A/T - Fluid Weepage From Speed Sensors
NUMBER: 21-007-03GROUP: Transmission
DATE: Aug. 1, 2003
SUBJECT:
New Fasteners To Prevent Possible 42RLE Transmission Fluid Weepage
OVERVIEW:
This bulletin involves replacing specific transmission fasteners as necessary.
MODELS:
2003 (KJ) Cherokee (International Markets)
2003 (KJ) Liberty
2003 (TJ) Wrangler
NOTE:
This bulletin applies to vehicles equipped with 42RLE transmissions (sales code DG6).
SYMPTOM/CONDITION:
Transmission fluid may be wicking at the input or output speed sensor to case fasteners (Fig. 1), transmission oil pan to case fastener on left side, item 5 (Fig. 2), or the four bottom adapter/extension housing to case fasteners, items 1, 6, & 8 (Fig. 3).
DIAGNOSIS:
If Symptom/Condition is present, refer to the appropriate KJ or TJ Repair Procedure.
PARTS REQUIRED:
NOTE:
These fasteners have a sealer on them and are intended to be used one time. They should be replaced each time they are removed.
REPAIR PROCEDURE FOR KJ VEHICLES WITH A 42RLE TRANSMISSION:
1. Raise the vehicle.
2. Inspect the input and output speed sensor to case fasteners (Fig. 1), the transmission oil pan to case fastener, item 5 (Fig. 2), and the adapter/extension to case fasteners (4), items 1, 6, & 8, (Fig. 3).
3. If transmission fluid is wicking at either sensor fastener or the transmission oil pan fastener, proceed to next step. If not, proceed to step 6.
NOTE:
If any one of the three fasteners, input speed sensor, output speed sensor or the oil pan, are wicking; replace all three fasteners.
4. Replace the input speed sensor fastener and the output speed sensor fastener (p/n 05134342AA) (Fig. 1). Torque the sensor fasteners to 9 Nm (80 in. lbs.).
5. Replace the transmission oil pan fastener (p/n 03836596), item 5 (Fig. 2). Torque the fastener to 20 Nm (14.5 ft. lbs.).
6. If transmission fluid is wicking at any of the 4 bottom adapter/extension fasteners, item 1, 6, or 8, (Fig. 3), proceed to next step. If there is no weeping from any of the adapter/extension fasteners, proceed to step 15.
NOTE:
If any one of the four adapter/extenslon housing fasteners are wicking; replace all four fasteners.
7. Remove the 2 nuts, item 5 (Fig. 3), securing the exhaust hanger bracket to the transmission. Slide the exhaust hanger bracket rearward as far as possible.
8. Using a suitable jack, support the transmission under the transmission oil pan.
9. Remove the 4 transmission mount fasteners, item 2 (Fig. 3) and pull the mount down as far as possible.
10. Lift the transmission as necessary for access.
NOTE:
Perform step 11 on each fastener; one at a time, in order to retain the integrity of the adapter/extension seal to the transmission case.
11. Replace each of the 4 fasteners, items 1, 6, and 8 (Fig. 3). Torque the fasteners to 54 Nm (40 ft. lbs.).
12. Lower transmission as necessary to install the 4 transmission mount fasteners.
13. Lower and remove the transmission jack.
14. Slide the exhaust hanger bracket onto the studs in the transmission. Install the two nuts.
15. Lower the vehicle.
16. Check the transmission fluid level and adjust as necessary.
REPAIR PROCEDURE FOR TJ VEHICLES WITH A 42RLE TRANSMISSION:
1. Raise the vehicle.
2. Remove the skid plate, if equipped. Refer to the service information available in TechCONNECT or the 2003 Wrangler Service Manual (Publication No. 81-370-03063) page 13-7.
3. Inspect the input and output speed sensor to case fasteners (Fig. 1), the transmission oil pan to case fastener, item 5 (Fig. 2), and the adapter/extension to case fasteners (4), items 1, 6, & 8, (Fig. 3).
4. If transmission fluid is wicking at either sensor fastener or the transmission oil pan fastener, proceed to step 7.
NOTE:
If any one of the three fasteners, input sensor, output sensor or the oil pan, are wicking; replace all three fasteners.
5. Replace the input speed sensor fastener and the output speed sensor fastener (p/n 05134342AA) (Fig. 1). Torque the sensor fasteners to 9 Nm (80 in. lbs.).
6. Replace the transmission oil pan fastener (p/n 03836596), item 5 (Fig. 2). Torque the fastener to 20 Nm (14.5 ft. lbs.).
7. If transmission fluid is wicking at any of the 4 bottom adapter/extension fasteners, item 1, 6, or 8 (Fig. 3), proceed to next step. If there is no weeping from any of the adapter/extension fasteners, proceed to step 10.
NOTE:
If any one of the four adapter/extension housing fasteners are wicking; replace all four fasteners.
NOTE:
Perform step 8 on each fastener, one at a time, in order to retain the integrity of the adapter/extension seal to the transmission case.
8. Replace each of the 4 fasteners, items 1 and 6 (p/n 03836592), and item 8 (Fig. 3) (2 - p/n 03836591). Torque the fasteners to 54 Nm (40 ft. lbs.).
9. Install the transfer case skid plate, if equipped.
10. Lower the vehicle.
11. Check the transmission fluid level and adjust as necessary.
POLICY:
Reimbursable within the provisions of the warranty
TIME ALLOWANCE:
FAILURE CODE: