[Gluckmysock]

I find that the electrical tape stiffens and gets hard after the elements get to it. If you look at the pictures I have of the temp senders in the post above(when I had just finished it from just under two years ago), those taped up connections have stiffened and unraveled to the point where one of the connections lost it's plastic coating and is now full of dirt and trans oil. I anticipate having to repair that connection eventually.

The cloth/tar-ish tape creates a water tight seal, and once the trans heats up a few times that tape is gonna be slightly flexible yet solid during everyday use. Also, once the dirt and dust gets on the outer shell, I think it'll be even more impervious to the elements.

Now, the last issue with the plug's wires melting most likely came from the internal temps of the transmission. I have the large cooler and the temp gauges for the trans oil installed since that event, and do not expect to have to ever pull it again to repair; mostly because I can monitor the internal temps at three different spots in the cooling circuit.

I wanted to have a water tight, element proof covering so as to not have any kind of chemical or oil on the wires that eventually could lead to degradation of the plastic sheathing of the wires. Resulting in having to do this repair again.

Ultimately, time will tell if this method will fail at some point, but I do not expect it to.

Awsome! Thanks!

I'm Just curious as to some of the wired melted more of the insulation than the others?? Do you think it was because they were slightly farther away?? Sorry, carry on with the funeral!

 

[DaingMaing]

I'm Just curious as to some of the wired melted more of the insulation than the others??

Some were more than others. In the pic above, the harness wire that is completely missing the insulation was pulled off and not melted. Pin for the Ground was the worst, followed by the Governor Pressure signal, and then the trans temperature signal.

Do you think it was because they were slightly farther away?? Sorry, carry on with the funeral!

I'm not so sure. I'd have to think on it more.

FYI, I did go back and try to replace a faulty relay only to find that the relay still worked; confirming it was a short from the harness.

 

[DaingMaing]

I just finished re-doing this job today to reinstall the newest solenoid packs that I mistakenly thought were bad about a month & a half ago.

The first pic is of the solenoid packs. The screws need 72 in/lbs when going back in. The valve body bolts need 100 in/lbs going back on starting from the middle/center towards to the outside of the body.

Note that the governor shield, governor, governor pressure solenoid & pressure switch are removed. This also is the VB unfastened to the trans and is hanging by the parking sprag. This position is moveable and can rotate around to get a better grasp on what you're doing.I do not recommend anyone do this. YMMV...

The second pic is pointing out the harness connector that is still in the housing. Note the broken mounting tab. If you do not break that tab; the harness connector will come down with the Valve Body.

The last is a picture of the harness connector properly attached to the valve body. BE SURE to NOT OVER TIGHTEN the harness mounting screw. The plastic will break. Gooten tight is all you need....

 

[Gluckmysock]

Looks like a royal pita. Think I'll follow your advice and not do this myself. :thumbsup:

 

[snowman_77]

One last thing before putting this thread to rest for the inter-webs archive: at least for the 90's ZJ(most likely the early aughts XJ and other associated JEEP 'RE' transmissions GC through 04) ALL of the wiring harnesses are the same color coding for the 42re & 44re's. FYI

If you have something other than a JEEP version of the 42/44re, your color coding will be slightly different.

I'm sorry to dig this old thread out of slumber but I desperately need help with an 04 WJ I have that NO ONE can seem to decipher for me.

I put an 02 GC/4.0/4×4 transmission in my 04 GC/4.0/4×4 and did not have 4th or overdrive. Which was odd because it worked perfectly when that transmission was in the 02. I checked the transmission shift solenoid (8 pin plug into top of valve body) and they are different color pin outs between the 02 and 04.

The 02 matches what's found online, the pinout list is pictured here

my 04 however does not match that diagram at all.

Does anyone have one for an 04 so I can figure out how to change the pin outs to make this transmission work?

 

[DaingMaing]

after a quick search this is what I've got. The cavities are the same the wiring is different.