft rpm. The TCM compares the input and output speed Fig. 229 Oil Pump Assembly signals to determine the following: 1 - PUMP HOUSING • 2 - OUTER PUMP GEAR Transmission gear ratio 3 - INNER PUMP GEAR • Speed ratio error detection 4 - REACTION SHAFT SUPPORT • CVI calculation 5 - SEAL RINGS (4) 6 - REACTION SHAFT The TCM also compares the input speed signal and 7 - CRESCENT the engine speed signal to determine the following: • Torque converter clutch slippage • Torque converter element speed ratio REMOVAL (1) Raise vehicle. (2) Place a suitable fluid catch pan under the transmission. 21 - 164 AUTOMATIC TRANSMISSION - 42RLE TJ OUTPUT SPEED SENSOR (Continued)

(3) Remove the wiring connector from the output speed sensor (Fig. 231). (4) Remove the bolt holding the output speed sensor to the transmission case. (5) Remove the output speed sensor from the transmission case.

Fig. 232 Overdrive Off Switch 1 - ACCESSORY SWITCH BEZEL 2 - OVERDRIVE OFF SWITCH

OFF mode defaults to ON after the ignition switch is cycled OFF and ON. The normal position for the control switch is the ON position. The switch must be in Fig. 231 Input and Output Speed Sensors and this position to energize the solenoid and allow a 3-4 Transmission Range Sensor upshift. The control switch indicator light illuminates 1 - INPUT SPEED SENSOR only when the overdrive switch is turned to the OFF 2 - OUTPUT SPEED SENSOR 3 - TRANSMISSION RANGE SENSOR position, or when illuminated by the transmission control module. INSTALLATION (1) Install the output speed sensor into the trans- REMOVAL mission case. (1) Remove the accessory switch bezel (Fig. (2) Install the bolt to hold the output speed sensor 233)(Refer to 23 - BODY/INSTRUMENT PANEL/AC- into the transmission case. Tighten the bolt to 9 N·m CESSORY SWITCH BEZEL - REMOVAL). (80 in.lbs.). (3) Install the wiring connector onto the output speed sensor (4) Verify the transmission fluid level. Add fluid as necessary. (5) Lower vehicle.

OVERDRIVE SWITCH DESCRIPTION The overdrive OFF (control) switch is located in the center console (Fig. 232). The switch is a momen- tary contact device that signals the PCM to toggle current status of the overdrive function.

OPERATION Fig. 233 Overdrive Off Switch At key-on, overdrive operation is allowed. Pressing 1 - ACCESSORY SWITCH BEZEL the switch once causes the overdrive OFF mode to be 2 - OVERDRIVE OFF SWITCH entered and the overdrive OFF switch lamp to be illuminated. Pressing the switch a second time (2) Remove the overdrive off switch from the acces- causes normal overdrive operation to be restored and sory switch bezel. the overdrive lamp to be turned off. The overdrive TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 165 OVERDRIVE SWITCH (Continued) INSTALLATION INSTALLATION (1) Install the overdrive off switch to the accessory (1) Clean and inspect oil pump seal seat. Then switch bezel. install seal using special tool C-4193-A. (2) Install the accesory switch bezel (Refer to 23 - (2) Clean and inspect torque converter hub. If BODY/INSTRUMENT PANEL/ACCESSORY nicks, scratches or hub wear are found, torque con- SWITCH BEZEL - INSTALLATION). verter replacement will be required.

CAUTION: If the torque converter is being replaced, PLANETARY GEARTRAIN apply a light coating of grease to the crankshaft pilot hole. Also inspect the engine drive plate for DESCRIPTION cracks. If any cracks are found replace the drive The planetary geartrain is located between the plate. Do not attempt to repair a cracked drive plate. input clutch assembly and the rear of the transmis- Always use new torque converter to drive plate sion case. The planetary geartrain consists of two bolts. sun gears, two planetary carriers, two annulus (ring) gears, and one output shaft (Fig. 234). (3) Apply a light film of transmission oil to the torque converter hub and oil seal lips. Then install torque converter into transmission. Be sure that the hub lugs mesh with the front pump lugs when installing. (4) Reinstall the transmission into the vehicle.

SHIFT MECHANISM DESCRIPTION The shift mechanism is cable operated and provides six shift positions. The shift indicator is located on the console next to the gear shift. The shift positions are: • Park (P) • Reverse (R) Fig. 234 Planetary Geartrain • Neutral (N) 1 - FRONT SUN GEAR ASSEMBLY • Drive (D) 2 - #6 THRUST BEARING • Manual Second (2) 3 - #7 THRUST BEARING 4 - REAR CARRIER FRONT ANNULUS ASSEMBLY • Manual Low (1) 5 - REAR SUN GEAR 6 - FRONT CARRIER REAR ANNULUS ASSEMBLY OPERATION Manual low (1) range provides first gear only. Over OPERATION run braking is also provided in this range. Manual The planetary geartrain utilizes two planetary gear second (2) range provides first and second gear only. sets that connect the transmission input shaft to the Drive range provides first, second, and third gear output shaft. Input and holding clutches drive or lock ranges. different planetary members to change output ratio or direction. DIAGNOSIS AND TESTING - SHIFT MECHANISM SEAL - OIL PUMP (1) The floor shifter lever and gate positions should be in alignment with all transmission PARK, REMOVAL NEUTRAL, and gear detent positions. (1) Remove the transmission from the vehicle (2) Engine starts must be possible with floor shift (Refer to 21 - TRANSMISSION/AUTOMATIC - lever in PARK or NEUTRAL gate positions only. 42RLE - REMOVAL). Engine starts must not be possible in any other gear (2) Remove the torque converter from the trans- position. mission bellhousing. (3) Use special tool C-3981B to remove oil pump seal. 21 - 166 AUTOMATIC TRANSMISSION - 42RLE TJ SHIFT MECHANISM (Continued) (3) With floor shift lever handle push-button not SOLENOID depressed and lever in: (a) PARK position - Apply forward force on cen- DESCRIPTION ter of handle and remove pressure. Engine starts The typical electrical solenoid used in automotive must be possible. applications is a linear actuator. It is a device that (b) PARK position - Apply rearward force on cen- produces motion in a straight line. This straight line ter of handle and remove pressure. Engine starts motion can be either forward or backward in direc- must be possible. tion, and short or long distance. (c) NEUTRAL position - Normal position. Engine A solenoid is an electromechanical device that uses starts must be possible. a magnetic force to perform work. It consists of a coil (d) NEUTRAL position - Engine running and of wire, wrapped around a magnetic core made from brakes applied, apply forward force on center of steel or iron, and a spring loaded, movable plunger, shift handle. Transmission shall not be able to shift which performs the work, or straight line motion. from NEUTRAL to REVERSE. The solenoids used in transmission applications ADJUSTMENTS - SHIFT MECHANISM are attached to valves which can be classified as normally open (Fig. 235) or normally closed (Fig. Check adjustment by starting the engine in PARK 236). The normally open solenoid valve is defined and NEUTRAL. Adjustment is CORRECT if the as a valve which allows hydraulic flow when no cur- engine starts only in these positions. Adjustment is rent or voltage is applied to the solenoid. The nor- INCORRECT if the engine starts in one but not both mally closed solenoid valve is defined as a valve positions. If the engine starts in any position other which does not allow hydraulic flow when no current than PARK or NEUTRAL, or if the engine will not or voltage is applied to the solenoid. These valves start at all, the TRS may be faulty. perform hydraulic control functions for the transmis- Gearshift Adjustment Procedure sion and must therefore be durable and tolerant of dirt particles. For these reasons, the valves have (1) Shift transmission into PARK. hardened steel poppets and ball valves. The solenoids (2) Remove floor console as necessary for access to operate the valves directly, which means that the the shift cable adjustment. (Refer to 23 - BODY/IN- solenoids must have very high outputs to close the TERIOR/FLOOR CONSOLE - REMOVAL) valves against the sizable flow areas and line pres- (3) Loosen the shift cable adjustment nut. sures found in current transmissions. Fast response (4) Raise vehicle. time is also necessary to ensure accurate control of (5) Unsnap cable eyelet from transmission shift the transmission. lever. (6) Verify transmission shift lever is in PARK detent by moving lever fully rearward. Last rearward detent is PARK position. (7) Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. (8) Snap cable eyelet onto transmission shift lever. (9) Lower vehicle (10) Tighten the shift cable adjustment screw to 12 N·m (105 in.lbs.). (11) Verify correct operation. (12) Install any floor console components removed for access. (Refer to 23 - BODY/INTERIOR/FLOOR CONSOLE - INSTALLATION)

Fig. 235 2/4 - Low Reverse and Underdrive Solenoids 1 - MANUAL VALVE 2 - LINE PRESSURE 3 - 2/4 - LOW REVERSE SOLENOID ENERGIZED 4 - UNDERDRIVE SOLENOID DE-ENERGIZED 5 - UNDERDRIVE CLUTCH TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 167 SOLENOID (Continued) OPERATION When an electrical current is applied to the solenoid coil, a magnetic field is created which produces an attraction to the plunger, causing the plunger to move and work against the spring pressure and the load applied by the fluid the valve is controlling. The plunger is normally directly attached to the valve which it is to operate. When the current is removed from the coil, the attraction is removed and the plunger will return to its original position due to spring pressure. The plunger is made of a conductive material and accomplishes this movement by providing a path for the magnetic field to flow. By keeping the air gap between the plunger and the coil to the minimum necessary to allow free movement of the plunger, the Fig. 236 Low Reverse/Converter Clutch and magnetic field is maximized. Overdrive Solenoids 1 - OVERDRIVE CLUTCH 2 - NO VENT SOLENOID/PRESSURE 3 - OVERDRIVE SOLENOID ENERGIZED 4 - MANUAL VALVE SWITCH ASSY 5 - LOW REVERSE/CONVERTER CLUTCH SOLENOID DE- ENERGIZED 6 - SOLENOID SWITCH VALVE DESCRIPTION 7 - TAPER The Solenoid/Pressure Switch Assembly (Fig. 237) 8 - VENT TO SUMP 9 - ORIFICE is inside the transmission and mounted to the valve 10 - CHECK BALL body assembly. The assembly consists of four solenoids that control hydraulic pressure to the L/R, 2/4, The strength of the magnetic field is the primary OD, and UD friction elements (transmission clutch- force that determines the speed of operation in a par- es), and the torque converter clutch. The reverse ticular solenoid design. A stronger magnetic field will clutch is controlled by line pressure from the manual cause the plunger to move at a greater speed than a valve in the valve body. The solenoids are contained weaker one. There are basically two ways to increase within the Solenoid/Pressure Switch Assembly, and the force of the magnetic field: can only be serviced by replacing the assembly. 1. Increase the amount of current applied to the The solenoid assembly also contains pressure coil or switches that monitor and send hydraulic circuit 2. Increase the number of turns of wire in the coil. information to the PCM. Likewise, the pressure The most common practice is to increase the num- switches can only be service by replacing the assem- ber of turns by using thin wire that can completely bly. fill the available space within the solenoid housing. The strength of the spring and the length of the OPERATION plunger also contribute to the response speed possible by a particular solenoid design. SOLENOIDS A solenoid can also be described by the method by The solenoids receive electrical power from the which it is controlled. Some of the possibilities Transmission Control Relay through a single wire. include variable force, pulse-width modulated, con- The PCM energizes or operates the solenoids individ- stant ON, or duty cycle. The variable force and pulse- ually by grounding the return wire of the solenoid width modulated versions utilize similar methods to needed. When a solenoid is energized, the solenoid control the current flow through the solenoid to posi- valve shifts, and a fluid passage is opened or closed tion the solenoid plunger at a desired position some- (vented or applied), depending on its default operat- where between full ON and full OFF. The constant ing state. The result is an apply or release of a fric- ON and duty cycled versions control the voltage tional element. across the solenoid to allow either full flow or no flow through the solenoid’s valve. 21 - 168 AUTOMATIC TRANSMISSION - 42RLE TJ SOLENOID/PRESSURE SWITCH ASSY (Continued)

PRESSURE SWITCH STATES

GEAR L/R 2/4 OD

ROPOPOP P/N CL OP OP 1st CL OP OP 2nd OP CL OP DOPOPCL OD OP CL CL OP = OPEN CL = CLOSED

A Diagnostic Trouble Code (DTC) will set if the PCM senses any switch open or closed at the wrong time in a given gear. The PCM also tests the 2/4 and OD pressure switches when they are normally off (OD and 2/4 are tested in 1st gear, OD in 2nd gear, and 2/4 in 3rd gear). The test simply verifies that they are opera- Fig. 237 Valve Body Assembly tional, by looking for a closed state when the corre- 1 - SOLENOID/PRESSURE SWITCH ASSEMBLY sponding element is applied. Immediately after a 2 - TRS shift into 1st, 2nd, or 3rd gear with the engine speed 3 - TRANSFER PLATE above 1000 rpm, the PCM momentarily turns on ele- 4 - SEPARATOR PLATE 5 - VALVE BODY ment pressure to the 2/4 and/or OD clutch circuits to identify that the appropriate switch has closed. If it The 2/4 and UD solenoids are normally applied, doesn’t close, it is tested again. If the switch fails to which allows fluid to pass through in their relaxed or close the second time, the appropriate Diagnostic “off” state. By design, this allows transmission Trouble Code (DTC) will set. limp-in (P,R,N,2) in the event of an electrical failure. The continuity of the solenoids and circuits are REMOVAL periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike NOTE: If the Solenoid/Pressure Switch Assembly is should be detected by the pcm during this test. If no being replaced, the Quick Learn Procedure must be spike is detected, the circuit is tested again to verify performed. (Refer to 8 - ELECTRICAL/ELECTRONIC the failure. In addition to the periodic testing, the CONTROL MODULES/TRANSMISSION CONTROL solenoid circuits are tested if a speed ratio or pres- MODULE - STANDARD PROCEDURE) sure switch error occurs. (1) Raise vehicle on hoist. PRESSURE SWITCHES (2) Remove valve body assembly from transmis- The PCM relies on three pressure switches to mon- sion. (Refer to 21 - TRANSMISSION/AUTOMATIC - itor fluid pressure in the L/R, 2/4, and OD hydraulic 42RLE/VALVE BODY - REMOVAL) circuits. The primary purpose of these switches is to (3) Remove Solenoid/Pressure Switch Assembly help the PCM detect when clutch circuit hydraulic retaining screws from solenoid (Fig. 238). failures occur. The range for the pressure switch clos- (4) Remove Solenoid/Pressure Switch Assembly ing and opening points is 11-23 psi. Typically the and screen from valve body (Fig. 239). switch opening point will be approximately one psi lower than the closing point. For example, a switch may close at 18 psi and open at 17 psi. The switches are continuously monitored by the PCM for the correct states (open or closed) in each gear as shown in the following chart: TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 169 SOLENOID/PRESSURE SWITCH ASSY (Continued) TORQUE CONVERTER DESCRIPTION The torque converter (Fig. 240) is a hydraulic device that couples the engine crankshaft to the transmission. The torque converter consists of an outer shell with an internal turbine, a stator, an overrunning clutch, an impeller and an electronically applied converter clutch. The converter clutch provides reduced engine speed and greater fuel economy when engaged. Clutch engagement also provides reduced transmission fluid temperatures. The torque converter hub drives the transmission oil (fluid) pump. The torque converter is a sealed, welded unit that Fig. 238 Solenoid Retaining Screws is not repairable and is serviced as an assembly. 1 - SOLENOID/PRESSURE SWITCH ASSEMBLY CAUTION: The torque converter must be replaced if 2 - RETAINING SCREWS a transmission failure resulted in large amounts of metal or fiber contamination in the fluid.

Fig. 239 Solenoid/Pressure Switch Assembly and Screen 1 - SOLENOID/PRESSURE SWITCH ASSEMBLY 2 - VALVE BODY 3 - SCREEN INSTALLATION

NOTE: If the Solenoid/Pressure Switch assembly is being replaced, the Quick Learn Procedure must be performed. (Refer to 8 - ELECTRICAL/ELECTRONIC Fig. 240 Torque Converter Assembly CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE)

(1) Install Solenoid/Pressure Switch Assembly and screen to the separator and transfer plates. (2) Install and tighten retaining screws to 5.5 N·m (50 in. lbs.) torque. (3) Install valve body. (Refer to 21 - TRANSMIS- SION/AUTOMATIC - 42RLE/VALVE BODY - INSTALLATION) 21 - 170 AUTOMATIC TRANSMISSION - 42RLE TJ TORQUE CONVERTER (Continued) IMPELLER TURBINE The impeller (Fig. 241) is an integral part of the The turbine (Fig. 242) is the output, or driven, converter housing. The impeller consists of curved member of the converter. The turbine is mounted blades placed radially along the inside of the housing within the housing opposite the impeller, but is not on the transmission side of the converter. As the con- attached to the housing. The input shaft is inserted verter housing is rotated by the engine, so is the through the center of the impeller and splined into impeller, because they are one and the same and are the turbine. The design of the turbine is similar to the driving members of the system. the impeller, except the blades of the turbine are curved in the opposite direction.

Fig. 241 Impeller 1 - ENGINE FLEXPLATE 4 - ENGINE ROTATION 2 - OIL FLOW FROM IMPELLER SECTION INTO TURBINE 5 - ENGINE ROTATION SECTION 3 - IMPELLER VANES AND COVER ARE INTEGRAL TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 171 TORQUE CONVERTER (Continued)

Fig. 242 Turbine 1 - TURBINE VANE 4 - PORTION OF TORQUE CONVERTER COVER 2 - ENGINE ROTATION 5 - ENGINE ROTATION 3 - INPUT SHAFT 6 - OIL FLOW WITHIN TURBINE SECTION

STATOR The stator assembly (Fig. 243) is mounted on a stationary shaft which is an integral part of the oil pump. The stator is located between the impeller and turbine within the torque converter case (Fig. 244). The stator contains an over-running clutch, which allows the stator to rotate only in a clockwise direction. When the stator is locked against the over-running clutch, the torque multiplication feature of the torque converter is operational.

Fig. 243 Stator Components 1 - CAM (OUTER RACE) 2 - ROLLER 3 - SPRING 4 - INNER RACE 21 - 172 AUTOMATIC TRANSMISSION - 42RLE TJ TORQUE CONVERTER (Continued)

Fig. 245 Torque Converter Clutch (TCC) 1 - IMPELLER FRONT COVER 2 - THRUST WASHER ASSEMBLY Fig. 244 Stator Location 3 - IMPELLER 1-STATOR 4-STATOR 2 - IMPELLER 5 - TURBINE 3 - FLUID FLOW 6 - PISTON 4 - TURBINE 7 - FRICTION DISC

TORQUE CONVERTER CLUTCH (TCC) OPERATION The TCC (Fig. 245) was installed to improve the The converter impeller (Fig. 246) (driving member), efficiency of the torque converter that is lost to the which is integral to the converter housing and bolted slippage of the fluid coupling. Although the fluid cou- to the engine drive plate, rotates at engine speed. pling provides smooth, shock-free power transfer, it is The converter turbine (driven member), which reacts natural for all fluid couplings to slip. If the impeller from fluid pressure generated by the impeller, rotates and turbine were mechanically locked together, a and turns the transmission input shaft. zero slippage condition could be obtained. A hydraulic piston was added to the turbine, and a friction material was added to the inside of the front cover to provide this mechanical lock-up. TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 173 TORQUE CONVERTER (Continued)

Fig. 246 Torque Converter Fluid Operation 1 - APPLY PRESSURE 3 - RELEASE PRESSURE 2 - THE PISTON MOVES SLIGHTLY FORWARD 4 - THE PISTON MOVES SLIGHTLY REARWARD

TURBINE that was hitting the stator in such as way as to As the fluid that was put into motion by the impel- cause it to lock-up is no longer doing so. In this con- ler blades strikes the blades of the turbine, some of dition of operation, the stator begins to free wheel the energy and rotational force is transferred into the and the converter acts as a fluid coupling. turbine and the input shaft. This causes both of them (turbine and input shaft) to rotate in a clockwise direction following the impeller. As the fluid is leaving the trailing edges of the turbine’s blades it con- tinues in a “hindering” direction back toward the impeller. If the fluid is not redirected before it strikes the impeller, it will strike the impeller in such a direction that it would tend to slow it down. STATOR Torque multiplication is achieved by locking the stator’s over-running clutch to its shaft (Fig. 247). Under stall conditions (the turbine is stationary), the oil leaving the turbine blades strikes the face of the stator blades and tries to rotate them in a counter- clockwise direction. When this happens the overrunning clutch of the stator locks and holds the stator Fig. 247 Stator Operation from rotating. With the stator locked, the oil strikes 1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL PUSHING ON BACKSIDE OF VANES the stator blades and is redirected into a “helping” 2 - FRONT OF ENGINE direction before it enters the impeller. This circula- 3 - INCREASED ANGLE AS OIL STRIKES VANES tion of oil from impeller to turbine, turbine to stator, 4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING AGAINST STATOR VANES and stator to impeller, can produce a maximum torque multiplication of about 2.4:1. As the turbine begins to match the speed of the impeller, the fluid 21 - 174 AUTOMATIC TRANSMISSION - 42RLE TJ TORQUE CONVERTER (Continued) TORQUE CONVERTER CLUTCH (TCC) (6) Check converter seating with a scale and The torque converter clutch is hydraulically straightedge (Fig. 248). Surface of converter lugs applied and is released when fluid is vented from the should be 1/2 in. to rear of straightedge when con- hydraulic circuit by the torque converter control verter is fully seated. (TCC) solenoid on the valve body. The torque con- (7) If necessary, temporarily secure converter with verter clutch is controlled by the Powertrain Control C-clamp attached to the converter housing. Module (PCM). The torque converter clutch engages (8) Install the transmission in the vehicle. in fourth gear, and in third gear under various con- (9) Fill the transmission with the recommended ditions, such as when the O/D switch is OFF, when fluid. the vehicle is cruising on a level surface after the vehicle has warmed up. The torque converter clutch will disengage momentarily when an increase in engine load is sensed by the PCM, such as when the vehicle begins to go uphill or the throttle pressure is increased. REMOVAL (1) Remove transmission and torque converter from vehicle. (2) Place a suitable drain pan under the converter housing end of the transmission.

CAUTION: Verify that transmission is secure on the lifting device or work surface, the center of gravity of the transmission will shift when the torque converter is removed creating an unstable condition. The torque converter is a heavy unit. Use caution when separating the torque converter from the transmission. Fig. 248 Checking Torque Converter Seating - (3) Pull the torque converter forward until the cen- Typical ter hub clears the oil pump seal. 1 - SCALE (4) Separate the torque converter from the trans- 2 - STRAIGHTEDGE mission. TRANSMISSION CONTROL INSTALLATION RELAY Check converter hub and drive notches for sharp edges, burrs, scratches, or nicks. Polish the hub and DESCRIPTION notches with 320/400 grit paper or crocus cloth if nec- The relay is supplied fused B+ voltage, energized essary. The hub must be smooth to avoid damaging by the TCM, and is used to supply power to the sole- the pump seal at installation. noid pack when the transmission is in normal oper- (1) Lubricate oil pump seal lip with transmission ating mode. fluid. (2) Place torque converter in position on transmis- OPERATION sion. When the relay is “off”, no power is supplied to the solenoid pack and the transmission is in “limp-in” CAUTION: Do not damage oil pump seal or bushing mode. After a controller reset, the TCM energizes the while inserting torque converter into the front of the relay. Prior to this, the TCM verifies that the con- transmission. tacts are open by checking for no voltage at the (3) Align torque converter to oil pump seal open- switched battery terminals. After this is verified, the ing. voltage at the solenoid pack pressure switches is (4) Insert torque converter hub into oil pump. checked. After the relay is energized, the TCM mon- (5) While pushing torque converter inward, rotate itors the terminals to verify that the voltage is converter until converter is fully seated in the oil greater than 3 volts. pump gears. TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 175

TRANSMISSION RANGE Since there are four switches, there are 16 possible combinations of open and closed switches (codes). SENSOR Seven of these codes are related to gear position and three are recognized as “between gear” codes. This DESCRIPTION results in six codes which should never occur. These The Transmission Range Sensor (TRS) is mounted are called “invalid” codes. An invalid code will result to the top of the valve body inside the transmission in a DTC, and the PCM will then determine the shift and can only be serviced by removing the valve body lever position based on pressure switch data. This assembly. The electrical connector extends through allows reasonably normal transmission operation the transmission case (Fig. 249). with a TRS failure.

TRS SWITCH STATES

SLP T42 T41 T3 T1 P CL CL CL OP R CL OP OP OP N CL CL OP CL D OP OP OP CL 2 OP OP CL OP 1 CL OP CL CL

REMOVAL (1) Disconnect the TRS connector. (2) Remove valve body assembly from vehicle. (3) Remove the manual shaft seal (Fig. 250).

Fig. 249 Valve Body Assembly 1 - SOLENOID/PRESSURE SWITCH ASSEMBLY 2 - TRS 3 - TRANSFER PLATE 4 - SEPARATOR PLATE 5 - VALVE BODY

The Transmission Range Sensor (TRS) has four switch contacts that monitor shift lever position and send the information to the PCM. OPERATION The Transmission Range Sensor (TRS) communi- cates shift lever position (SLP) to the PCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states Fig. 250 Manual Shaft Seal - Typical (open/closed) that the PCM receives from four sense 1 - SEAL circuits. The PCM interprets this information and 2 - MANUAL SHAFT determines the appropriate transmission gear position and shift schedule. 21 - 176 AUTOMATIC TRANSMISSION - 42RLE TJ TRANSMISSION RANGE SENSOR (Continued)

(4) Remove manual shaft/TRS retaining screw (Fig. 251).

Fig. 252 Transmission Temperature Sensor 1 - TRANSMISSION RANGE SENSOR 2 - TEMPERATURE SENSOR Fig. 251 Manual Shaft Retaining Screw OPERATION 1 - SCREW 2 - TRS The TRS has an integrated thermistor that the PCM uses to monitor the transmission’s sump tem- (5) Slide TRS off of manual valve shaft. perature. Since fluid temperature can affect transmission shift quality and convertor lock up, the PCM INSTALLATION requires this information to determine which shift (1) Install the TRS to the manual shaft. Make sure schedule to operate in. The PCM also monitors this TRS locating pin rests in manual valve bore slot. temperature data so it can energize the vehicle cool- (2) Install the TRS/manual shaft retaining screw ing fan(s) when a transmission “overheat” condition and torque to 5 N·m (45 in. lbs.) torque. exists. If the thermistor circuit fails, the PCM will (3) Install the manual shaft seal. revert to calculated oil temperature usage. (4) Install valve body to the transmission. CALCULATED TEMPERATURE A failure in the temperature sensor or circuit will TRANSMISSION result in calculated temperature being substituted for TEMPERATURE SENSOR actual temperature. Calculated temperature is a pre- dicted fluid temperature which is calculated from a combination of inputs: DESCRIPTION • Battery (ambient) temperature The transmission temperature sensor (Fig. 252) is • Engine coolant temperature located in the transmission range sensor and commu- • In-gear run time since start-up nicates transmission sump temperature to the PCM. TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 177

VALVE BODY The valves contained within the valve body include the following (Fig. 254): DESCRIPTION • Regulator valve • Solenoid switch valve The valve body assembly (Fig. 253) consists of a • Manual valve cast aluminum valve body, a separator plate, and • Converter clutch switch valve transfer plate. The valve body contains valves and • Converter clutch control valve check balls that control fluid delivery to the torque • Torque converter regulator valve converter clutch, solenoid/pressure switch assembly, • Low/Reverse switch valve and frictional clutches. In addition, the valve body also contains the ther- Also mounted to the valve body assembly are the mal valve, #2, 3,4&5check balls and the 2/4 accu- solenoid/pressure switch assembly and the transmis- mulator assembly. sion range sensor (Fig. 253). OPERATION

NOTE: (Refer to 21 - TRANSMISSION/AUTOMATIC - 42RLE - SCHEMATICS AND DIAGRAMS) for a visual aid in determining valve location, operation and design.

THERMAL VALVE The thermal valve is a bi-metallic shudder valve that helps control the venting rate of oil pressure in the underdrive clutch passage during release of the clutch (Fig. 255). When the oil temperature is approximately 20 degrees Fahrenheit or less, the valve is fully open to assist in venting oil past the U1 orifice. At temperatures above 20 degrees, the valve starts to close and becomes fully closed at approximately 140 degrees. The thermal valve is located in the transfer plate of the valve body. REGULATOR VALVE The regulator valve (Fig. 256) controls hydraulic Fig. 253 Valve Body Assembly pressure in the transmission. It receives unregulated 1 - SOLENOID/PRESSURE SWITCH ASSEMBLY pressure from the pump, which works against spring 2 - TRS tension to maintain oil at specific pressures. A sys- 3 - TRANSFER PLATE tem of sleeves and ports allows the regulator valve to 4 - SEPARATOR PLATE 5 - VALVE BODY work at one of three predetermined pressure levels. Regulated oil pressure is also referred to as “line pressure.” 21 - 178 AUTOMATIC TRANSMISSION - 42RLE TJ VALVE BODY (Continued)

Fig. 254 Valve Body - Exploded 1 - VALVE BODY 5 - MANUAL VALVE 2 - T/C REGULATOR VALVE 6 - CONVERTER CLUTCH SWITCH VALVE 3 - L/R SWITCH VALVE 7 - SOLENOID SWITCH VALVE 4 - CONVERTER CLUTCH CONTROL VALVE 8 - REGULATOR VALVE

Fig. 255 Thermal Valve Fig. 256 Regulator Valve 1 - THERMAL VALVE 1 - FROM OVERDRIVE CLUTCH CIRCUIT 2 - U1 ORIFICE 2 - FROM MANUAL VALVE 3 - NUMBER 2 CHECK BALL 3 - HYDRAULIC PRESSURE 4 - FILTER 5 - PUMP INLET 6 - PUMP OUTLET 7 - OIL PRESSURE REGULATED AT THIS POINT 8 - SPRING TENSION 9 - REGULATOR VALVE 10 - TORQUE CONVERTER CONTROL VALVE TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 179 VALVE BODY (Continued) SOLENOID SWITCH VALVE MANUAL VALVE The solenoid switch valve (Fig. 257) controls line The manual valve (Fig. 258) is operated by the pressure from the LR/CC solenoid. In one position, it mechanical shift linkage. Its primary responsibility is allows the low/reverse clutch to be pressurized. In to send line pressure to the appropriate hydraulic cir- the other, it directs line pressure to the converter cuits and solenoids. The valve has three operating control and converter clutch valves. ranges or positions.

Fig. 258 Manual Valve 1 - UD CLUTCH 2 - LR/CC CLUTCH 3 - REVERSE CLUTCH 4 - MANUAL VALVE 5 - REGULATOR VALVE 6 - REGULATOR VALVE 7 - CONVERTER CLUTCH CONTROL VALVE 8 - 2/4 CLUTCH 9 - 2/4 - L/R SOLENOID 10 - L/R CLUTCH

CONVERTER CLUTCH SWITCH VALVE The main responsibility of the converter clutch switch valve (Fig. 259) is to control hydraulic pressure applied to the front (off) side of the converter clutch piston. Line pressure from the regulator valve Fig. 257 Solenoid Switch Valve De-Energized is fed to the torque converter regulator valve. The 1 - 2/4 CLUTCH pressure is then directed to the converter clutch 2 - MANUAL VALVE switch valve and to the front side of the converter 3 - UD CLUTCH clutch piston. This pressure pushes the piston back 4 - LR/CC SOLENOID DE-ENERGIZED 5 - MANUAL VALVE and disengages the converter clutch. 6 - LINE PRESSURE 7 - CONVERTER CLUTCH SWITCH AND CONTROL VALVES 8 - LR CLUTCH 21 - 180 AUTOMATIC TRANSMISSION - 42RLE TJ VALVE BODY (Continued)

Fig. 259 Converter Clutch Switch Valve 1 - CONVERTER CLUTCH 2 - TORQUE CONVERTER 3 - LR CLUTCH 4 - DRIBBLERS 5 - REGULATOR VALVE 6 - SOLENOID SWITCH VALVE 7 - CONVERTER CLUTCH CONTROL VALVE Fig. 260 Converter Clutch Control Valve 8 - REGULATOR VALVE 9 - CONVERTER CLUTCH CONTROL VALVE 1 - CONVERTER CLUTCH 10 - CONVERTER CLUTCH SWITCH VALVE 2 - TORQUE CONVERTER 11 - BYPASS VALVE 3 - LR/CC SOLENOID 12 - LUBE 4 - FROM MANUAL VALVE 13 - COOLER 5 - CONVERTER CLUTCH CONTROL VALVE 6 - TORQUE CONVERTER REGULATOR VALVE 7 - CONVERTER CLUTCH SWITCH VALVE CONVERTER CLUTCH CONTROL VALVE 8 - BYPASS VALVE The converter clutch control valve (Fig. 260) con- 9 - COOLER trols the back (on) side of the torque converter clutch. When the controller energizes or modulates the REMOVAL LR/CC solenoid to apply the converter clutch piston, both the converter clutch control valve and the con- NOTE: If valve body is being reconditioned or verter control valve move, allowing pressure to be replaced, it is necessary to perform the Quick Learn applied to the back side of the clutch. Procedure.(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL T/C REGULATOR VALVE MODULE - STANDARD PROCEDURE) The torque converter regulator valve slightly regu- lates the flow of fluid to the torque converter. (1) Disconnect the TRS and solenoid wiring connectors. LOW/REVERSE SWITCH VALVE (2) Disconnect the shift cable from the shift lever The low/reverse clutch is applied from different (at the transmission). sources, depending on whether low (1st) gear or (3) Move the manual shift lever clockwise as far as reverse is selected. The low/reverse switch valve it will go. This should be one position past the L posi- alternates positions depending on from which direction. Then remove the manual shift lever. tion fluid pressure is applied. By design, when the (4) Remove transmission pan bolts (Fig. 261). valve is shifted by fluid pressure from one channel, (5) Remove transmission oil pan (Fig. 262). the opposing channel is blocked. The switch valve (6) Remove oil filter from valve body (Fig. 263). It alienates the possibility of a sticking ball check, thus is held in place by two screws. providing consistent application of the low/reverse (7) Remove valve body bolts-to-case (Fig. 264). clutch under these operating conditions. TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 181 VALVE BODY (Continued)

Fig. 261 Remove Transmission Oil Pan Bolts Fig. 264 Remove Valve Body Bolts 1 - TRANSMISSION OIL PAN 2 - BOLTS 1 - BOLTS

(8) Carefully remove valve body assembly from transmission (Fig. 265).

Fig. 262 Remove Transmission Oil Pan 1 - TRANSMISSION OIL PAN

Fig. 265 Remove Valve Body From Transmission 1 - VALVE BODY

CAUTION: The overdrive and underdrive accumulators and springs may fall out when removing the valve body (Fig. 266) (Fig. 267) (Fig. 268).

Fig. 263 Remove Transmission Filter 1 - TRANSMISSION FILTER 21 - 182 AUTOMATIC TRANSMISSION - 42RLE TJ VALVE BODY (Continued)

Fig. 266 Accumulator Assembly - Typical Fig. 268 Accumulator Location 1 - ACCUMULATOR PISTON (UNDERDRIVE) 2 - RETURN SPRINGS 1 - OVERDRIVE ACCUMULATOR LOCATION 3 - SEAL RING 2 - UNDERDRIVE ACCUMULATOR LOCATION 4 - SEAL RING 3 - LOW/REVERSE ACCUMULATOR

(1) Remove manual shaft seal. (2) Remove manual shaft screw (Fig. 269).

Fig. 267 Overdrive Accumulator and Springs 1 - OVERDRIVE ACCUMULATOR PISTON 2 - RETURN SPRINGS 3 - SEAL RING 4 - SEAL RING

DISASSEMBLY Fig. 269 Manual Shaft Retaining Screw 1 - SCREW NOTE: If the valve body is being reconditioned or 2 - TRS replaced, it is necessary to perform the Quick Learn Procedure using the DRBIIIா Scan Tool (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/ TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE) TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 183 VALVE BODY (Continued)

(3) Remove Transmission Range Sensor (TRS) and (5) Remove valve body stiffener plate (Fig. 272). manual shaft (Fig. 270).

Fig. 272 Remove Stiffener Plate 1 - STIFFENER PLATE Fig. 270 Manual Shaft/Rooster Comb and Transmission Range Sensor (6) Invert valve body assembly and remove trans- 1 - TRANSMISSION RANGE SENSOR fer plate-to-valve body screws (Fig. 273). 2 - MANUAL SHAFT 3 - ROOSTER COMB

(4) Remove Solenoid/Pressure Switch Assembly from valve body (Fig. 271).

Fig. 273 Remove Transfer Plate-to-Valve Body Fig. 271 Solenoid Retaining Screws Screws 1 - SOLENOID/PRESSURE SWITCH ASSEMBLY 2 - RETAINING SCREWS 1 - SCREW (24) 2 - TRANSFER PLATE 21 - 184 AUTOMATIC TRANSMISSION - 42RLE TJ VALVE BODY (Continued)

(7) Remove transfer/separator plate from valve body (Fig. 274)

Fig. 276 Remove Separator Plate to Transfer Plate 1 - SEPARATOR PLATE Fig. 274 Remove Transfer Plate to Valve Body 2 - TRANSFER PLATE 1 - TRANSFER PLATE (10) Remove the oil screen from the transfer plate 2 - VALVE BODY (Fig. 277). (8) Remove separator plate-to-transfer plate (11) Remove thermal valve (Fig. 278) from transfer screws (Fig. 275). plate. (9) Remove separator plate from transfer plate (Fig. 276).

Fig. 277 Remove Oil Screen to Transfer Plate 1 - OIL SCREEN Fig. 275 Remove Separator Plate-to-Transfer Plate Screws 1 - SEPARATOR PLATE 2 - SCREW (2) 3 - TRANSFER PLATE TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 185 VALVE BODY (Continued)

Fig. 280 2/4 Accumulator Assembly Fig. 278 Remove Thermal Valve to Transfer Plate 1 - VALVE BODY 2 - RETAINER PLATE 1 - THERMAL VALVE 3 - DETENT SPRING 4 - SPRINGS (12) Remove valve body check balls. Note their 5 - SEALS location for assembly ease (Fig. 279). 6 - PISTON (13) Remove 2/4 accumulator assembly as shown in (Fig. 280).

Fig. 279 Ball Check Location 1 - (#4) BALL CHECK LOCATION 3 - (#5) BALL CHECK LOCATION 2 - (#2) BALL CHECK LOCATION 4 - (#3) BALL CHECK LOCATION 21 - 186 AUTOMATIC TRANSMISSION - 42RLE TJ VALVE BODY (Continued)

(14) Remove dual retainer plate from valve body. (16) Remove remaining retainers as shown in (Fig. Use special tool 6301 to remove plate (Fig. 281). 283).

Fig. 281 Remove Dual Retainer Plate using Tool Fig. 283 Valve Retainer Location 6301 1 - RETAINER 1 - TOOL 6301 2 - RETAINER 2 - RETAINER (17) Remove valves and springs as shown in (Fig. (15) Remove regulator valve spring retainer (Fig. 284). 282). (18) Cleanliness through entire disassembly and assembly of the valve body cannot be overempha- sized. When disassembling, each part should be washed in a suitable solvent, then dried by compressed air. Do not wipe parts with shop towels. All mating surfaces in the valve body are accurately machined; therefore, careful handling of all parts must be exercised to avoid nicks or burrs.

Fig. 282 Remove Regulator Valve Spring Retainer using Tool 6302 1 - TOOL 6302 2 - RETAINER TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 187 VALVE BODY (Continued)

Fig. 284 Valve Body Assembly 1 - VALVE BODY 5 - MANUAL VALVE 2 - T/C REGULATOR VALVE 6 - CONVERTER CLUTCH SWITCH VALVE 3 - L/R SWITCH VALVE 7 - SOLENOID SWITCH VALVE 4 - CONVERTER CLUTCH CONTROL VALVE 8 - REGULATOR VALVE 21 - 188 AUTOMATIC TRANSMISSION - 42RLE TJ VALVE BODY (Continued) ASSEMBLY

NOTE: If the valve body assembly is being reconditioned or replaced, it is necessary to perform the Quick Learn Procedure using the DRBIIIா Scan Tool. (Refer to 8 - ELECTRICAL/ELECTRONIC CON- TROL MODULES/TRANSMISSION CONTROL MOD- ULE - STANDARD PROCEDURE)

(1) Install valves and springs as shown in (Fig. 285). (2) Install regulator valve spring retainer (Fig. 286).

Fig. 286 Install Regulator Valve Spring Retainer using Tool 6302 1 - TOOL 6302 2 - RETAINER

Fig. 285 Valve Body Assembly 1 - VALVE BODY 5 - MANUAL VALVE 2 - T/C REGULATOR VALVE 6 - CONVERTER CLUTCH SWITCH VALVE 3 - L/R SWITCH VALVE 7 - SOLENOID SWITCH VALVE 4 - CONVERTER CLUTCH CONTROL VALVE 8 - REGULATOR VALVE TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 189 VALVE BODY (Continued)

(3) Install dual retainer plate using Tool 6301 (Fig. (5) Install 2/4 Accumulator components as shown 287). in (Fig. 289). Torque 2/4 Accumulator retainer plate to 5 N·m (45 in. lbs.).

Fig. 289 2/4 Accumulator Assembly Fig. 287 Install Dual Retainer Plate using Tool 6301 1 - VALVE BODY 1 - TOOL 6301 2 - RETAINER PLATE 2 - RETAINER 3 - DETENT SPRING 4 - SPRINGS 5 - SEALS (4) Verify that all retainers are installed as shown 6 - PISTON in (Fig. 288). Retainers should be flush or below valve body surface. (6) Install check balls into position as shown in (Fig. 290). If necessary, secure them with petrolatum or transmission assembly gel for assembly ease. (7) Install thermal valve to the transfer plate (Fig. 291).

Fig. 288 Valve Retainer Location 1 - RETAINER 2 - RETAINER 21 - 190 AUTOMATIC TRANSMISSION - 42RLE TJ VALVE BODY (Continued)

Fig. 290 Ball Check Location 1 - (#4) BALL CHECK LOCATION 3 - (#5) BALL CHECK LOCATION 2 - (#2) BALL CHECK LOCATION 4 - (#3) BALL CHECK LOCATION

(9) Install separator plate to transfer plate (Fig. 293).

Fig. 291 Install Thermal Valve to Transfer Plate 1 - THERMAL VALVE

(8) Install the oil screen to the transfer plate (Fig. Fig. 292 Install Oil Screen to Transfer Plate 292). 1 - OIL SCREEN TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 191 VALVE BODY (Continued)

Fig. 293 Install Separator Plate to Transfer Plate Fig. 295 Install Transfer Plate to Valve Body 1 - SEPARATOR PLATE 1 - TRANSFER PLATE 2 - TRANSFER PLATE 2 - VALVE BODY

(10) Install the two separator plate-to-transfer (12) Install the transfer plate-to-valve body screws plate screws (Fig. 294). (Fig. 296) and torque to 5 N·m (45 in. lbs.). (11) Install the transfer plate to the valve body (Fig. 295).

Fig. 296 Install Transfer Plate-to-Valve Body Screws Fig. 294 Install Separator Plate-to-Transfer Plate 1 - SCREW (24) 2 - TRANSFER PLATE Screws 1 - SEPARATOR PLATE 2 - SCREW (2) 3 - TRANSFER PLATE 21 - 192 AUTOMATIC TRANSMISSION - 42RLE TJ VALVE BODY (Continued)

(13) Install the stiffener plate (Fig. 297).

Fig. 299 Manual Shaft/Rooster Comb and Fig. 297 Install Stiffener Plate Transmission Range Sensor 1 - STIFFENER PLATE 1 - TRANSMISSION RANGE SENSOR 2 - MANUAL SHAFT (14) Install the solenoid/pressure switch assembly 3 - ROOSTER COMB and to the transfer plate (Fig. 298) and torque to 5.5 N·m (50 in. lbs.). (16) Install the TRS/manual shaft retaining screw (Fig. 300) and torque to 5 N·m (45 in. lbs.).

Fig. 298 Solenoid Retaining Screws 1 - SOLENOID/PRESSURE SWITCH ASSEMBLY 2 - RETAINING SCREWS

(15) Install the manual shaft/rooster comb and Fig. 300 Manual Shaft Retaining Screw transmission range sensor to the valve body (Fig. 299). 1 - SCREW 2 - TRS

(17) Install manual shaft seal. TJ AUTOMATIC TRANSMISSION - 42RLE 21 - 193 VALVE BODY (Continued) INSTALLATION (3) Make sure oil pan and case rail are clean and (1) Install valve body into position and start bolts. dry. Install an 1/8” bead of RTV to the transmission Torque valve body to transmission case bolts (Fig. oil pan and install to case. Tighten bolts (Fig. 303) to 301) to 12 N·m (105 in. lbs.) torque. 20 N·m (14.5 ft. lbs.).

Fig. 301 Install Valve Body Bolts Fig. 303 Install Transmission Oil Pan Bolts 1 - BOLTS 1 - TRANSMISSION OIL PAN 2 - BOLTS (2) Install transmission oil filter (Fig. 302). (4) Lower vehicle and connect the TRS connector. (5) Connect solenoid/pressure switch assembly connector. (6) Lower vehicle. (7) Fill transmission with ATF+4, Automatic Transmission Fluid. Verify proper fluid level. (Refer to 21 - TRANSMISSION/AUTOMATIC - 42RLE/ FLUID - STANDARD PROCEDURE)

NOTE: If the valve body has been reconditioned or replaced, it is necessary to perform the Quick Learn Procedure. (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/TRANSMISSION CONTROL MODULE - STANDARD PROCEDURE)

Fig. 302 Install Transmission Filter 1 - TRANSMISSION FILTER 21 - 194 TRANSFER CASE - NV231 TJ

TRANSFER CASE - NV231

TABLE OF CONTENTS

page page

TRANSFER CASE - NV231 FRONT OUTPUT SHAFT SEAL DESCRIPTION ...... 194 REMOVAL ...... 221 OPERATION ...... 195 INSTALLATION ...... 221 DIAGNOSIS AND TESTING - TRANSFER REAR OUTPUT SHAFT SEAL CASE - NV231 ...... 195 REMOVAL ...... 221 REMOVAL ...... 196 INSTALLATION ...... 222 DISASSEMBLY ...... 196 SHIFT LEVER CLEANING ...... 204 REMOVAL ...... 224 INSPECTION ...... 204 INSTALLATION ...... 224 ASSEMBLY ...... 207 ADJUSTMENTS - SHIFT LINKAGE ...... 226 INSTALLATION ...... 218 SPEEDOMETER DRIVE ADAPTER SPECIFICATIONS REMOVAL ...... 226 TRANSFER CASE - NV231 ...... 218 INSTALLATION ...... 226 SPECIAL TOOLS VEHICLE SPEED SENSOR NV231 ...... 219 DESCRIPTION ...... 227 FLUID OPERATION ...... 227 STANDARD PROCEDURE - FLUID DRAIN AND REMOVAL ...... 228 FILL ...... 221 INSTALLATION ...... 228

TRANSFER CASE - NV231 The 4x4 and 4 Lo ranges are for off road use only. They are not for use on hard surface roads. The only DESCRIPTION exception being when the road surface is wet or slip- pery or covered by ice and snow. The NV231 is a part-time transfer case with a low The low range reduction gear system is operative range reduction gear system. The NV231 has three in 4 Lo range only. This range is for extra pulling operating ranges plus a NEUTRAL position. A low power in off road situations. Low range reduction range system provides a reduction ratio for increased ratio is 2.72:1. low speed torque capability. The geartrain is mounted in two aluminum case SHIFT MECHANISM halves attached with bolts. The mainshaft front and Operating ranges are selected with a floor mounted rear bearings are mounted in aluminum retainer shift lever. The shift lever is connected to the trans- housings bolted to the case halves. fer case range lever by an adjustable linkage rod. A OPERATING RANGES straight line shift pattern is used. Range positions are marked on the shifter bezel cover plate. Transfer case operating ranges are: • 2WD (2-wheel drive) • 4x4 (4-wheel drive) • 4 Lo (4-wheel drive low range The 2WD range is for use on any road surface at any time. TJ TRANSFER CASE - NV231 21 - 195 TRANSFER CASE - NV231 (Continued) IDENTIFICATION A circular ID tag is attached to the rear case of each transfer case (Fig. 1). The ID tag provides the transfer case model number, assembly number, serial number, and low range ratio. The transfer case serial number also represents the date of build. OPERATION The input gear is splined to the transmission output shaft. The input gear drives the mainshaft through the planetary assembly and range hub. The front output shaft is operated by a drive chain that connects the shaft to a drive sprocket on the mainshaft. The drive sprocket is engaged/disengaged by the mode fork, which operates the mode sleeve and hub. The sleeve and hub are not equipped with a Fig. 1 Fill/Drain Plug And I.D. Tag Locations - synchronizer mechanism for shifting. Typical 1 - I.D. TAG 2 - FILL PLUG 3 - DRAIN PLUG

DIAGNOSIS AND TESTING - TRANSFER CASE - NV231

DIAGNOSIS CHART

Condition Possible Cause Correction

Transfer case difficult to shift or will 1) Vehicle speed to great to permit 1) Slow vehicle and shift into not shift into desired range. shifting. desired range.

2) If vehicle was operated for an 2) Stop vehicle and shift transfer extended period in 4H mode on dry case to Neutral position. Transfer surface, driveline torque load may case can then be shifted to the cause difficulty. desired mode. 3) Transfer case shift linkage 3) Repair or replace linkage as binding. necessary. 4) Insufficient or incorrect lubricant. 4) Drain and refill transfer case with the correct type and quantity of lubricant. 5) Internal transfer case 5) Repair or replace components as components binding, worn, or necessary. damaged.

Transfer case noisy in all drive 1) Insufficient or incorrect lubricant. 1) Drain and refill transfer case with modes. the correct type and quantity of lubricant. 21 - 196 TRANSFER CASE - NV231 TJ TRANSFER CASE - NV231 (Continued)

Condition Possible Cause Correction

Transfer case noisy while in, or 1) Transfer case not completely 1) Slow vehicle, shift transfer case jumps out of, 4L mode. engaged in 4L position. to the Neutral position, and then shift into the 4L mode.

2) Transfer case shift linkage out of 2) Adjust linkage as necessary. adjustment. 3) Transfer case shift linkage loose 3) Repair, replace, or tighten linkage or binding. components as necessary. 4) Range fork damaged, inserts 4) Repair or replace components as worn, or fork is binding on the shift necessary. rail. 5) Low range gear worn or 5) Repair or replace components as damaged. necessary.

Lubricant leaking from transfer case 1) Transfer case overfilled. 1) Drain lubricant to the correct seals or vent. level.

2) Transfer case vent closed or 2) Clean or replace vent as restricted. necessary. 3) Transfer case seals damaged or 3) Replace suspect seal. installed incorrectly.

Abnormal tire wear. 1) Extended operation in 4H mode 1) Operate vehicle in 2H mode on on dry surfaces, dry surfaces.

REMOVAL (1) Shift transfer case into NEUTRAL. (2) Raise vehicle. (3) Drain transfer case lubricant. (4) Mark front and rear propeller shaft yokes for alignment reference. (5) Support transmission with jack stand. (6) Remove rear crossmember, or skid plate. (7) Disconnect front/rear propeller shafts at transfer case. (8) Disconnect vehicle speed sensor wires. (9) Disconnect transfer case linkage rod from range lever. (10) Disconnect transfer case vent hose (Fig. 2) and indicator switch harness, if necessary. (11) Support transfer case with transmission jack. (12) Secure transfer case to jack with chains. Fig. 2 Transfer Case Mounting (13) Remove nuts attaching transfer case to trans- 1 - VENT TUBE 2 - TRANSFER CASE mission. 3 - TRANSMISSION (14) Pull transfer case and jack rearward to disengage transfer case. DISASSEMBLY (15) Remove transfer case from under vehicle. Position transfer case on shallow drain pan. Remove drain plug and drain lubricant remaining in case. TJ TRANSFER CASE - NV231 21 - 197 TRANSFER CASE - NV231 (Continued) REAR RETAINER AND OIL PUMP (1) Remove the speedometer adapter. (2) Spread band clamp which holds output shaft boot to the output shaft slinger, or output shaft damper, with a suitable awl, or equivalent.

NOTE: Vehicles built with a 4.0L engine and a manual transmission use a damper weight on the transfer case output shaft. Be sure to identify the transfer case before proceeding.

(3) Remove output shaft boot from slinger, or output shaft damper, and output shaft. (4) If the vehicle is not equipped with an output shaft damper, remove the output shaft rear slinger Fig. 4 Rear Retainer Seal using Puller MD-998056-A (Fig. 3). 1 - REAR RETAINER 2 - OUTPUT SHAFT SEAL

Fig. 3 Rear Slinger Removal Fig. 5 Output Shaft Rear Bearing Retaining Ring 1 - TRANSFER CASE 1 - SNAP-RING PLIERS 2 - SPECIAL TOOL MD-998056-A 2 - REAR BEARING I.D. RETAINING RING 3 - SLINGER

(5) If the vehicle is equipped with an output shaft damper, use Screws 8421 and the puller yoke and forcing screw from a bolt-grip puller set, such as those used to remove steering wheels and harmonic balancers, to remove the transfer case output shaft damper. (6) Use a suitable pry tool, or a slide hammer mounted screw, to remove the seal from the rear retainer (Fig. 4). (7) Remove the rear output bearing I.D. retaining ring (Fig. 5). (8) Remove the bolts holding the rear retainer to the rear case half. (9) Tap rear retainer with rawhide or rubber mallet to loosen sealer bead. Fig. 6 Rear Retainer Removal (10) Remove rear retainer from rear case half (Fig. 1 - MAINSHAFT 6). 2 - REAR RETAINER (11) Remove snap-ring holding oil pump in position on output shaft. 21 - 198 TRANSFER CASE - NV231 TJ TRANSFER CASE - NV231 (Continued)

(12) Disengage oil pickup tube from oil pump and (3) Remove yoke. If yoke is difficult to remove by remove oil pump assembly. Remove oil pump by tilt- hand, remove it with bearing splitter, or with stan- ing the edge of the oil pump from under the edge of dard two jaw puller (Fig. 10). Be sure puller tool is the rear case half and sliding the pump (Fig. 7). positioned on yoke and not on slinger as slinger will be damaged.

Fig. 7 Oil Pump Removal 1 - OIL PUMP

(13) Remove pick-up tube o-ring from oil pump (Fig. 8), if necessary. Do not disassemble the oil pump, it is not serviceable. Fig. 9 Yoke Nut Removal 1 - IMPACT WRENCH 2 - SOCKET 3 - YOKE

Fig. 8 Pick-up Tube O-ring Location 1 - OIL PUMP 2 - O-RING

YOKE AND RANGE LEVER Fig. 10 Yoke Removal (1) Remove transfer case indicator switch. (2) Remove front yoke nut as follows: 1 - PULLER TOOL 2 - YOKE (a) Move range lever to 4L position. (b) Then remove nut with socket and impact wrench (Fig. 9). TJ TRANSFER CASE - NV231 21 - 199 TRANSFER CASE - NV231 (Continued)

(4) Remove seal washer from front output shaft. Discard washer as it should not be reused. (5) Remove nut and washer that attach range lever to sector shaft. Then move sector to neutral position and remove range lever from shaft (Fig. 11).

Fig. 11 Range Lever Removal Fig. 13 Loosening Rear Case - Typical 1 - RANGE LEVER 1 - REAR CASE 2 - SECTOR SHAFT 2 - PRY TOOL (IN CASE SLOT) 3 - FRONT CASE

FRONT OUTPUT SHAFT AND DRIVE CHAIN (5) Remove oil pickup tube from rear case (Fig. (1) Support transfer case so rear case is facing 14). upward. (6) Remove mode fork spring (Fig. 15). (2) Remove bolts holding front case to rear case. (7) Pull front output shaft upward and out of front The case alignment bolts require flat washers (Fig. output shaft bearing (Fig. 16). 12). (8) Remove front output shaft and chain. (3) Loosen rear case with flat blade screwdriver to break sealer bead. Insert pry tool blade only into notches provided at each end of case (Fig. 13). (4) Remove rear case from front case.

Fig. 14 Oil Pickup Tube Removal 1 - CONNECTING HOSE 2 - PICKUP SCREEN 3 - PICKUP TUBE Fig. 12 Rear Case Alignment Bolt Locations 1 - DOWEL BOLT AND WASHER (2) 2 - CASE BOLT (5) 3 - SPLINE HEAD BOLT (1) 21 - 200 TRANSFER CASE - NV231 TJ TRANSFER CASE - NV231 (Continued)

Fig. 17 Detent Plug, Spring And Plunger Removal Fig. 15 Mode Fork Spring Removal 1 - POPPET 1 - MODE SPRING 2 - SPRING 3 - SCREW 4 - POPPET BORE (IN CASE)

(3) Remove mode fork and sleeve as an assembly (Fig. 18). Note position of sleeve for assembly reference. The short side of the sleeve faces upward. (4) Remove range fork and hub as an assembly (Fig. 19). Note fork position for installation reference. (5) Remove shift sector from front case (Fig. 20). (6) Remove shift sector bushing and O-ring (Fig. 21).

Fig. 16 Remove Front Output Shaft And Chain 1 - DRIVE CHAIN 2 - FRONT OUTPUT SHAFT 3 - SHAFT FRONT BEARING

SHIFT FORKS AND MAINSHAFT Fig. 18 Mode Fork And Sleeve Removal 1 - MODE SLEEVE (1) Remove detent plug, O-ring, detent spring and 2 - MODE FORK AND RAIL detent plunger (Fig. 17). (2) Remove mainshaft from mode sleeve and input gear pilot bearing. TJ TRANSFER CASE - NV231 21 - 201 TRANSFER CASE - NV231 (Continued) MAINSHAFT (1) Remove mode hub retaining ring with heavy duty snap-ring pliers (Fig. 22). (2) Slide mode hub off mainshaft (Fig. 23). (3) Slide drive sprocket off mainshaft (Fig. 24).

Fig. 19 Range Fork And Sleeve Removal 1 - RANGE HUB 2 - RANGE FORK

Fig. 22 Mode Hub Retaining Ring Removal 1 - MODE HUB 2 - SNAP-RING PLIERS (HEAVY DUTY) 3 - MODE HUB RETAINING RING

Fig. 20 Shift Sector Removal 1 - SHIFT SECTOR

Fig. 23 Mode Hub Removal 1 - MAINSHAFT 2 - MODE HUB

Fig. 21 Sector Bushing And O-Ring Removal 1 - SEAL RETAINER 2 - SECTOR SHAFT BORE 3 - O-RING SEAL 21 - 202 TRANSFER CASE - NV231 TJ TRANSFER CASE - NV231 (Continued)

Fig. 24 Drive Sprocket Removal 1 - DRIVE SPROCKET 2 - MAINSHAFT Fig. 26 Front Bearing Retainer Removal INPUT GEAR AND LOW RANGE GEAR 1 - FRONT BEARING RETAINER (1) Remove front bearing retainer attaching bolts 2 - RETAINER SLOT (Fig. 25). (2) Remove front bearing retainer. Pry retainer (4) Remove input gear retaining ring with heavy loose with pry tool positioned in slots at each end of duty snap-ring pliers (Fig. 27) retainer (Fig. 26).

Fig. 27 Removing Input Gear Retaining Ring Fig. 25 Front Bearing Retainer Bolts 1 - INPUT GEAR BEARING RETAINING RING 1 - FRONT CASE 2 - INPUT GEAR BEARING 2 - FRONT BEARING RETAINER 3 - SNAP-RING PLIERS 3 - RETAINER BOLTS

(3) Remove front bearing retainer seal. Tap seal out with drift and hammer. TJ TRANSFER CASE - NV231 21 - 203 TRANSFER CASE - NV231 (Continued)

(5) Place front case in horizontal position. Then remove input gear and low range gear as an assembly (Fig. 28). Tap gear out of bearing with plastic mallet if necessary.

Fig. 30 Input Gear Retainer Removal 1 - INPUT GEAR 2 - LOW RANGE GEAR 3 - RETAINER

Fig. 28 Input Gear And Planetary Carrier Removal 1 - PLANETARY ASSEMBLY 2 - INPUT GEAR

INPUT AND LOW RANGE GEAR (1) Remove snap-ring that retains input gear in low range gear (Fig. 29). (2) Remove retainer (Fig. 30). (3) Remove front tabbed thrust washer (Fig. 31). (4) Remove input gear (Fig. 32). (5) Remove rear tabbed thrust washer from low range gear (Fig. 33).

Fig. 31 Front Tabbed Thrust Washer Removal 1 - FRONT TABBED THRUST WASHER

Fig. 29 Input Gear Snap-Ring Removal 1 - CARRIER LOCK RETAINING RING 2 - INPUT GEAR 3 - PLANETARY CARRIER 4 - SCREWDRIVER Fig. 32 Input Gear Removal 1 - INPUT GEAR 2 - LOW RANGE GEAR 21 - 204 TRANSFER CASE - NV231 TJ TRANSFER CASE - NV231 (Continued) INSPECTION

MAINSHAFT/SPROCKET/HUB Inspect the splines on the hub and shaft and the teeth on the sprocket (Fig. 34). Minor nicks and scratches can be smoothed with an oilstone. However, replace any part that is damaged. Check the contact surfaces in the sprocket bore and on the mainshaft. Minor nicks and scratches can be smoothed with 320-400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe. INPUT GEAR AND PLANETARY CARRIER Check the teeth on the gear (Fig. 35). Minor nicks can be dressed off with an oilstone but replace the Fig. 33 Rear Tabbed Thrust Washer Removal gear if any teeth are broken, cracked, or chipped. The 1 - LOW RANGE GEAR bearing surface on the gear can be smoothed with 2 - REAR TABBED THRUST WASHER 300-400 grit emery cloth if necessary. Examine the carrier body and pinion gears for CLEANING wear or damage. The carrier will have to be replaced Clean the transfer case parts with a standard as an assembly if the body, pinion pins, or pinion parts cleaning solvent. Remove all traces of sealer gears are damaged. from the cases and retainers with a scraper and Check the lock ring and both thrust washers for 3M™ all purpose cleaner. Use compressed air to wear or cracks. Replace them if necessary. Also remove solvent residue from oil feed passages in the replace the lock retaining ring if bent, distorted, or case halves, retainers, gears, and shafts. broken.

Fig. 34 Mainshaft, Mode Hub, And Drive Sprocket 1 - MODE HUB 3 - MAINSHAFT 2 - DRIVE SPROCKET 4 - MODE HUB RETAINING RING TJ TRANSFER CASE - NV231 21 - 205 TRANSFER CASE - NV231 (Continued)

Fig. 35 Input Gear And Carrier Components 1 - PLANETARY CARRIER 4 - CARRIER LOCK RING 2 - REAR THRUST WASHER 5 - CARRIER LOCK RETAINING RING 3 - FRONT THRUST WASHER 6 - INPUT GEAR

SHIFT FORKS/HUBS/SLEEVES Check condition of the shift forks and mode fork shift rail (Fig. 36). Minor nicks on the shift rail can be smoothed with 320-400 grit emery cloth.

Fig. 37 Shift Fork And Wear Pad Locations 1 - RANGE FORK 2 - MODE FORK 3 - WEAR PADS (SERVICEABLE) 4 - WEAR PADS (NON-SERVICEABLE)

Check both of the sleeves for wear or damage, Fig. 36 Shift Forks especially on the interior teeth. Replace the sleeves if 1 - RANGE FORK wear or damage is evident. 2 - MODE FORK AND RAIL 3 - MODE SPRING

Inspect the shift fork wear pads (Fig. 37). The mode fork pads are serviceable and can be replaced if necessary. The range fork pads are not serviceable. The fork must be replaced as an assembly if the pads are worn or damaged. 21 - 206 TRANSFER CASE - NV231 TJ TRANSFER CASE - NV231 (Continued) REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT Inspect the shaft threads, sprocket teeth, and bear- Inspect the retainer components (Fig. 38). Replace ing surfaces. Minor nicks on the teeth can be the bearing if rough or noisy. Check the retainer for smoothed with an oilstone. Use 320-400 grit emery to cracks or wear in the bearing bore. Clean the smooth minor scratches on the shaft bearing sur- retainer sealing surfaces with a scraper and 3M™ all faces. Rough threads on the shaft can be chased if purpose cleaner. This will ensure proper adhesion of necessary. Replace the shaft if the threads are dam- the sealer during reassembly. aged, bearing surfaces are scored, or if any sprocket An output shaft slinger is used on some vehicles, teeth are cracked or broken. while an output shaft damper is used on other vehi- Examine the drive chain and shaft bearings. cles. The output shaft slinger and seal should be Replace the chain and both sprockets if the chain is replaced outright; do not reuse either part. stretched, distorted, or if any of the links bind. Replace any part if distorted, bent, or broken. Also Replace the bearings if rough, or noisy. replace the boot if cut or torn. Replace the boot band clamps, do not reuse them. LOW RANGE ANNULUS GEAR Inspect annulus gear condition carefully. The gear REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN is only serviced as part of the front case. If the gear Check condition of the seal contact surfaces of the is damaged, it will be necessary to replace the gear yoke slinger (Fig. 39). This surface must be clean and and front case as an assembly. Do not attempt to smooth to ensure proper seal life. Replace the yoke remove the gear (Fig. 40) nut and seal washer as neither part should be reused.

Fig. 38 Rear Retainer Without Output Shaft Damper 1 - REAR RETAINER 5 - BAND CLAMPS 2 - REAR BEARING I.D. MAINSHAFT RETAINING RING 6 - REAR SLINGER 3 - REAR SEAL 7 - REAR BEARING O.D. RETAINING RING 4 - BOOT 8 - REAR BEARING TJ TRANSFER CASE - NV231 21 - 207 TRANSFER CASE - NV231 (Continued)

Or the threads can be repaired with Helicoil™ stain- less steel inserts if required. OIL PUMP/OIL PICKUP Examine the oil pump pickup parts. Replace the pump if any part appears to be worn or damaged. Do not disassemble the pump as individual parts are not available. The pump is only available as a complete assembly. The pickup screen, hose, and tube are the only serviceable parts and are available separately. ASSEMBLY Lubricate transfer case components with Mopar௡ ATF +4, type 9602, Automatic Transmission Fluid or petroleum jelly (where indicated) during assembly.

Fig. 39 Seal Contact Surface Of Yoke Slinger BEARINGS AND SEALS 1 - FRONT SLINGER (PART OF YOKE) 2 - SEAL CONTACT SURFACE MUST BE CLEAN AND SMOOTH CAUTION: The bearing bores in various transfer case components contain oil feed holes. Make sure replacement bearings do not block the holes.

(1) Remove the front output shaft seal from case with pry tool (Fig. 41). (2) Remove the front output shaft bearing retaining ring with screwdriver (Fig. 42). (3) Remove bearing with Tool Handle C-4171 and Tool 5065 (Fig. 43).

Fig. 40 Low Range Annulus Gear 1 - FRONT CASE 2 - LOW RANGE ANNULUS GEAR

FRONT/REAR CASES AND FRONT RETAINER Inspect the cases and retainer for wear and damage. Clean the sealing surfaces with a scraper and 3M™ all purpose cleaner. This will ensure proper sealer adhesion at assembly. Replace the input Fig. 41 Front Output Seal Removal - Typical retainer seal; do not reuse it. 1 - OUTPUT SHAFT SEAL Check case condition. If leaks were a problem, look 2 - PRYBAR for gouges and severe scoring of case sealing surfaces. Also make sure the front case mounting studs are in good condition. Check the front case mounting studs and vent tube. The tube can be secured with Loctite™ 271 or 680 if loose. The stud threads can be cleaned up with a die if necessary. Also check condition of the fill/ drain plug threads in the rear case. The threads can be repaired with a thread chaser or tap if necessary. 21 - 208 TRANSFER CASE - NV231 TJ TRANSFER CASE - NV231 (Continued)

Fig. 44 Front Output Shaft Bearing Installation Fig. 42 Front Output Shaft Bearing Retaining Ring Removal 1 - SPECIAL TOOL C-4171 2 - SPECIAL TOOL 5064 1 - SCREWDRIVERS 2 - SNAP-RING 3 - FRONT OUTPUT SHAFT BEARING 4 - FRONT CASE

Fig. 45 Installing Output Shaft Front Bearing Retaining Ring 1 - WORK RETAINING RING INTO BORE GROOVE WITH SMALL SCREWDRIVER

Fig. 43 Front Output Shaft Bearing Removal 1 - FRONT CASE 2 - SPECIAL TOOL C-4171 3 - SPECIAL TOOL 5065

(4) Install front output shaft front bearing in case with Tool Handle C-4171 and Installer 5064 (Fig. 44). (5) Install output shaft front bearing retaining ring (Fig. 45). Start ring into place by hand. Then use small screwdriver to work ring into case groove. Be sure ring is fully seated before proceeding. (6) Install new front output seal in front case with Installer Tool 8143-A as follows: Fig. 46 Front Output Seal Installation - Typical (a) Place new seal on tool. Garter spring on 1 - INSTALLER 8143-A seal goes toward interior of case. 2 - TRANSFER CASE (b) Start seal in bore with light taps from hammer (Fig. 46). Once seal is started, continue tap- (7) Remove the output shaft rear bearing with the ping seal into bore until installer tool bottoms screw and jaws from Remover L-4454 and Cup 8148 against case. (Fig. 47). TJ TRANSFER CASE - NV231 21 - 209 TRANSFER CASE - NV231 (Continued)

(8) Install new bearing with Tool Handle C-4171 and Installer 5066 (Fig. 48). The bearing bore is chamfered at the top. Install the bearing so it is flush with the lower edge of this chamfer (Fig. 49).

Fig. 49 Output Shaft Rear Bearing Installation Depth 1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER 2 - CHAMFER

(9) Using Remover C-4210 and Handle C-4171, drive input shaft bearing from inside the annulus gear opening in the case (Fig. 50).

Fig. 47 Output Shaft Rear Bearing Removal 1 - REAR CASE 2 - SPECIAL TOOL L-4454-1 AND L-4454-3 3 - SPECIAL TOOL 8148

Fig. 50 Input Shaft Bearing Removal 1 - SPECIAL TOOL C-4171 2 - SPECIAL TOOL C-4210

(10) Install locating ring on new bearing. (11) Position case so forward end is facing upward. (12) Using Remover C-4210 and Handle C-4171, drive input shaft bearing into case. The bearing locating ring must be fully seated against case surface (Fig. 51). (13) Remove input gear pilot bearing by inserting a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer (Fig. 52). Fig. 48 Output Shaft Rear Bearing Installation (14) Install new pilot bearing with Installer 5065 1 - HANDLE C-4171 and Handle C-4171 (Fig. 53). 2 - OUTPUT SHAFT INNER BEARING (15) Remove front bearing retainer seal with suit- 3 - INSTALLER 5066 able pry tool. 21 - 210 TRANSFER CASE - NV231 TJ TRANSFER CASE - NV231 (Continued)

Fig. 51 Seating Input Shaft Bearing 1 - SNAP-RING 2 - INPUT SHAFT BEARING Fig. 53 Install Input Gear Pilot Bearing 1 - SPECIAL TOOL C-4171 2 - SPECIAL TOOL 5065 3 - INPUT GEAR

Fig. 52 Remove Input Gear Pilot Bearing 1 - DRIFT 2 - INPUT GEAR Fig. 54 Install Front Bearing Retainer Seal (16) Install new front bearing retainer seal with 1 - FRONT BEARING RETAINER Installer 7884 (Fig. 54). 2 - SPECIAL TOOL 7884 (17) Remove seal from oil pump housing with a suitable pry tool (20) Install rear bearing in retainer with Handle (18) Install new seal in oil pump housing with C-4171 and Installer 5064 (Fig. 56). Installer 7888 (Fig. 55). (19) Remove rear retainer bearing with Installer 8128 and Handle C-4171. TJ TRANSFER CASE - NV231 21 - 211 TRANSFER CASE - NV231 (Continued)

Fig. 55 Oil Pump Seal Installation 1 - HOUSING SEAL 2 - SPECIAL TOOL 7888 3 - OIL PUMP FEED HOUSING

Fig. 57 Input/Low Range Gear Components 1 - SNAP-RING 2 - RETAINER PLATE 3 - INPUT GEAR 4 - LOW RANGE GEAR 5 - THRUST WASHERS

INPUT GEAR AND LOW RANGE GEAR (1) Align and install low range/input gear assembly in front case (Fig. 58). Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing. (2) Install snap-ring to hold input/low range gear into front bearing (Fig. 59).

Fig. 56 Installing Rear Bearing In Retainer 1 - SPECIAL TOOL C-4171 2 - SPECIAL TOOL 5064 3 - REAR RETAINER

INPUT AND LOW RANGE GEAR (1) Install first thrust washer in low range gear (Fig. 57). Be sure washer tabs are properly aligned in gear notches. (2) Install input gear in low range gear. Be sure input gear is fully seated. (3) Install remaining thrust washer in low range gear and on top of input gear. Be sure washer tabs are properly aligned in gear notches. (4) Install retainer on input gear and install snap- ring. Fig. 58 Input/Low Range Gear Installation 1 - ANNULUS GEAR 2 - INPUT/LOW RANGE GEAR 21 - 212 TRANSFER CASE - NV231 TJ TRANSFER CASE - NV231 (Continued) MAINSHAFT (1) Lubricate mainshaft splines with recommended transmission fluid. (2) Slide drive sprocket onto mainshaft. (3) Slide mode hub onto mainshaft. (4) Install mode hub retaining ring. Verify that the retaining ring is fully seated in mainshaft groove. SHIFT FORKS AND MAINSHAFT (1) Install new sector shaft O-ring and bushing (Fig. 61).

Fig. 59 Install Snap-Ring 1 - INPUT GEAR 2 - SNAP-RING

(3) Clean gasket sealer residue from retainer and inspect retainer for cracks or other damage. (4) Applya3mm(1/8 in.) bead of Mopar௡ gasket maker or silicone adhesive to sealing surface of retainer. (5) Align cavity in seal retainer with fluid return hole in front of case.

CAUTION: Do not block fluid return cavity on sealing surface of retainer when applying Moparா gasket maker or silicone adhesive sealer. Seal failure and fluid leak can result. Fig. 61 Sector O-Ring And Bushing Installation (6) Install bolts to hold retainer to transfer case (Fig. 60). Tighten to 21 N·m (16 ft. lbs.) of torque. 1 - SECTOR BUSHING 2 - O-RING

(2) Install shift sector in case (Fig. 62). Lubricate sector shaft with transmission fluid before installation.

Fig. 60 Install Front Bearing Retainer 1 - FRONT BEARING RETAINER Fig. 62 Shift Sector Installation 1 - SHIFT SECTOR TJ TRANSFER CASE - NV231 21 - 213 TRANSFER CASE - NV231 (Continued)

(3) Install range lever, washer, and nut on sector shaft (Fig. 63). Tighten range lever nut to 27-34 N·m (20-25 ft. lbs.) torque.

Fig. 65 Mainshaft Assembly Installation 1 - DRIVE SPROCKET 2 - MODE HUB 3 - MAINSHAFT Fig. 63 Range Lever Installation 1 - RANGE LEVER 2 - LEVER NUT

(4) Assemble and install range fork and hub (Fig. 64). Be sure hub is properly seated in low range gear and engaged to the input gear. (5) Align and insert range fork pin in shift sector slot.

Fig. 66 Assembling Mode Fork And Sleeve 1 - MODE SLEEVE 2 - MODE FORK AND RAIL

Fig. 64 Install Range Fork And Sleeve Assembly 1 - RANGE HUB 2 - RANGE FORK

(6) Install assembled mainshaft (Fig. 65). Be sure shaft is seated in pilot bearing and input gear. (7) Install new pads on mode fork if necessary. (8) Insert mode sleeve in mode fork mode fork. Be sure long side of sleeve is toward long end of shift rail (Fig. 66). (9) Install assembled mode fork and sleeve (Fig. 67). Be sure fork rail goes through range fork and Fig. 67 Mode Fork And Sleeve Installation into case bore. Also be sure sleeve is aligned and 1 - MODE SLEEVE seated on mainshaft hub. 2 - MODE FORK AND RAIL (10) Rotate sector to NEUTRAL position. 21 - 214 TRANSFER CASE - NV231 TJ TRANSFER CASE - NV231 (Continued)

(11) Install new O-ring on detent plug (Fig. 68). (12) Lubricate detent plunger with transmission fluid or light coat of petroleum jelly. (13) Install detent plunger, spring and plug (Fig. 68). (14) Verify that plunger is properly engaged in sector.

Fig. 69 Installing Drive Chain And Front Output Shaft Fig. 68 Shift Detent Components 1 - FRONT OUTPUT SHAFT 1 - POPPET 2 - DRIVE CHAIN 2 - SPRING 3 - MAINSHAFT 3 - SCREW 4 - DRIVE SPROCKET 4 - POPPET BORE (IN CASE)

FRONT OUTPUT SHAFT AND DRIVE CHAIN (1) Lubricate front output shaft-sprocket assembly, drive chain, and drive sprocket with transmission fluid. (2) Assemble drive chain and front output shaft (Fig. 69). (3) Start chain on mainshaft drive sprocket. (4) Guide front shaft into bearing and drive sprocket onto mainshaft drive gear (Fig. 69). (5) Install mode spring on upper end of mode fork shift rail (Fig. 70). OIL PUMP AND REAR CASE (1) Install magnet in front case pocket (Fig. 71). (2) Assemble oil pickup screen, connecting hose, and tube. Fig. 70 Install Mode Fork Spring (3) Install new pickup tube O-ring in oil pump (Fig. 72). 1 - MODE SPRING (4) Insert oil pickup tube in oil pump inlet. (5) Position assembled oil pump and pickup tube in rear case. Be sure pickup screen is securely seated in case slot. Also be sure oil pump locating tabs are outside rear case (Fig. 73). TJ TRANSFER CASE - NV231 21 - 215 TRANSFER CASE - NV231 (Continued)

(6) Apply 3 mm (1/8 in.) wide bead of Mopar௡ gasket maker or silicone adhesive sealer to mounting flange of front case. Work sealer bead around bolt holes. (7) Lift rear case and oil pump and carefully position assembly on front case. Be sure case dowels are aligned and that mode fork rail extends through rear case before seating rear case on front case. (8) Install case attaching bolts. Alignment bolts at each end of case are only ones requiring washers (Fig. 74). (9) Tighten case bolts to 27-34 N·m (20-25 ft. lbs.) torque.

Fig. 71 Installing Case Magnet 1 - MAGNET

Fig. 74 Alignment Bolt Location 1 - ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)

YOKE AND RANGE LEVER (1) Install indicator switch in front case. Tighten switch to 20-34 N·m (15-25 ft. lbs.) torque. (2) Install range lever, washer and locknut on sector shaft (Fig. 75). Tighten locknut to 27-34 N·m (20-25 ft. lbs.) torque.

Fig. 72 Pickup Tube O-Ring Position 1 - OIL PUMP 2 - O-RING

Fig. 75 Range Lever Installation 1 - RANGE LEVER 2 - WASHER Fig. 73 Oil Pump And Pickup Tube Installation 3 - LOCKNUT 1 - OIL PUMP 2 - PICKUP TUBE 3 - PICKUP SCREEN AND CONNECTOR 21 - 216 TRANSFER CASE - NV231 TJ TRANSFER CASE - NV231 (Continued)

(3) Install new seal washer on front output shaft (5) Slide seal onto Seal Protector 6992 (Fig. 78). (Fig. 77). Slide seal protector and seal onto output shaft. (4) Lubricate yoke hub with transmission fluid and (6) Slide Installer C-4076-B onto seal protector install yoke on front shaft. with the recessed side of the tool toward the seal. (5) Install new seal washer on front shaft. Drive seal into rear bearing retainer with Installer (6) Install yoke and new yoke nut on front output C-4076-B and Handle MD-998323 (Fig. 79). shaft (Fig. 76). (7) Tighten yoke nut to 122-176 N·m (90-130 ft. lbs.) torque. Use Tool C-3281, or similar tool to hold yoke while tightening yoke nut.

Fig. 78 Output Shaft Seal and Protector 1 - OUTPUT SHAFT SEAL 2 - SPECIAL TOOL 6992 3 - TRANSFER CASE Fig. 76 Output Shaft Yoke Installation 1 - OUTPUT SHAFT YOKE 2 - YOKE NUT

Fig. 77 Seal Washer Installation 1 - YOKE SEAL WASHER Fig. 79 Rear Seal Installation REAR RETAINER 1 - SPECIAL TOOL C-4076-B (1) Apply bead of Mopar௡ Sealer P/N 82300234, or 2 - SPECIAL TOOL MD-998323 3 - TRANSFER CASE Loctite™ Ultra Gray, to mating surface of rear retainer. Sealer bead should be a maximum of 3/16 NOTE: Vehicles built with a 4.0L engine and a man- inch. ual transmission use a damper weight on the trans- (2) Install rear retainer on rear case. Tighten fer case output shaft. Be sure to identify the retainer bolts to 20-27 N·m (15-20 ft. lbs.) torque. transfer case before proceeding. (3) Install rear bearing I.D. retaining ring and spacer on output shaft. (7) Install a new output shaft rear slinger with (4) Apply liberal quantity of petroleum jelly to new Installer 8408, if the vehicle is not equipped with an rear seal and to output shaft. Petroleum jelly is output shaft damper. needed to protect seal lips during installation. TJ TRANSFER CASE - NV231 21 - 217 TRANSFER CASE - NV231 (Continued)

(8) If the vehicle is equipped with an output shaft damper, install the output shaft damper as follows: (a) Position the damper weight on the output shaft. Start the damper onto the output shaft chamfer, being careful to keep the weight square to the output shaft. (Fig. 80) (b) Position the driver portion of Installer 8422 (Fig. 81) onto the damper, making sure the legs of the damper are positioned through the slots of the damper. (c) Thread the puller screw of Installer 8422 into the output shaft by hand only. Make sure the screw is fully threaded into the output shaft. (d) Using a wrench to hold the pulling screw stationary (Fig. 82), turn the pulling screw nut until the driver legs contact the rear face of the transfer case rear retainer. When the legs contact the Fig. 81 Driver Installer 8422 retainer, the damper is properly positioned on the 1 - Pulling Screw output shaft. 2 - Pulling Screw Nut 3 - Bearing 4 - Driver Legs 5 -Installer Driver

Fig. 80 Position Damper on Output Shaft 1 - Transfer Case 2 - Output Shaft 3 - Damper Weight Fig. 82 Install Damper 4 - Chamfer 1 - Damper 2 - Installer Driver (9) Install boot on output shaft slinger, or output 3 - Pulling Screw Nut shaft damper, and crimp retaining clamp with tool 4 - Pulling Screw C-4975-A (Fig. 83). 21 - 218 TRANSFER CASE - NV231 TJ TRANSFER CASE - NV231 (Continued)

(3) Position transfer case under vehicle. (4) Align transfer case and transmission shafts and install transfer case on transmission. (5) Install and tighten transfer case attaching nuts to 35 N·m (26 ft. lbs.) torque (Fig. 2). (6) Connect vehicle speed sensor wires, and vent hose. (7) Connect indicator switch harness to transfer case switch, if necessary. Secure wire harness to clips on transfer case. (8) Align and connect propeller shafts. Refer to Differential and Driveline for proper procedures and specifications. (9) Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary. (10) Install rear crossmember, or skid plate. Fig. 83 Slinger Boot Installation - Typical Tighten crossmember bolts to 41 N·m (30 ft. lbs.) 1 - SPECIAL TOOL C-4975–A torque. 2 - SLINGER (11) Remove transmission jack and support stand. 3 - BOOT (12) Connect shift rod to transfer case range lever. 4 - CLAMP (13) Adjust transfer case shift linkage. INSTALLATION (14) Lower vehicle and verify transfer case shift operation. (1) Mount transfer case on a transmission jack. (2) Secure transfer case to jack with chains.

SPECIFICATIONS

TRANSFER CASE - NV231

TORQUE

DESCRIPTION N·m Ft. Lbs. In. Lbs. Plug, Detent 16-24 12-18 - Plug, Drain/Fill 20-34 15-25 - Bolt, Front Brg. Retainer 21 16 - Bolt, Case Half 27-34 20-25 - Nut, Front Yoke 122-176 90-130 - Nut, Range Lever 27-34 20-25 - Bolt, Rear Retainer 35-46 26-34 - Nuts, Mounting 35-47 26-35 - Switch, Indicator 20-34 15-25 - TJ TRANSFER CASE - NV231 21 - 219 TRANSFER CASE - NV231 (Continued) SPECIAL TOOLS NV231

Installer, Seal - 8143-A

Installer - C-4076-B

Handle, Universal - C-4171 Puller, Slinger - MD-998056-A

Installer - MD-998323 Installer, Seal - C-4210

Protector, Seal - 8824 Installer, Bearing - 5052

Installer, Bearing - 5065 Installer, Boot Clamp - C-4975-A 21 - 220 TRANSFER CASE - NV231 TJ TRANSFER CASE - NV231 (Continued)

Installer, Bushing - 5066

Installer, Pump Housing Seal - 7888

Installer, Bearing - 8128

Installer, Transfer Case Damper Driver - 8422

Remover - L-4454

Installer, Output Shaft Slinger - 8408

Cup - 8148

Installer, Seal - 7884 TJ TRANSFER CASE - NV231 21 - 221

FLUID STANDARD PROCEDURE - FLUID DRAIN AND FILL The fill and drain plugs are both in the rear case (Fig. 84). Correct fill level is to the bottom edge of the fill plug hole. Be sure the vehicle is level to ensure an accurate fluid level check.

Fig. 85 Remove Front Output Shaft Seal - Typical 1 - OUTPUT SHAFT SEAL 2 - PRYBAR

Fig. 84 Transfer Case Identification Tag and Fill/Drain Plugs 1 - IDENTIFICATION TAG 2 - FILL PLUG 3 - DRAIN PLUG FRONT OUTPUT SHAFT SEAL REMOVAL (1) Raise vehicle. (2) Remove front propeller shaft. (Refer to 3 - DIF- FERENTIAL & DRIVELINE/PROPELLER SHAFT/ Fig. 86 Front Output Seal Installation - Typical PROPELLER SHAFT - REMOVAL) 1 - INSTALLER 8143-A (3) Remove front output shaft yoke. 2 - TRANSFER CASE (4) Remove seal from front case with pry tool (Fig. 85). REAR OUTPUT SHAFT SEAL INSTALLATION REMOVAL (1) Install new front output seal in front case with (1) Shift the transmission and transfer case into Installer Tool 8143-A as follows: NEUTRAL. (a) Place new seal on tool. Garter spring on seal (2) Raise and support vehicle. goes toward interior of case. (3) Mark a line across the pinion shaft and at each (b) Start seal in bore with light taps from ham- end of the propeller shaft for installation reference. mer (Fig. 86). Once seal is started, continue tap- (4) Remove the U-joint strap bolts at the pinion ping seal into bore until installer tool seats against shaft yoke. case. (5) Pry open clamp holding the dust boot to propeller shaft yoke (Fig. 87). (6) Slide the slip yoke off of the transmission/ transfer case output shaft and remove the propeller shaft. 21 - 222 TRANSFER CASE - NV231 TJ REAR OUTPUT SHAFT SEAL (Continued)

(10) If the vehicle is equipped with an output shaft damper, use Screws 8421 and the puller yoke and forcing screw from a bolt-grip puller set, such as those used to remove steering wheels and harmonic balancers, to remove the transfer case output shaft damper. (11) Use a suitable pry tool, or a slide hammer mounted screw, to remove the seal from the rear retainer (Fig. 89).

Fig. 87 Dust Boot Clamp 1 - SLINGER 2 - BOOT 3-AWL 4 - TRANSFER CASE

(7) Spread band clamp which holds output shaft boot to the output shaft slinger, or output shaft Fig. 89 Rear Output Shaft Seal damper, with a suitable awl, or equivalent. 1 - REAR RETAINER 2 - OUTPUT SHAFT SEAL NOTE: Vehicles built with a 4.0L engine and a manual transmission use a damper weight on the trans- INSTALLATION fer case output shaft. Be sure to identify the (1) Apply liberal quantity of petroleum jelly to new transfer case before proceeding. rear seal and to output shaft. Petroleum jelly is needed to protect seal lips during installation. (8) Remove output shaft boot from slinger, or out- (2) Slide seal onto Seal Protector 6992 (Fig. 90). put shaft damper, and output shaft. Slide seal protector and seal onto output shaft. (9) If the vehicle is not equipped with an output (3) Slide Installer C-4076-B onto seal protector shaft damper, remove the output shaft rear slinger with the recessed side of the tool toward the seal. using Puller MD-998056-A (Fig. 88). Drive seal into rear bearing retainer with Installer C-4076-B and Handle MD-998323 (Fig. 91).

Fig. 88 Rear Slinger Removal Fig. 90 Output Shaft Seal and Protector 1 - TRANSFER CASE 2 - SPECIAL TOOL MD-998056-A 1 - OUTPUT SHAFT SEAL 3 - SLINGER 2 - SPECIAL TOOL 6992 3 - TRANSFER CASE TJ TRANSFER CASE - NV231 21 - 223 REAR OUTPUT SHAFT SEAL (Continued)

Fig. 91 Rear Seal Installation 1 - SPECIAL TOOL C-4076-B Fig. 92 Position Damper on Output Shaft 2 - SPECIAL TOOL MD-998323 1 - Transfer Case 3 - TRANSFER CASE 2 - Output Shaft 3 - Damper Weight NOTE: Vehicles built with a 4.0L engine and a man- 4 - Chamfer ual transmission use a damper weight on the transfer case output shaft. Be sure to identify the transfer case before proceeding.

(4) Install a new output shaft rear slinger with Installer 8408, if the vehicle is not equipped with an output shaft damper. (5) If the vehicle is equipped with an output shaft damper, install the output shaft damper as follows: (a) Position the damper weight on the output shaft. Start the damper onto the output shaft chamfer, being careful to keep the weight square to the output shaft. (Fig. 92) (b) Position the driver portion of Installer 8422 (Fig. 93) onto the damper, making sure the legs of the damper are positioned through the slots of the damper. (c) Thread the puller screw of Installer 8422 into Fig. 93 Driver Installer 8422 the output shaft by hand only. Make sure the 1 - Pulling Screw screw is fully threaded into the output shaft. 2 - Pulling Screw Nut (d) Using a wrench to hold the pulling screw sta- 3 - Bearing 4 - Driver Legs tionary (Fig. 94), turn the pulling screw nut until 5 -Installer Driver the driver legs contact the rear face of the transfer case rear retainer. When the legs contact the retainer, the damper is properly positioned on the output shaft. 21 - 224 TRANSFER CASE - NV231 TJ REAR OUTPUT SHAFT SEAL (Continued)

(7) Slide the slip yoke on the transmission/transfer case output shaft. Align installation reference marks at the axle yoke and install the propeller shaft. (8) Tighten the U-joint strap/clamp bolts at the axle yoke to 19 N·m (14 ft. lbs.). (9) Crimp clamp with Clamp Tool C-4975A to hold dust boot to propeller shaft yoke. (10) Remove support and lower the vehicle.

SHIFT LEVER REMOVAL (1) Shift transfer case into 4L. (2) Raise vehicle. (3) Loosen adjusting trunnion locknut and slide Fig. 94 Install Damper shift rod out of trunnion (Fig. 96). If rod lacks 1 - Damper enough travel to come out of trunnion, push trunnion 2 - Installer Driver out of torque shaft. 3 - Pulling Screw Nut (4) Lower vehicle. 4 - Pulling Screw (5) Remove console. (Refer to 23 - BODY/INTERI- (6) Install boot on output shaft slinger, or output OR/FLOOR CONSOLE - REMOVAL) shaft damper, and crimp retaining clamp with tool (6) Remove screws attaching lever assembly to C-4975-A (Fig. 95). floorpan and remove assembly and shift rod (if left attached). INSTALLATION (1) If shift rod was not removed from lever assembly, work rod down through floorpan opening. Then position lever assembly on floorpan and install assembly attaching screws. (2) Install console. (Refer to 23 - BODY/INTERI- OR/FLOOR CONSOLE - INSTALLATION) (3) Raise vehicle. (4) Connect trunnion to torque shaft arm. Or, slide shift rod into trunnion on range lever. Be sure shift rod slides freely in trunnion. (5) Verify that range lever is in 4L position. Then tighten trunnion lock bolt. (6) Lower vehicle and check transfer case shift operation. Fig. 95 Slinger Boot Installation - Typical 1 - SPECIAL TOOL C-4975–A 2 - SLINGER 3 - BOOT 4 - CLAMP TJ TRANSFER CASE - NV231 21 - 225 SHIFT LEVER (Continued)

Fig. 96 Shift Linkage 1 - Rivnut (4) 8 - Torque Shaft 2 - Shift Lever Assembly 9 - Transfer Case Shift Lever 3 - Floorpan 10 - Torque Shaft Transfer Case Bracket 4 - Trunnion Lock Bolt A - 3-4 N·m (27-35 in. lbs.) 5 - Selector Rod and Trunnion B - 11-14 N·m (97-123 in. lbs.) 6 - Shift Lever Rod C - 8-14 N·m (72-120 in. lbs.) 7 - Torque Shaft Frame Bracket 21 - 226 TRANSFER CASE - NV231 TJ SHIFT LEVER (Continued) ADJUSTMENTS - SHIFT LINKAGE SPEEDOMETER DRIVE (1) Shift transfer case into 4L position. ADAPTER (2) Raise vehicle. (3) Loosen lock bolt on adjusting trunnion (Fig. 97). REMOVAL (4) Be sure linkage rod slides freely in trunnion. (1) Raise vehicle. Clean rod and apply spray lube if necessary. (2) Disconnect wires from vehicle speed sensor. (5) Verify that transfer case range lever is fully (3) Remove adapter clamp and screw (Fig. 98). engaged in 4L position. (4) Remove speed sensor and speedometer adapter (6) Tighten adjusting trunnion lock bolt. as an assembly. (7) Lower vehicle. (5) Remove speed sensor retaining screw and remove sensor from adapter. (6) Remove speedometer pinion from adapter. Replace pinion if chipped, cracked, or worn. (7) Inspect sensor and adapter O-rings (Fig. 98). Remove 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 if pins are loose, severely corroded, or damaged. INSTALLATION (1) Thoroughly clean adapter flange and adapter mounting surface in housing. Surfaces must be clean for proper adapter alignment and speedometer operation. (2) Install new O-rings on speed sensor and speedometer adapter (Fig. 98), if necessary. (3) Lubricate sensor and adapter O-rings with transmission fluid. (4) Install vehicle speed sensor in speedometer adapter. Tighten sensor attaching screw to 2-3 N·m (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. Then lubricate pinion teeth with transmission fluid. (7) Note index numbers on adapter body (Fig. 99). Fig. 97 Shift Linkage These numbers will correspond to number of teeth on 1 - TRANSFER CASE SHIFT LEVER SHAFT pinion. 2 - SEAL (8) Install speedometer assembly in housing. 3 - TRANSFER CASE SHIFT LEVER ASSEMBLY 4 - FLOORPAN (9) Rotate adapter until required range numbers 5 - TRUNNION LOCK BOLT are at 6 o-clock position. Be sure range index num- 6 - SHIFT ROD bers correspond to number of teeth on pinion gear. 7 - ADJUSTING TRUNNION 8 - TORQUE SHAFT BRACKET 9 - RANGE LEVER 10 - TORQUE SHAFT ROD 11 - TORQUE SHAFT 12 - LINKAGE BRACKET TJ TRANSFER CASE - NV231 21 - 227 SPEEDOMETER DRIVE ADAPTER (Continued)

Fig. 98 Speedometer 1 - Sensor O-ring 5 - Adapter Clamp 2 - Speedometer Adapter 6 - Vehicle Speed Sensor 3 - Adapter O-ring A - 2-3 N·m (15-27 in. lbs.) 4 - Speedometer Pinion B - 10-12 N·m (90-110 in. lbs.)

(10) Install speedometer adapter clamp and retain- VEHICLE SPEED SENSOR ing screw. Tighten clamp screw to 10-12 N·m (90-110 in. lbs.) torque. DESCRIPTION (11) Connect wires to vehicle speed sensor. The 3-wire Vehicle Speed Sensor (VSS) is located (12) Lower vehicle and top off transmission fluid on the speedometer pinion gear adapter. If equipped level if necessary. with 4WD, this adapter is located on the extension housing of the transfer case (drivers side). If equipped with 2WD, this adapter is located on the left side of the transmission extension housing. OPERATION The VSS is a 3-circuit (3–wire), magnetic, hall-ef- fect sensor. The 3 circuits are: • A 5-volt power supply from the Powertrain Con- trol Module (PCM). • A ground is provided for the sensor though a low-noise sensor return circuit in the PCM. • An input to the PCM is used to determine vehicle speed and distance traveled. The speed sensor generates 8 pulses per sensor Fig. 99 Location Of Index Numbers On Speedometer revolution. These signals, in conjunction with a Adapter closed throttle signal from the throttle position sen- 1 - SPEEDOMETER ADAPTER sor, indicate a closed throttle deceleration to the 2 - INDEX NUMBER LOCATION PCM. When the vehicle is stopped at idle, a closed throttle signal is received by the PCM (but a speed sensor signal is not received). 21 - 228 TRANSFER CASE - NV231 TJ VEHICLE SPEED SENSOR (Continued)

Under deceleration conditions, the PCM adjusts the Idle Air Control (IAC) motor to maintain a desired MAP value. Under idle conditions, the PCM adjusts the IAC motor to maintain a desired engine speed. REMOVAL The Vehicle Speed Sensor (VSS) is located on the speedometer pinion gear adapter. If equipped with 4WD, this adapter is located on the transfer case extension (left side) (Fig. 100). If equipped with 2WD, this adapter is located on the extension housing of the transmission (left side).

Fig. 101 VSS Removal/Installation 1 - ELECTRICAL CONNECTOR 2 - SENSOR MOUNTING BOLT 3 - O-RING 4 - SPEEDOMETER PINION GEAR 5 - SPEEDOMETER PINION GEAR ADAPTER 6 - O-RING 7 - VEHICLE SPEED SENSOR

(3) Remove sensor mounting bolt (Fig. 101). (4) Remove sensor (pull straight out) from speedometer pinion gear adapter (Fig. 101). Do not remove gear adapter from transmission. INSTALLATION Fig. 100 VSS Location (1) Clean inside of speedometer pinion gear 1 - SENSOR ELECTRICAL CONNECTOR adapter before installing speed sensor. 2 - SLIDE TAB (2) Install sensor into speedometer gear adapter 3 - 4WD TRANSFER CASE EXTENSION 4 - VEHICLE SPEED SENSOR and install mounting bolt. Before tightening bolt, ver- 5 - RELEASE LOCK ify speed sensor is fully seated (mounted flush) to speedometer pinion gear adapter. (1) Raise and support vehicle. (3) Tighten sensor mounting bolt to 2.2 N·m (20 in. (2) Disconnect electrical connector from sensor by lbs.) torque. pushing slide tab (Fig. 100). After slide tab has been (4) Connect electrical connector to sensor. positioned, push in on secondary release lock (Fig. 100) on side of connector and pull connector from sensor. TJ TRANSFER CASE - NV241 21 - 229

TRANSFER CASE - NV241

TABLE OF CONTENTS

page page

TRANSFER CASE - NV241 FRONT OUTPUT SHAFT SEAL DESCRIPTION ...... 229 REMOVAL ...... 256 OPERATION ...... 229 INSTALLATION ...... 257 DIAGNOSIS AND TESTING - TRANSFER POSITION SENSOR CASE ...... 230 DESCRIPTION ...... 258 REMOVAL ...... 231 OPERATION ...... 258 DISASSEMBLY ...... 231 REMOVAL ...... 259 CLEANING ...... 241 INSTALLATION ...... 259 INSPECTION ...... 241 SHIFT LEVER ASSEMBLY ...... 242 REMOVAL ...... 259 INSTALLATION ...... 253 INSTALLATION ...... 259 SPECIFICATIONS ADJUSTMENTS - SHIFT LINKAGE ...... 261 TRANSFER CASE - NV241 ...... 254 VEHICLE SPEED SENSOR SPECIAL TOOLS DESCRIPTION ...... 261 TRANSFER CASE - NV241 ...... 254 OPERATION ...... 261 REAR EXTENSION SEAL REMOVAL ...... 262 REMOVAL ...... 256 INSTALLATION ...... 262 INSTALLATION ...... 256 FLUID STANDARD PROCEDURE - FLUID DRAIN AND FILL ...... 256 TRANSFER CASE - NV241 DESCRIPTION The NV241 transfer case (Fig. 1) is a part-time transfer case with a low-range gear system. It provides three operating ranges plus a NEUTRAL position. The low range position provides a gear reduction ratio of 4.0:1 for increased low speed torque capability. The gear cases, retainer and extension are all of aluminum. Drive sprockets and an interconnecting drive chain are used to transmit engine torque to the front/rear propeller shafts. The mainshaft, input gear and front output shaft are supported by ball and needle bearings. IDENTIFICATION Fig. 1 NV241 - Front View An identification tag (Fig. 2) is attached to the rear OPERATION case of every transfer case. The tag provides the transfer case model number, assembly number, serial OPERATING RANGES number, and low range ratio. Transfer case operating ranges are: The transfer case serial number also represents • 2H (2-wheel drive) the date of build. • 4H (4-wheel drive) • 4LO (4-wheel drive low range The 2H range is for use on any road surface at any time. 21 - 230 TRANSFER CASE - NV241 TJ TRANSFER CASE - NV241 (Continued) SHIFT MECHANISM The transfer case is operated by an adjustable floor mounted shift linkage. The transfer case shift lever is directly attached to the shift sector. The sector operates the range and mode forks within the transfer case. A straight line shift pattern is used with a NEU- TRAL detent. Lever range positions are imprinted in the shift knob. SHIFTING The vehicle must have the transmission placed in NEUTRAL, or the clutch depressed in the case of a manual transmission, and be moving less than 2-3 MPH when shifting into the 4L operating range.

Fig. 2 Transfer Case Identification Tag and Fill/Drain DIAGNOSIS AND TESTING - TRANSFER CASE Plugs Before beginning repair on a suspected transfer 1 - IDENTIFICATION TAG case malfunction, check all other driveline compo- 2 - FILL PLUG nents beforehand. 3 - DRAIN PLUG The actual cause of a problem may be related to The 4H and 4LO ranges are for off road use only. such items as: front hubs, axles, propeller shafts, They are not for use on hard surface roads. The only wheels and tires, transmission, or clutch instead. If exception being when the road surface is covered by all other driveline components are in good condition ice and snow. and operating properly, refer to the Diagnosis Chart The low range reduction gear system is operative for further information. in 4LO range only. This range is for extra pulling power in off road situations. Low range reduction ratio is 4.0:1.

DIAGNOSIS CHART

Condition Possible Cause Correction

Transfer Case difficult to shift or will 1) Vehicle speed too great to permit 1) Stop vehicle and shift into not shift into desired range. shifting. desired range. Or, reduce speed to below 3-4 km/h (2-3 mph) before attempting the shift. 2) If vehicle was operated for an 2) Stop vehicle and shift the extended period in 4H on a dry transmission into neutral. Shift the paved surface, the driveline torque transfer case to 2H and operate load may be causing a bind. vehicle in 2H on dry paved surfaces. 3) Transfer case external shift 3) Lubricate, repair, or replace linkage binding. linkage bushings, or tighten loose components as necessary. 4) Insufficient or incorrect lubricant. 4) Drain and refill to edge of fill hole with Moparா ATF +4, type 9602, Automatic Transmission fluid. 5) Internal components binding, 5) Disassemble the transfer case worn, or damaged. and replace worn or damaged components as necessary. TJ TRANSFER CASE - NV241 21 - 231 TRANSFER CASE - NV241 (Continued)

Condition Possible Cause Correction

Transfer Case noisy in all operating 1) Insufficient or incorrect lubricant. 1) Drain and refill to edge of fill hole ranges. with Moparா ATF +4, type 9602, Automatic Transmission fluid.

Noisy in, or jumps out of, four wheel 1) Transfer case not completely 1) With the transmission in drive low range. engaged in 4L position. NEUTRAL, or the clutch depressed in the case of a manual transmission and the vehicle moving under 3-4 km/h (2-3 mph), shift the transfer case to NEUTRAL and then shift into the 4L position.

2) Shift linkage out of adjustment. 2) Adjust linkage. 3) Shift linkage loose or binding. 3) Tighten, lubricate, or repair linkage as necessary. 4) Range fork damaged, inserts 4) Disassemble unit and repair as worn, or fork is binding on the shift necessary. rail. 5) Low range gear worn or 5) Disassemble unit and repair as damaged. necessary.

Lubricant leaking from output shaft 1) Transfer case overfilled. 1) Drain lubricant to the correct seal or vent. level.

2) Vent closed or restricted. 2) Clear or replace vent as necessary. 3) Output shaft seals damaged or 3) Replace seal as necessary. installed incorrectly. Check to ensure that another component, the propeller shaft slip yoke for example, is not causing damage to seal.

Abnormal tire wear. 1) Extended operation on hard, dry 1) Operate vehicle in the 2H surfaces in the 4H position. position on hard, dry surfaces.

REMOVAL (10) Remove front and rear propeller shafts. (Refer (1) Raise and support vehicle. to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER (2) Remove skid plate, if equipped. (Refer to 13 - SHAFT/PROPELLER SHAFT - REMOVAL) FRAMES & BUMPERS/FRAME/TRANSFER CASE (11) Support transfer case with suitable jack. SKID PLATE - REMOVAL) Secure transfer case to jack with safety chains. (3) Position drain oil container under transfer (12) Remove nuts attaching transfer case to trans- case. mission. (4) Remove transfer case drain plug and drain (13) Move transfer case assembly rearward until lubricant into container. free of transmission output shaft. (5) Disconnect vent hose and vacuum harness at (14) Lower jack and move transfer case from transfer case switch. under vehicle. (6) Disconnect shift rod from grommet in transfer case shift lever, or from floor shift arm whichever DISASSEMBLY provides easy access. Use channel lock style pliers to Position transfer case in a shallow drain pan. press rod out of lever grommet. Remove drain plug and drain any remaining lubri- (7) Support transmission with jack stand. cant remaining in case. (8) Remove rear crossmember. (9) Mark front and rear propeller shafts for assembly reference. 21 - 232 TRANSFER CASE - NV241 TJ TRANSFER CASE - NV241 (Continued) REAR EXTENSION, RETAINER, AND REAR CASE (1) Install bolts into two threaded holes in the rear propeller shaft companion flange 180° apart (Fig. 3). (2) Place the Holder 6719 (Fig. 3) over the two bolts and use the Holder to remove the rear companion flange nut.

Fig. 4 Speedometer Sensor Bolt Removal 1 - EXTENSION HOUSING 2 - BOLT 3 - SPEEDOMETER SENSOR

Fig. 3 Rear Companion Flange Nut Removal 1 - TRANSFER CASE 2 - HOLDER 6719 3 - COMPANION FLANGE 4 - BOLTS

(3) Remove the rear companion flange from the output shaft.

NOTE: The companion flange is a taper fit onto the output shaft. It may be necessary to use Puller 8992 to remove the companion flange.

(4) There is a seal slinger located on the rear of the companion flange that can be replaced if necessary. Use a suitable cold chisel to strike the slinger Fig. 5 Speedometer Sensor Removal hub parallel to the centerline in several spots to 1 - EXTENSION HOUSING expand the slinger hub. A new slinger can be driven 2 - SPEEDOMETER SENSOR onto the flange hub using a suitable pipe tool. (5) Remove the speedometer sensor bolt (Fig. 4). (6) Remove the speedometer sensor (Fig. 5) from the extension housing. TJ TRANSFER CASE - NV241 21 - 233 TRANSFER CASE - NV241 (Continued)

(7) Remove rear extension bolts (Fig. 6).

Fig. 8 Speedometer Sensor Tone Wheel Removal Fig. 6 Rear Extension Bolt Removal 1 - TRANSFER CASE 2 - OUPUT SHAFT 1 - EXTENSION HOUSING 3 - SENSOR TONE WHEEL 2 - BOLTS (3) Remove the yoke (Fig. 10) from the front out- (8) Remove rear extension housing (Fig. 7). Tap put shaft. extension once or twice with a plastic mallet to break sealer bead and loosen it. NOTE: The yoke is a taper fit onto the output shaft. (9) Remove the speedometer sensor tone wheel It may be necessary to use a puller such as C-452 (Fig. 8) from the output shaft. to remove the yoke.

Fig. 7 Rear Extension Removal Fig. 9 Front Yoke Nut Removal 1 - TRANSFER CASE 1 - TRANSFER CASE 2 - EXTENSION HOUSING 2 - HOLDER 6958 3 - FRONT YOKE YOKE AND SHIFT LEVER (1) Shift transfer case into a 4WD mode. (2) Use Holder 6958 to secure the yoke and remove the yoke nut (Fig. 9). Discard nut after removal. It is not reusable. 21 - 234 TRANSFER CASE - NV241 TJ TRANSFER CASE - NV241 (Continued)

Fig. 10 Front Yoke Removal Fig. 12 Shift Lever Removal 1 - TRANSFER CASE 1 - SHIFT LEVER 2 - FRONT YOKE 2 - SECTOR SUPPORT 3 - SHIFT SECTOR (4) There is a seal slinger located on the rear of the yoke that can be replaced if necessary. Use a (8) Remove the detent plug (Fig. 13). suitable cold chisel to strike the slinger hub parallel (9) Remove the detent plug (Fig. 14), spring, and to the centerline in several spots to expand the plunger from the transfer case. slinger hub. A new slinger can be driven onto the yoke hub using a suitable pipe tool. (5) Remove yoke rubber seal from front output shaft. (6) Remove bolt (Fig. 11) that retains the shift lever to sector shaft. (7) Remove the shift lever (Fig. 12) from the shift sector.

Fig. 13 Detent Plug Removal 1 - DETENT PLUG 2 - SPRING

Fig. 11 Shift Lever Bolt Removal 1 - SHIFT LEVER 2 - BOLT 3 - SECTOR SUPPORT TJ TRANSFER CASE - NV241 21 - 235 TRANSFER CASE - NV241 (Continued)

Fig. 14 Detent Plug, Spring, and Plunger Removal Fig. 16 Shift Sector Support Removal 1 - DETENT PLUG 1 - SHIFT SECTOR SHAFT 2 - SPRING 2 - SECTOR SUPPORT 3 - PLUNGER MAINSHAFT, FRONT OUTPUT SHAFT, AND DRIVE (10) Remove the transfer case position sensor (Fig. CHAIN 15). (11) Remove the shift sector support (Fig. 16). (1) Note position of bolts that attach rear case to front case. Some bolts are unique. Mark position of these bolts with paint or scriber. (2) Remove rear case-to-front case bolts (Fig. 17).

Fig. 15 Remove Transfer Case Position Sensor 1 - TRANSFER CASE POSITION SENSOR 2 - TRANSFER CASE Fig. 17 Case Half Bolt Removal 1 - REAR CASE HALF 2 - FRONT CASE HALF 3 - BOLTS 21 - 236 TRANSFER CASE - NV241 TJ TRANSFER CASE - NV241 (Continued)

(3) Loosen rear case with pry tool to break sealer (6) Remove shift rail cups and spring (Fig. 20). bead. (4) Unseat rear case from alignment dowels (Fig. 18). (5) Remove rear case and oil pump assembly from front case (Fig. 19).

CAUTION: Do not remove the bolts holding the oil pump cover to the rear case half. The oil pump cover is aligned to the rear output shaft bearing inner race and will become mis-aligned if the bolts are loosened. If the transfer case failure has generated any debris which may have become trapped in the oil pump, the rear case and oil pump assembly MUST be replaced.

Fig. 20 Shift Rail Cup And Spring Removal 1 - SHIFT RAIL 2 - SPRING 3 - CUPS (2)

(7) Remove front drive sprocket retaining ring (Fig. 21).

Fig. 18 Case Alignment Dowel 1 - REAR CASE HALF 2 - FRONT CASE HALF 3 - ALIGNMENT DOWEL

Fig. 21 Front Drive Sprocket Snap-Ring Removal 1 - DRIVE CHAIN 2 - FRONT DRIVE SPROCKET 3 - SNAP-RING

(8) Remove mainshaft, front sprocket, and chain as an assembly (Fig. 22).

Fig. 19 Rear Case Half Removal 1 - REAR CASE HALF 2 - FRONT CASE HALF TJ TRANSFER CASE - NV241 21 - 237 TRANSFER CASE - NV241 (Continued)

Fig. 24 Shift Fork Rail Removal Fig. 22 Remove Mainshaft, Drive Chain, and Front 1 - FRONT CASE HALF Sprocket 2 - SHIFT RAIL 1 - MAINSHAFT 2 - DRIVE CHAIN 3 - DRIVE SPROCKET

SHIFT FORKS (1) Remove front output shaft from bearing in case (Fig. 23).

Fig. 25 Mode Fork and Sleeve Removal 1 - MODE FORK 2 - MODE SLEEVE

Fig. 23 Front Output Shaft Removal 1 - FRONT CASE HALF 2 - FRONT OUTPUT SHAFT

(2) Remove the shift rail (Fig. 24) from the shift forks. (3) Remove mode fork, mode sleeve (Fig. 25). Note which way sleeve fits in fork (long side of sleeve goes to front). (4) Remove range fork and hub as an assembly (Fig. 26). Note fork position for installation reference. (5) Remove shift sector (Fig. 27). Fig. 26 Range Fork and Hub Removal 1 - RANGE FORK 2 - RANGE HUB 21 - 238 TRANSFER CASE - NV241 TJ TRANSFER CASE - NV241 (Continued)

Fig. 29 Mainshaft Drive Sprocket Removal Fig. 27 Shift Sector Removal 1 - MAINSHAFT 1 - FRONT CASE HALF 2 - DRIVE SPROCKET 2 - SHIFT SECTOR

MAINSHAFT (1) Remove the snap-ring that secures the chain drive sprocket onto mainshaft (Fig. 28). Use standard (instead of parallel jaw) snap-ring pliers to remove this snap-ring. (2) Remove drive sprocket (Fig. 29).

Fig. 30 Sliding Clutch Gear Removal 1 - MAINSHAFT 2 - SLIDING CLUTCH GEAR

Fig. 28 Mainshaft Drive Sprocket Snap-Ring Removal 1 - MAINSHAFT 2 - DRIVE SPROCKET 3 - SNAP-RING

(3) Remove the sliding clutch gear (Fig. 30) from the mainshaft. (4) Rotate the mainshaft 180° and remove the mode hub snap-ring (Fig. 31).

Fig. 31 Mode Hub Snap-Ring Removal 1 - MAINSHAFT 2 - MODE HUB 3 - SNAP-RING TJ TRANSFER CASE - NV241 21 - 239 TRANSFER CASE - NV241 (Continued) (5) Remove the mode hub (Fig. 32) from the main- INPUT AND PLANETARY GEAR shaft. (1) Remove front input retainer attaching bolts (6) Remove the drive sprocket drive hub (Fig. 33) (Fig. 34). from the mainshaft. (2) Remove the input gear seal with a suitable screw and slide hammer. (3) Remove the input gear snap-ring (Fig. 35) from the input retainer.

Fig. 32 Mode Hub Removal 1 - MAINSHAFT 2 - MODE HUB Fig. 34 Front Input Retainer Bolt Removal 1 - INPUT RETAINER 2 - INPUT GEAR 3 - BOLT 4 - FRONT CASE HALF

Fig. 33 Drive Sprocket Drive Hub Removal 1 - MAINSHAFT 2 - DRIVE SPROCKET DRIVE HUB

Fig. 35 Input Gear Snap-Ring Removal 1 - INPUT RETAINER 2 - INPUT GEAR 3 - SNAP-RING 21 - 240 TRANSFER CASE - NV241 TJ TRANSFER CASE - NV241 (Continued)

(4) Remove the input gear (Fig. 36) from the input gear bearing with suitable hammer. (5) Remove front input retainer (Fig. 37).

Fig. 38 Low Range Planetary Plastic Spacer 1 - LOW RANGE PLANETARY 2 - PLASTIC SPACER

Fig. 36 Input Gear Removal 1 - INPUT RETAINER 2 - INPUT GEAR

Fig. 39 Low Range Planetary Removal 1 - FRONT CASE HALF 2 - LOW RANGE PLANETARY 3 - ANNULUS GEAR

Fig. 37 Front Input Retainer Removal 1 - INPUT RETAINER 2 - FRONT CASE HALF

(6) Remove the low range planetary plastic spacer (Fig. 38) from the planetary carrier or back side of the input retainer. (7) Remove the low range planetary gear set (Fig. 39) from the front case half. (8) Remove the annulus gear (Fig. 40) from the front case half. (9) Support the input retainer on Cup 8148 as shown (Fig. 41). (10) While using suitable snap-ring pliers to spread the input gear bearing snap-ring (Fig. 42), Fig. 40 Remove Annulus Gear press downward on the retainer to remove the bear- 1 - FRONT CASE HALF ing. 2 - ANNULUS GEAR TJ TRANSFER CASE - NV241 21 - 241 TRANSFER CASE - NV241 (Continued)

Fig. 41 Support Input Gear Bearing For Removal Fig. 43 Front Output Bearing Removal 1 - INPUT RETAINER 1 - HANDLE C-4171 2 - CUP 8148 2 - INSTALLER 8239 3 - INPUT GEAR BEARING

Fig. 44 Rear Output Bearing Removal Fig. 42 Input Gear Bearing Removal 1 - REAR CASE HALF 1 - INPUT RETAINER 2 - HANDLE C-4171 2 - CUP 8148 3 - INSTALLER 8239 3 - INPUT GEAR BEARING INSPECTION (11) Remove the front output shaft bearing with Handle C-4171 and Installer 8239 (Fig. 43). MAINSHAFT/SPROCKET/HUB (12) Remove the rear output shaft bearing with Inspect the splines on the hub and shaft and the Handle C-4171 and Installer 8239 (Fig. 44). teeth on the sprocket. Minor nicks and scratches can CLEANING be smoothed with an oilstone, however, replace any part that is damaged. Clean the transfer case parts with a standard Check the contact surfaces in the sprocket bore parts cleaning solvent. Remove all traces of sealer and on the mainshaft. Minor nicks and scratches can from the cases and retainers with a scraper and be smoothed with 320-400 grit emery cloth but do not 3M™ all purpose cleaner. Use compressed air to try to salvage the shaft if nicks or wear is severe. remove solvent residue from oil feed passages in the case halves, retainers, gears, and shafts. 21 - 242 TRANSFER CASE - NV241 TJ TRANSFER CASE - NV241 (Continued) INPUT GEAR AND PLANETARY CARRIER OIL PUMP/OIL PICKUP Check the teeth on the gear. Minor nicks can be Examine the oil pump pickup parts. Replace the dressed off with an oilstone but replace the gear if pump if any evidence of debris or damage exists. Do any teeth are broken, cracked, or chipped. The bear- not disassemble the pump from the rear case half as ing surface on the gear can be smoothed with individual parts are not available and it will not be 300-400 grit emery cloth if necessary. possible to reassemble the pump cover to the rear Examine the carrier body and pinion gears for case half. The pump is only available as part of the wear or damage. The carrier will have to be replaced rear case half assembly. The pickup screen, hose, and as an assembly if the body, pinion pins, or pinion tube are the only serviceable parts and are available gears are damaged. Inspect the plastic washer on the separately. inside, bottom of the planetary carrier. The washer is trapped by the pinion gears and the complete plane- ASSEMBLY tary will need to be replaced if the washer is worn or damaged. BEARINGS AND SEALS (1) Position the input gear bearing in the input SHIFT FORKS/HUBS/SLEEVES retainer bearing bore. Spread the snap-ring captured Check condition of the shift forks and mode fork in the retainer with suitable snap-ring pliers and shift rail. Minor nicks on the shift rail can be press the bearing into place. Verify that the snap- smoothed with 320-400 grit emery cloth. ring has engaged the groove in the bearing. Inspect the shift fork wear pads. The mode and (2) Start front output shaft bearing in case (Fig. range fork pads are serviceable and can be replaced 45). Then seat bearing with Handle C-4171 and if necessary. Installer 6953. Check both of the sleeves for wear or damage, especially on the interior teeth. Replace the sleeves if wear or damage is evident. DRIVE CHAIN Examine the drive chain and shaft bearings. replace the chain if stretched, distorted, or if any of the links bind. Replace the bearings if rough, or noisy. LOW RANGE ANNULUS GEAR Inspect annulus gear condition carefully. The gear can be serviced separately. FRONT-REAR CASES Inspect the cases for wear and damage. Replace the input retainer seal, do not reuse it. Fig. 45 Front Output Shaft Bearing Installation Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing sur- 1 - HANDLE C-4171 2 - INSTALLER 6953 faces. Also make sure the front case mounting studs 3 - BEARING are in good condition. Check the front case mounting studs and vent (3) Install the front output shaft bearing retaining tube. The tube can be secured with Loctite™ 271 or ring. 680 if loose. The stud threads can be cleaned up with (4) Install the rear output shaft bearing into the a die if necessary. Also check condition of the fill/ rear case half with Installer 6953 and Handle C-4171 drain plug threads in the rear case. The threads can (Fig. 46). be repaired with a thread chaser or tap if necessary. (5) Remove the input gear pilot bearing using Or the threads can be repaired with Helicoil™ stain- Puller Jaws 8240 and Cup 8148. less steel inserts if required. TJ TRANSFER CASE - NV241 21 - 243 TRANSFER CASE - NV241 (Continued)

(10) Install new bearing with Tool Handle C-4171 and Installer 5066 (Fig. 49). The bearing bore is chamfered at the top. Install the bearing so it is flush with the lower edge of this chamfer (Fig. 50).

Fig. 46 Rear Output Bearing Installation 1 - REAR CASE HALF 2 - HANDLE C-4171 3 - INSTALLER 6953

(6) Remove the input gear cup plug (Fig. 47) with a suitable drift and hammer inserted from the front of the input gear.

Fig. 48 Front Output Shaft Rear Bearing Removal 1 - REAR CASE 2 - SPECIAL TOOL L-4454-1 AND L-4454-3 3 - SPECIAL TOOL 8148

Fig. 47 Remove Input Gear Cup Plug 1 - DRIFT 2 - INPUT GEAR

(7) Install a new input gear cup plug with Installer 9045 and Handle C-4171. (8) Install new input gear pilot bearing with Installer 9047 and Handle C-4171. (9) Remove the front output shaft rear bearing Fig. 49 Output Shaft Rear Bearing Installation with the screw and jaws from Remover L-4454 and 1 - HANDLE C-4171 Cup 8148 (Fig. 48). 2 - OUTPUT SHAFT INNER BEARING 3 - INSTALLER 5066 21 - 244 TRANSFER CASE - NV241 TJ TRANSFER CASE - NV241 (Continued)

Fig. 50 Output Shaft Rear Bearing Installation Depth Fig. 52 Low Range Planetary Installation 1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER 1 - FRONT CASE HALF 2 - CHAMFER 2 - LOW RANGE PLANETARY 3 - ANNULUS GEAR INPUT AND PLANETARY GEAR (1) Install the annulus gear (Fig. 51) into the front case half. (2) Align and install low range planetary assembly into the front case half (Fig. 52). Be sure low range planetary pinions are engaged in annulus gear.

Fig. 53 Low Range Planetary Plastic Spacer 1 - LOW RANGE PLANETARY 2 - PLASTIC SPACER

Fig. 51 Install Annulus Gear 1 - FRONT CASE HALF 2 - ANNULUS GEAR

(3) Install the low range planetary plastic spacer (Fig. 53) onto the low range planetary carrier. (4) Clean gasket sealer residue from retainer and inspect retainer for cracks or other damage. (5) Applya3mm(1/8 in.) bead of Mopar௡ Gasket Maker, or equivalent silicone adhesive, to sealing surface of retainer. (6) Install the front input retainer (Fig. 54) onto the front case half. Fig. 54 Front Input Retainer Installation (7) Install bolts to hold retainer to transfer case 1 - INPUT RETAINER (Fig. 55). Tighten to 21 N·m (16 ft. lbs.) of torque. 2 - FRONT CASE HALF TJ TRANSFER CASE - NV241 21 - 245 TRANSFER CASE - NV241 (Continued)

Fig. 55 Front Input Retainer Bolt Installation Fig. 57 Input Gear Seal Installation 1 - INPUT RETAINER 1 - HANDLE C-4171 2 - INPUT GEAR 2 - INSTALLER 8841 3 - BOLT 3 - INPUT RETAINER 4 - FRONT CASE HALF SHIFT FORKS AND MAINSHAFT (8) Install the input gear to the low range plane- (1) Lubricate mainshaft splines with recommended tary assembly and the input gear bearing. transmission fluid. (9) Install the input gear retaining snap-ring (Fig. (2) Install the drive sprocket drive hub onto the 56) onto the input gear. mainshaft (Fig. 58). Verify that the long shoulder is (10) Install new oil seal in front input retainer towards the front of the mainshaft. with Installer 8841 and Handle C-4171 (Fig. 57).

Fig. 58 Drive Sprocket Drive Hub Installation Fig. 56 Input Gear Snap-Ring Installation 1 - MAINSHAFT 1 - INPUT RETAINER 2 - DRIVE SPROCKET DRIVE HUB 2 - INPUT GEAR 3 - SNAP-RING 21 - 246 TRANSFER CASE - NV241 TJ TRANSFER CASE - NV241 (Continued)

(3) Install the mode hub (Fig. 59) onto the main- (5) Rotate the mainshaft 180° and install the slid- shaft. ing clutch gear (Fig. 61) onto the drive sprocket drive (4) Install the mode hub snap-ring (Fig. 60) onto hub. the mainshaft. (6) Install the mainshaft drive sprocket (Fig. 62) onto the drive hub. (7) Install the mainshaft drive sprocket retaining ring (Fig. 63) onto the drive hub.

Fig. 59 Mode Hub Installation 1 - MAINSHAFT 2 - MODE HUB Fig. 61 Sliding Clutch Gear Installation 1 - MAINSHAFT 2 - SLIDING CLUTCH GEAR

Fig. 60 Mode Hub Snap-Ring Installation 1 - MAINSHAFT 2 - MODE HUB 3 - SNAP-RING Fig. 62 Mainshaft Drive Sprocket Installation 1 - MAINSHAFT 2 - DRIVE SPROCKET TJ TRANSFER CASE - NV241 21 - 247 TRANSFER CASE - NV241 (Continued)

(11) Assemble and install range fork and hub (Fig. 65). Be sure hub is properly seated in low range gear and engaged to the input gear. (12) Align and insert range fork pin in shift sector slot.

Fig. 63 Mainshaft Drive Sprocket Snap-Ring Installation 1 - MAINSHAFT 2 - DRIVE SPROCKET 3 - SNAP-RING

(8) Support front case on wood blocks so case inte- Fig. 65 Range Fork and Hub Installation rior is facing up. Place blocks between mounting 1 - RANGE FORK studs on forward surface of case. 2 - RANGE HUB (9) Lubricate mainshaft components with transmission fluid. (13) Install mode fork and mode sleeve (Fig. 66). (10) Lubricate sector shaft with transmission fluid Verify that the long side of the mode sleeve is and install shift sector in case (Fig. 64). Position slot towards the front of the transfer case. in sector so it will be aligned with shift fork pin (14) Install the shift rail (Fig. 67) through the shift when shift forks are installed. forks and into the shift rail pocket in the front case half.

Fig. 64 Shift Sector Installation Fig. 66 Mode Fork and Sleeve Installation 1 - FRONT CASE HALF 2 - SHIFT SECTOR 1 - MODE FORK 2 - MODE SLEEVE 21 - 248 TRANSFER CASE - NV241 TJ TRANSFER CASE - NV241 (Continued)

Fig. 67 Shift Fork Rail Installation Fig. 69 Front Output Shaft Seal Installation 1 - FRONT CASE HALF 1 - HANDLE C-4171 2 - SHIFT RAIL 2 - INSTALLER 9041

FRONT OUTPUT SHAFT AND DRIVE CHAIN (4) Insert front sprocket in drive chain (Fig. 70). (1) Install front output shaft into the font output (5) Install drive chain around mainshaft drive shaft bearing (Fig. 68). sprocket (Fig. 70). Then position front sprocket over front output shaft. (6) Install the mainshaft into the range hub and mode sleeve and seat the front drive sprocket onto the front output shaft (Fig. 70). (7) Install the front drive sprocket retaining ring (Fig. 71).

Fig. 68 Front Output Shaft Installation 1 - FRONT CASE HALF 2 - FRONT OUTPUT SHAFT

(2) Install the front output shaft snap-ring onto the front output shaft. (3) Install new front output seal (Fig. 69) in front Fig. 70 Install Mainshaft, Drive Chain, and Front case with Installer 9041 and Handle C-4171. Sprocket 1 - MAINSHAFT 2 - DRIVE CHAIN 3 - DRIVE SPROCKET TJ TRANSFER CASE - NV241 21 - 249 TRANSFER CASE - NV241 (Continued) OIL PUMP AND REAR CASE

CAUTION: Do not remove the bolts holding the oil pump cover to the rear case half. The oil pump cover is aligned to the rear output shaft inner bearing race and will become mis-aligned if the bolts are loosened. If the transfer case failure has generated any debris which may have become trapped in the oil pump. the rear case and oil pump assembly MUST be replaced.

Lubricate the oil pump components before installation. Prime the oil pickup tube by pouring a little oil into the tube before installation. (1) Install new o-ring in pickup tube inlet of oil pump. Fig. 71 Front Drive Sprocket Snap-Ring Installation (2) Position oil pickup tube and filter in rear case. Be sure pickup filter is seated in case pocket and 1 - DRIVE CHAIN 2 - FRONT DRIVE SPROCKET that pickup tube is aligned in case notches. Be sure 3 - SNAP-RING hose that connects tube to filter is securely positioned. (8) Install spring and cups on shift rail (Fig. 72). (3) Install the transfer case position sensor (Fig. 74). Tighten the sensor to 20-34 N·m (16-25 ft.lbs.). (4) Install the shift sector support (Fig. 75). Tighten the sector support to 27-42 N·m (20-30 ft.lbs.).

Fig. 72 Shift Rail Spring And Cups Installation 1 - CUPS (2) 2 - SPRING

(9) Insert magnet in front case pocket (Fig. 73).

Fig. 74 Install Transfer Case Position Sensor 1 - TRANSFER CASE POSITION SENSOR 2 - TRANSFER CASE

Fig. 73 Case Magnet Installation 1 - MAGNET 2 - CASE POCKET 21 - 250 TRANSFER CASE - NV241 TJ TRANSFER CASE - NV241 (Continued)

Fig. 75 Shift Sector Support Installation Fig. 77 Shift Lever Installation 1 - SHIFT SECTOR SHAFT 1 - SHIFT LEVER 2 - SECTOR SUPPORT 2 - SECTOR SUPPORT 3 - SHIFT SECTOR (5) Install detent plunger and spring into the front case half. (Fig. 76). (6) Install new o-ring on detent plug and install plug in front case (Fig. 76). Tighten plug to 16-25 N·m (12-18 ft. lbs.).

Fig. 78 Shift Lever Bolt Installation 1 - SHIFT LEVER 2 - BOLT 3 - SECTOR SUPPORT

Fig. 76 Detent Plug, Spring, and Plunger Installation (10) Verify that the transfer case alignment dowels 1 - DETENT PLUG are properly installed. 2 - SPRING (11) Apply bead of Mopar௡ Gasket Maker, or 3 - PLUNGER equivalent, to mating surface of front case. Keep sealer bead width to maximum of 3/16 inch. Do not (7) Install shift lever onto the sector shaft (Fig. use excessive amount of sealer as excess will be dis- 77). placed into case interior. (8) Install the shift lever bolt (Fig. 78). Tighten the bolt to 20-34 N·m (15-25 ft.lbs.) (9) Shift the transfer case into a 4WD range. This will raise the mainshaft slightly and make installation of the rear case half much easier. TJ TRANSFER CASE - NV241 21 - 251 TRANSFER CASE - NV241 (Continued)

(12) Align oil pump with mainshaft and align shift (14) Apply Loctite™ 242 to remainder of rear case- rail with bore in rear case. Then install rear case and to-front case bolt threads and install bolts (Fig. 81). oil pump assembly (Fig. 79). Be sure oil pickup tube Tighten all bolts to 20-27 N·m (15-20 ft. lbs.). remains in position during case installation.

Fig. 81 Case Half Bolt Installation Fig. 79 Rear Case Half Installation 1 - REAR CASE HALF 1 - REAR CASE HALF 2 - FRONT CASE HALF 2 - FRONT CASE HALF 3 - BOLTS

(13) Install 4-5 rear case-to front case bolts to hold YOKE rear case in position. Tighten bolts snug but not to (1) Install yoke seal onto front shaft (Fig. 82). specified torque at this time.

CAUTION: Verify that shift rail, and case alignment dowels (Fig. 80) are seated before installing any bolts. Case could be cracked if shaft rail or dowels are misaligned.

Fig. 82 Installing Flange Seal On Front Shaft 1 - FRONT OUTPUT SHAFT 2 - FLANGE SEAL

Fig. 80 Case Alignment Dowel 1 - REAR CASE HALF 2 - FRONT CASE HALF 3 - ALIGNMENT DOWEL 21 - 252 TRANSFER CASE - NV241 TJ TRANSFER CASE - NV241 (Continued)

(2) Install yoke onto front shaft (Fig. 83). Then install and tighten a new yoke nut to 122-176 N·m (90-130 ft. lbs.) torque. Never re-use a yoke nut.

Fig. 84 Speedometer Sensor Tone Wheel Installation 1 - TRANSFER CASE 2 - OUPUT SHAFT 3 - SENSOR TONE WHEEL Fig. 83 Front Yoke Installation 1 - TRANSFER CASE 2 - FRONT YOKE

REAR EXTENSION (1) Clean mating surfaces of transfer case housing and the rear retainer of any original gasket material. (2) Apply bead of Mopar௡ Gasket Maker, or equivalent, to mating surface of rear case. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess will be displaced into case interior. (3) Install the speedometer sensor tone wheel (Fig. 84) onto the output shaft. (4) Align and install rear extension on rear case (Fig. 85). (5) Apply Mopar௡ Silicone Sealer to threads of rear extension bolts. Then install extension bolts (Fig. 86). Fig. 85 Rear Extension Installation Tighten the extension bolts to 16-25 N·m (12-18 1 - TRANSFER CASE ft.lbs.). 2 - EXTENSION HOUSING (6) Install new seal in rear extension housing with Installer 9041 and Handle C-4171. (10) Install bolts into two threaded holes in the (7) Install the speedometer sensor (Fig. 87) into rear propeller shaft companion flange 180° apart the extension housing. (Fig. 89). (8) Install the speedometer sensor bolt (Fig. 88). (11) Place the Holder 6719 (Fig. 89) over the two Tighten the bolt to 11-16 N·m (8-12 ft.lbs.). bolts and use the Holder to install a new rear com- (9) Install the rear companion flange onto the out- panion flange nut. Never re-use the companion put shaft. flange nut once it has been installed. Tighten the companion flange nut to 122-176 N·m (90-130 ft.lbs.). TJ TRANSFER CASE - NV241 21 - 253 TRANSFER CASE - NV241 (Continued)

Fig. 86 Rear Extension Bolt Installation Fig. 88 Speedometer Sensor Bolt Installation 1 - EXTENSION HOUSING 1 - EXTENSION HOUSING 2 - BOLTS 2 - BOLT 3 - SPEEDOMETER SENSOR

Fig. 87 Speedometer Sensor Installation Fig. 89 Rear Companion Flange Nut Removal 1 - EXTENSION HOUSING 2 - SPEEDOMETER SENSOR 1 - TRANSFER CASE 2 - HOLDER 6719 3 - COMPANION FLANGE INSTALLATION 4 - BOLTS (1) Align and seat transfer case on transmission. Be sure transfer case input gear splines are aligned (7) Connect shift rod to transfer case lever or floor with transmission output shaft. Align splines by shift arm. Use channel lock style pliers to press rod rotating transfer case rear output shaft yoke if nec- back into lever grommet. essary. Do not install any transfer case attaching (8) Adjust shift linkage, if necessary. nuts until the transfer case is completely seated (9) Fill transfer case with recommended transmis- against the transmission. sion fluid and install fill plug. (2) Install and tighten transfer case attaching (10) Install skid plate, if equipped. (Refer to 13 - nuts. Tighten nuts to 30-41 N·m (20-30 ft.lbs.). FRAMES & BUMPERS/FRAME/TRANSFER CASE (3) Install rear crossmember. SKID PLATE - INSTALLATION) (4) Remove jack stand from under transmission. (11) Lower vehicle (5) Align and connect propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPELLER SHAFT - INSTALLATION) (6) Connect vacuum harness and vent hose. 21 - 254 TRANSFER CASE - NV241 TJ TRANSFER CASE - NV241 (Continued) SPECIFICATIONS TRANSFER CASE - NV241

TORQUE SPECIFICATIONS

DESCRIPTION N·m Ft. Lbs. In. Lbs. Plug, Detent 16-25 12-18 - Plug, Drain/Fill 20-34 15-25 - Bolt, Rear Extension 16-24 12-18 - Bolt, Front Input Retainer 21 16 - Bolt, Case Half 20-27 15-20 - Nut, Front Yoke 122-176 90-130 - Nut, Rear Companion Flange 258-312 190-230 - Bolt, Shift Lever 20-34 15-25 - Nuts, Mounting 30-41 20-30 - Bolts, U-Joint 19 17 - Support, Sector 27-42 20-30 - Sensor, Transfer Case Position 20-34 16-25 - Bolt, Speed Sensor 11-16 8-12 -

SPECIAL TOOLS TRANSFER CASE - NV241

Remover - L-4454 Puller - C-452

Installer, Bushing - 5066

Handle, Universal - C-4171

Holder, Yoke - 6719A TJ TRANSFER CASE - NV241 21 - 255 TRANSFER CASE - NV241 (Continued)

Installer, Bearing - 6953

Installer, Seal - 8841

Spanner Wrench - 6958

Cup - 8148 Flange Puller - 8992

Installer, Bearing - 8239

Installer, Cup Seal - 9045

Remover - 8240 21 - 256 TRANSFER CASE - NV241 TJ TRANSFER CASE - NV241 (Continued) FLUID STANDARD PROCEDURE - FLUID DRAIN AND FILL The fill and drain plugs are both in the rear case (Fig. 91). Correct fill level is to the bottom edge of the fill plug hole. Be sure the vehicle is level to ensure an accurate fluid level check.

Installer, Bearing - 9047 REAR EXTENSION SEAL REMOVAL (1) Raise and support vehicle. (2) Remove rear propeller shaft. (Refer to 3 - DIF- FERENTIAL & DRIVELINE/PROPELLER SHAFT/ PROPELLER SHAFT - REMOVAL) (3) Remove the rear companion flange from the output shaft. (4) Using a suitable pry tool or slide-hammer mounted screw, remove the rear extension seal. Fig. 91 Transfer Case Identification Tag and Fill/Drain Plugs INSTALLATION 1 - IDENTIFICATION TAG (1) Clean fluid residue from sealing surface and 2 - FILL PLUG inspect for defects. 3 - DRAIN PLUG (2) Using Installer 9041 and Handle C-4171, install seal in rear extension (Fig. 90). FRONT OUTPUT SHAFT SEAL REMOVAL (1) Shift transfer case into NEUTRAL. (2) Raise vehicle. (3) Remove front propeller shaft. (Refer to 3 - DIF- FERENTIAL & DRIVELINE/PROPELLER SHAFT/ PROPELLER SHAFT - REMOVAL) (4) Using Spanner Wrench 6958, remove yoke nut (Fig. 92). Discard nut after removal. It is not reusable. (5) Remove yoke from output shaft (Fig. 93). Use puller C-452 if flange can not be removed by hand. Fig. 90 Install Rear Extension Seal (6) Remove yoke rubber seal from front output 1 - SPECIAL TOOL C-4171 shaft (Fig. 94). 2 - SPECIAL TOOL 9041 (7) Remove front output shaft seal with suitable (3) Install the companion flange onto the output pry tool, or a slide hammer mounted screw. shaft. (4) Install a new companion flange nut and tighten to 176-271 N·m (130-200 ft.lbs.). (5) Install propeller shaft. (Refer to 3 - DIFFER- ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO- PELLER SHAFT - INSTALLATION) (6) Verify proper transfer case fluid level. (7) Lower vehicle. TJ TRANSFER CASE - NV241 21 - 257 FRONT OUTPUT SHAFT SEAL (Continued) INSTALLATION (1) Install new front output seal in front case with Installer Tool 9041 and Handle C-4171 (Fig. 95).

Fig. 92 Front Yoke Nut Removal 1 - TRANSFER CASE 2 - HOLDER 6958 3 - FRONT YOKE Fig. 95 Front Output Seal Installation - Typical 1 - SPECIAL TOOL C-4171 2 - SPECIAL TOOL 9041

(2) Install yoke seal on front output shaft (Fig. 96).

Fig. 93 Front Yoke Removal 1 - TRANSFER CASE 2 - FRONT YOKE

Fig. 96 Installing Flange Seal On Front Shaft 1 - FRONT OUTPUT SHAFT 2 - FLANGE SEAL

Fig. 94 Yoke Seal Removal 1 - FLANGE SEAL 21 - 258 TRANSFER CASE - NV241 TJ FRONT OUTPUT SHAFT SEAL (Continued) (3) Install yoke on front output shaft (Fig. 97). POSITION SENSOR Install a new yoke nut onto the front output shaft. (4) Using Spanner Wrench 6958 (Fig. 98), tighten DESCRIPTION the yoke nut to 176-271 N·m (130-200 ft. lbs.) torque. The transfer case position sensor is an electronic (5) Install propeller shaft. (Refer to 3 - DIFFER- device whose output can be interpreted to indicate ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO- the transfer case’s current operating mode. The sen- PELLER SHAFT - INSTALLATION) sor consists of a five position, resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module (PCM) for each transfer case operating mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector plate rooster- comb. The PCM supplies 5VDC (+/- 0.5V) to the sensor and monitors the return voltage to determine the sector plate, and therefore the transfer case, position. OPERATION During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position sensor return voltage to determine the operating mode of the transfer case. Refer to the Operat- ing Mode Versus Resistance table for the correct resistance for each position (Fig. 99). Fig. 97 Front Yoke Installation 1 - TRANSFER CASE 2 - FRONT YOKE

Fig. 98 Front Yoke Nut Installation 1 - TRANSFER CASE 2 - HOLDER 6958 3 - FRONT YOKE TJ TRANSFER CASE - NV241 21 - 259 POSITION SENSOR (Continued)

OPERATING MODE VERSUS RESISTANCE

SENSOR POSITION OPERATING MODE SENSOR RESISTANCE (ohms) 1 2H 1124-1243 2 4H 650-719 3 NEUTRAL 389-431 4 4L 199-221 5 NOT USED 57-64

SHIFT LEVER REMOVAL (1) Shift transfer case into 4L. (2) Raise vehicle. (3) Loosen adjusting trunnion locknut and slide shift rod out of trunnion (Fig. 100). If rod lacks enough travel to come out of trunnion, push trunnion out of torque shaft. (4) Lower vehicle. (5) Remove console. (Refer to 23 - BODY/INTERI- OR/FLOOR CONSOLE - REMOVAL) (6) Remove screws attaching lever assembly to floorpan and remove assembly and shift rod (if left attached).

Fig. 99 Position Sensor Linear Movement INSTALLATION 1 - POSITION 1 - 10mm ±0.5mm (1) If shift rod was not removed from lever assem- 2 - POSITION 2 - 12mm ±0.5mm bly, work rod down through floorpan opening. Then 3 - POSITION 3 - 14mm ±0.5mm position lever assembly on floorpan and install 4 - POSITION 4 - 16mm ±0.5mm 5 - POSITION 5 - 18mm ±0.5mm assembly attaching screws. 6 - POSITION 6 - 20mm±0.5mm - FULL EXTENSION (2) Install console. (Refer to 23 - BODY/INTERI- OR/FLOOR CONSOLE - INSTALLATION) REMOVAL (3) Raise vehicle. (1) Raise and support the vehicle. (4) Connect trunnion to torque shaft arm. Or, slide (2) Disengage the transfer case position sensor shift rod into trunnion on range lever. Be sure shift connector from the position sensor. rod slides freely in trunnion. (3) Remove the position sensor from the transfer (5) Verify that range lever is in 4L position. Then case. tighten trunnion lock bolt. (6) Lower vehicle and check transfer case shift INSTALLATION operation. (1) Inspect the o-ring seal on the transfer case position sensor. Replace the o-ring if necessary. (2) Install the transfer case position sensor into the transfer case. Torque the sensor to 20-34 N·m (15-25 ft.lbs.). (3) Engage the transfer case position sensor connector to the position sensor. (4) Lower vehicle. (5) Verify proper sensor operation. 21 - 260 TRANSFER CASE - NV241 TJ SHIFT LEVER (Continued)

Fig. 100 Shift Linkage 1 - Rivnut (4) 8 - Torque Shaft 2 - Shift Lever Assembly 9 - Transfer Case Shift Lever 3 - Floorpan 10 - Torque Shaft Transfer Case Bracket 4 - Trunnion Lock Bolt A - 3-4 N·m (27-35 in. lbs.) 5 - Selector Rod and Trunnion B - 11-14 N·m (97-123 in. lbs.) 6 - Shift Lever Rod C - 8-14 N·m (72-120 in. lbs.) 7 - Torque Shaft Frame Bracket TJ TRANSFER CASE - NV241 21 - 261 SHIFT LEVER (Continued) ADJUSTMENTS - SHIFT LINKAGE VEHICLE SPEED SENSOR (1) Shift transfer case into 4L position. (2) Raise vehicle. DESCRIPTION (3) Loosen lock bolt on adjusting trunnion (Fig. The 3-wire Vehicle Speed Sensor (VSS) (Fig. 102) is 101). located in the transfer case rear extension. (4) Be sure linkage rod slides freely in trunnion. Clean rod and apply spray lube if necessary. (5) Verify that transfer case range lever is fully engaged in 4L position. (6) Tighten adjusting trunnion lock bolt. (7) Lower vehicle.

Fig. 102 Speedometer Sensor 1 - EXTENSION HOUSING 2 - SPEEDOMETER SENSOR OPERATION The VSS is a 3-circuit (3–wire), magnetic, hall-ef- fect sensor. The 3 circuits are: • A 5-volt power supply from the Powertrain Con- trol Module (PCM). • A ground is provided for the sensor though a low-noise sensor return circuit in the PCM. • An input to the PCM is used to determine vehicle speed and distance traveled. The speed sensor generates 8 pulses per sensor revolution. These signals, in conjunction with a Fig. 101 Shift Linkage closed throttle signal from the throttle position sen- 1 - TRANSFER CASE SHIFT LEVER SHAFT sor, indicate a closed throttle deceleration to the 2 - SEAL PCM. When the vehicle is stopped at idle, a closed 3 - TRANSFER CASE SHIFT LEVER ASSEMBLY 4 - FLOORPAN throttle signal is received by the PCM (but a speed 5 - TRUNNION LOCK BOLT sensor signal is not received). 6 - SHIFT ROD Under deceleration conditions, the PCM adjusts 7 - ADJUSTING TRUNNION 8 - TORQUE SHAFT BRACKET the Idle Air Control (IAC) motor to maintain a 9 - RANGE LEVER desired MAP value. Under idle conditions, the PCM 10 - TORQUE SHAFT ROD adjusts the IAC motor to maintain a desired engine 11 - TORQUE SHAFT 12 - LINKAGE BRACKET speed. 21 - 262 TRANSFER CASE - NV241 TJ VEHICLE SPEED SENSOR (Continued) REMOVAL INSTALLATION The Vehicle Speed Sensor (VSS) is located in the (1) Install sensor into transfer case rear extension transfer case rear extension. and install mounting bolt. Before tightening bolt, ver- (1) Raise and support vehicle. ify speed sensor is fully seated (mounted flush) to (2) Disconnect electrical connector from sensor by rear extension. pushing slide tab. After slide tab has been positioned, (2) Tighten sensor mounting bolt to 11-16 N·m push in on secondary release lock on side of connec- (8-12 ft. lbs.) torque. tor and pull connector from sensor. (3) Connect electrical connector to sensor. (3) Remove sensor mounting bolt. (4) Remove sensor (pull straight out) from rear extension.