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Huge fix for 2005 Wrangler X with 42RLE

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58K views 84 replies 29 participants last post by  Hot box  
#1 ·
Been on this forum too many times to count trying to find some answer to my transmission woes on the TJ. I've learned something every time and these posts have been invaluable to me. So hopefully I can be a help to all you other jeepers out there. This has been a 2+ year ordeal that had progressively gotten worse with transmission slippage, a multitude of OBDII codes and dozens of hours of frustrating work and missed fun on weekends trying to figure this out. I had been blaming all my problems on the 42RLE that has 124000 miles on it and was about to get one from a scrap yard and this only after I traced all the wiring from tranny to PCM and power dist center. Changing transmission fluid and filter twice in a year while removing valve body and taking out and cleaning TRS TPS input and output speed sensors.Everything I could find on the transmission. The only thing was after I would disconnect the battery my Jeep would run perfectly until the devilish computer had a chance to relearn its evil ways. Then my CEL started throwing the dreaded U0101 (TCM not communicating with PCM) and P1603 (one of those arbitrary,vague codes that the Jeep/Chrysler techies must have fun laughing at us trying to figure out). Every thread I've ever read on this and other sites pointed to a new computer only there aren't any of my specific models out there. So now I'm totally stuck! Jeep goes into limp mode after 10-15 miles after disconnecting battery all night and this has become my daughters only mode of transportation. So... I made myself go back to square 1 and started looking at this as primarily a PCM/TCM issue which is EXACTLY WHAT IT WAS!!!!!!!!!! I had read a post sometime earlier in my quest that dealt with removing the PCM and taking the circuit board out and resoldering the "pads". But that was for an older XJ, i think, and quite frankly scared me. I have 0 experience working on any kind of microelectronics and didn't want to risk fooling with that. Fast forward to Monday night 4/18/2016 and in my frustration I decided to pull the circuit board out to see what I could see. I researched the PCM post again and went to FRYs electronics to purchase the DeOxit, 30watt soldering iron, and the proper Rosin core solder. While i was looking around for the DeOxit an older, very kind gentleman asked what I was going to tinker on. I ended up sharing my whole story with him. He told me about a product called PureTronics and that it was just as good as DeOxit and then proceeded to inform me that he was a retired electrical engineer and that he'd be happy to give me his phone number and talk me thru the fix once I got home. So we exchanged numbers and off I go feeling more confident and hopeful than I have in months. I get home and immediately pull the PCM then called my new hero. He told me what to do in these exact steps.
1) clean the outside of the unit and the PCM plugs with QD electrical spray before i even take off PCM. Make sure it's not dusty or dirty. Oops.
2)remove torx screws and spray screw holes with QD spray
3)remove PCM black cover gently be very aware of contaminants that may
have tried to sneak in. I have no idea what the gel is called that is in the PCM but I know that it works actively against you from this point on.
NOTE: it will be best to perform this with new, anti static gloves
4)this was by far the most difficult part. Gently begin to pry up circuit board. It is unbelievably difficult to do. I was able to use a piece of a split drumstick to get to the very edge of the board, being careful to not touch any of the copper trace or circuits. It took a long time to get this out. The gel is strong and is pulling against you the whole time. I eventually got the board up enough to get another drumstick wedged between the board and PCM casing. Then I was able to slowly roll the stick for maybe an inch or so at a time to hold board and let the gel release. Finally after 15-18 minutes or so I finally got Circuit board out. I was very apprehensive but I was ALL IN at this point.
5)gently remove gel from the pin sites where you can see the little solder joints where pins meet circuit board. I used a #10 blade scalpel(I'm an RN in the OR). I tried my best not to touch the board with the blade and was able to keep the piece of gel mostly intact so I could put it back on after I was done.
6)So now I'm at the mercy of my new friend on the phone and he asks me if I see bad solder, a broken pin site, corrosion, contamination or any other suspicious thing. I tell him I have absolutely no idea what any of those things look like on the microelectronic level and that I'm definitely not comfortable trying to solder anything this small even if it is broken. He tells me to very gently rub with my gloved finger or thumb the rest of the gel off of the pin solder sites. I did. It was very obvious after this what was going on. The gel is very clear/transparent. As I started gently rubbing the gel off the solder the gel all turned brown!!!! He told me that is corrosion on the micro level. Oxidation on the back of the pins!!!! I got my large Magnifying glass and could see what looked like little brown freckles on the solder.
7)Using a new tooth brush gently clean/remove the rest of the gel remnant on the pins and also on the closest surrounding components as they could very well have some contaminant on them because of proximity to the pins. I did each of the four plug- 32 pin sites the same way.
8)This is when the magic happened!! He then told me to hold the board upright and quickly spray 2 very short sprays of PureTronic on the exposed pinsite solder joints and the microcomponents. WOW!!!!!!!!! in less than a second all that metal turned from dull to freaking BRILLIANT, SHINY, New looking metal!!! I've certainly never seen anything like it. And that was my fix!!!
9)Put the circuit board back in the casing making completely sure that the gel is covering EVERY SINGLE part of board. If it doesn't you can gently massage the gel to cover up uncovered pieces. It's not difficult at all. If you have any uncovered areas or contaminated gel that you don't feel comfortable reusing. He said you can use a very small shot of clear,silicone caulk.
*NOTE* You must get the cover on and make sure you push it down hard enough so that the plug ports are our far enough to receive the harness plugs completely. If not they won't snap on.
10)Spray all Torx screws with PureTronic/DeOxit whichever you prefer to use. Also spray in the screw holes of PCM. Make sure to get the long screws very clean and oxidation free before you reattach to firewall.
11)spray inside harness plugs with PureTronic and let dry. Then reconnect PCM.

I can honestly say that when I started my/my daughters JEEP IT HAS NEVER RUN AS GOOD!!!!!! My transmission shifted smoother and responded quicker than it ever had. EVERYTHING seemed better. Faster start on ignition, brighter lights, more responsive breaking. I mean EVERYTHING! I put over 50 miles on it that night. Running it hard on hwy. On a few trails. and thru a couple big ditches. lots of off/on starts and getting into passing gear then slowing down and going thru all the gears/shifts again. It's now Wednesday. My daughter has taken it to the beach and had blast for the first time. I truly believe that she is in a safe, dependable vehicle now. And I pray that my efforts can help all of y'all. I believe we should all do this as a PM after maybe 5-6 years or 80000-90000 miles. I will also admit I was ready to blame ALL MY PROBLEMS on the 42RLE but it is performing incredibly as of now!!!!!!
Good Luck and Keep the rubber side down!!!!
 
#4 ·
I opened this thread as I am too nervous and suspicious of the 42RLE, and when I saw the length of your post I was ready to close it down. But I decided to just read a sentence or 2 to see what was going on, and wow, before I knew it I had read the whole WAR and PEACE. But I want to thank you for sharing this ordeal in great detail, because I think it just may benefit me as well.
 
#14 ·
Before 2005 the TCM is separate from the PCM and before that it was a 3 SPd non overdrive auto where all PCM did was control t/c lockup

So yes only 05-06 have a TCM integrated into the PCM and only 05-06 with auto tranny have a PCM with 4 harness plugs as far as I know all other TJ have a PCM with 3 harness plugs


Sent from my iPod touch using Tapatalk
 
#15 ·
Ok. Sorry for the delay in updating this. As of this moment the 05 X is still running great. Made it thru the summer and 100+ deg days with my daughter driving 60-70 miles a day. Mostly highway but then in the sand on the beach. Pulling cars and trucks out of this muck we have down here in Galveston,Tx. Made a good bit of $ doing it too. I'm not sure why it's still working well but I'm darn sure not gonna mess with a blessing. Maybe it was in the wiring harness. Maybe in the solder point of the pins in PCM. I'm just happy it's working. I did get a couple of codes pop up but just reset with my code reader and they've not come back. Since the PCM fix I've also replaced radiator, water pump, thermostat, housing, hoses, fan and fan clutch. I did install a tranny cooler as well and that little TJ is running as good as she ever has. Took it on 5 hour trip up into the hill county(Garner St Park area) and that's when I found my radiator leak. Patched it, got her home and replaced everything. Well... I hope at least a couple other folks have this same good luck! Keep Jeepin!!!
Oh btw, I got me a 2000 TJ too! MANUAL TRANNY!!!! Thank the Lord!!!
 
#16 ·
huge fix

Hello Big Drummer, I am attempting your fix because I have the same issues. Can you tell me which spot you started prying on the circuit board please? I am prying from the bottom right corner but it seems like the board under the plug sockets is not coming up. I sure don't want to crack the board. Thanks for the info.
 
#17 ·
First Benz is a dick for putting this crap out. My 93 JK auto will out climb any stick with style. My beautiful 03 TJ with front driveshaft and inner axles removed(its to pretty to off road) is as far as I can tell is a time bomb. I have had 2 JKs and hammered the trannys - my 03 TJ is made to be 2WD and must say it gets 20% better mileage but has a little 'buck' when rolling through a stop sign and taking off . . . pretty but I'm doomed
 
#22 ·
I'm having the same exact issue. 2005 Jeep Wrangler TJ with the Auto Tranny. My jeeps been in the dealership for 3 weeks and apparently they've shipped off my PCM to be rebuilt twice but it didn't solve the issue.

Currently, I have code P1604 reading on the 3 key turn reader. I'm in limp mode most of the time. I've followed the service manual diagnostics in checking the pins in the PCM connections wires with a test light and came back with positive results. The dealership has claimed to use a test PCM from another shop to confirm that it was, in fact, the PCM, and when they put that one in it came back without the p1604 code so it's definitely the PCM.

I'm told the PCM I have (P/N 56044533AC) is on national back order, and 155+ have been ordered with no delivery date so getting one any time soon doesn't seem like its going to happen.

I'm considering giving this a shot, but I'm curious if anyone out there has had positive results from this. I would have to probably spend the next couple of weeks learning as much as I can about microelectronics and I would really appreciate if anyone who has successfully completed this repair could let me know if they have had good results and would be willing to walk me through it.
 
#23 ·
I performed the deoxit fix today. As we all know, it will take a few days to know if the problem is gone for good. If it is solved, I will post here (and every other thread with this issue). I did not add new solder, I only sprayed deoxit all over everything.

Immediately I did notice that my ignition was very quick and it seemed like the “brightest” mode on the interior light switch made the odometer and stock head unit a brighter than I’ve ever seen before. These are both signs of increased conductivity, and I hope they’re not placebo.

I was experiencing the same symptoms as reported with a stored p0714. I live in Austin, TX and it just started hitting high 90s/100s here which is optimization for the jerking shifting.

I’m lead to believe it’s deteriorating conductivity as it seems like even with a replaced PCM the problem can come back. It also seems to occur with humidity and is obviously electrical as unplugging the battery fixes it.

Again, not sure if it fixed yet. If the problem returns I am going to resolder the pin connections.
 
#25 ·
220 miles and the problem returned. It started right after a sun shower, and I’m suspicious of the moisture.

However, this is the longest the Jeep has gone without this behavior. It’s possible the conductivity was improved temporarily.

I’m going to open the PCM again and inspect it, it’s easy enough to do once you’ve got the board out once.

I’m going to deox the connections a second time when I open the PCM. If that doesn’t work, I’ll try reflowing the solder points. 250 miles is what I’ll shoot for.

My buddy here repairs PCB and should be able to provide some insight if it comes to that.
 
#30 ·
So what has happened to the two guys that supposedly fixed their PCM?
Three post for one, four for the OP.
.???
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#32 ·
Literally just registered on here to follow this thread. This might be the first pinch of light that I’ve been able to get a peek of at the end of this endless Tunnel of PCM woes... I have an 05’ LJ with the 529AC 4-plug PCM.. got the dreaded tcm communication fault, and tried every trick in the book, including a manual reflash with HPtuning software to defeat the faults and trick the pcm into ignoring the startup voltage reference command that causes limp mode in the first place. All was temporary, and I now find myself flipping my battery disconnect every single time I need to start the Jeep within an hour of running it. I just moved to Oregon, and unfortunately need to pass DEQ because I’m within the metro boundary, so this has become a race against time for me... I’ll be attempting this fix hopefully this weekend, and will document it for you guys if it works. I don’t know if you’ve noticed, but the price of this PCM (reliably sourced) has jumped to $3,300 from $2,200 just within the past couple months. We NEED to get to the bottom of what’s causing this, because Chrysler frankly doesn’t give a damn about us.
 
#33 ·
I’ve had 2 since December that bring up all 4 O2 codes. They cancelled all orders (180 between US and Canada) so you can’t even get one right now. It fixed the limp mode P1603 but still no good with upper O2 sensors on. The eta was December 31 for anything new. That’s from my Jeep mechanic buddy that works at a dealership. I had a third on order that was supposed to be here in April.
 
#34 ·
No success for me guys, if anything, I’ve had a failure. Contacts definitely needed cleaning, but I think I have a solder joint failure somewhere. After the whole process my LJ is indefinitely stuck in limp mode... Flexing the motherboard was probably the last nail in the coffin. Will update you if I find out anything more, as I’m not giving up on it just yet.