Chrysler 42RE Automatic Transmission Service and Repair Manual, 1993–2004

ATSG’s Techtran manual covers diagnosis and internal repair of the Chrysler 42RE (A500SE) automatic transmission for Jeep Grand Cherokee and Jeep Grand Wagoneer applications. It combines mechanical overhaul procedures with electronic governor and transmission control module diagnostics.

Text Search, Diagram Detail and PDF Contents

Search and diagram navigation: An embedded OCR layer makes much of the main text searchable, but recognition errors affect some words and drawing labels. Embedded bookmarks use generic scan numbers rather than chapter names. Small connector numbers, wire codes, and hydraulic-chart labels require zooming.

Supplied as one printable, 106-page PDF, including the cover, one blank page, and one duplicate of printed page 6. The application chart listed for printed page 4 is missing from this file.

Electronic Governor Diagnosis and Transmission Overhaul

These selected coverage highlights summarize the main workshop sections. Other topics include park/neutral switch troubleshooting and speedometer adapter installation.

• Fault diagnosis: Road-test guidance, overdrive-switch flash codes, DRB II scan-tool references, and symptom charts for harsh engagement, delayed shifts, slippage, and no-drive conditions.

• Hydraulic testing: Line and governor pressure tests, pressure-port illustrations, test-result analysis, and clutch and servo air checks.

• Internal overhaul: Step-by-step procedures for transmission disassembly and reassembly, with oil-pump, reaction-shaft support, clutch, servo, and planetary geartrain work.

• Valve body service: Upper and lower housing reassembly, transfer-plate and checkball locations, accumulator assembly, and line and throttle pressure adjustments.

• Overdrive rebuilding: Section teardown and assembly, direct-clutch spring compression, retaining-ring identification, and selective spacer and thrust-plate measurements.

• Electrical reference: Transmission wiring schematic, connector views, terminal functions, solenoid resistance specifications, and governor pressure sensor and thermistor information.

The press work, selective measurements, and diagnostic-tool references make this manual suited to transmission rebuilders and technicians familiar with automatic transmission service.

Pressure Tests and Shift-Complaint Diagnosis

The diagnosis charts connect symptoms with possible mechanical, hydraulic, and electrical causes. Combined with the pressure-test analysis chart, they help technicians distinguish governor-control faults and internal leakage possibilities when assessing a shift complaint.

The electronic sections explain how the TCM uses sensor inputs to control the converter clutch, overdrive solenoid, and governor pressure solenoid. References include the Chrysler 42RE Wiring Schematic, case-connector terminal function chart, and Ohms Reading Chart.

Hydraulic flow charts show circuit operation in reverse, forward gears, and fourth gear with the converter clutch applied or released. They provide circuit context alongside the symptom-based diagnosis tables.

Bench Assembly, Selective Fitting and Repair Limits

Exploded views identify the planetary geartrain, clutch assemblies, valve body, and overdrive components. The pump section distinguishes the earlier square-lug drive from the flat-drive design and illustrates bushing replacement tooling.

Overdrive selective-fitting tables link measured dimensions to spacer and thrust-plate selection. Dimensioned drawings for making the required measuring tools support workshop tool fabrication for these checks.

Assembly cautions: The governor pressure solenoid illustration warns that disturbing its calibration screw can cause solenoid failure. The overdrive section identifies incorrect placement of the flat, waved, and round snap rings as a common assembly error.

Specification differences: Some pump, planetary geartrain, and clutch clearances differ between the summary specification table and the corresponding assembly text.

The torque-converter section describes operation and diagnosis, with replacement as a complete assembly when faulty. It does not provide an internal converter rebuilding procedure.

Transmission work involves heavy components and pressurized hydraulic fluid. The overdrive direct-clutch procedures also require suitable spring-compression equipment and a hydraulic shop press.

Examples from the Torque and Electrical Test Tables

The torque table lists oil-pump bolts at 20 N·m (15 ft-lb) and valve-body-to-case bolts at 12 N·m (100 in-lb), identifying the fasteners separately from the smaller valve-body assembly screws.

At 70°F, the Ohms Reading Chart specifies 25–40 ohms for the overdrive and converter-clutch solenoids, compared with 3.0–5.0 ohms for the governor pressure solenoid.