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96 GC 4.0L 42RE 4x4 rebuilt Trans overdrive issue

Old 02-27-2019, 10:40 PM
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Model: Cherokee (XJ)
Default 96 GC 4.0L 42RE 4x4 rebuilt Trans overdrive issue

Bought a 96 GC 4.0L 4x4 with bad 42RE transmission as a project vehicle.
Bought ASTG 42RE manual and referenced YouTube to walk me through my first transmission rebuild.
Used a Deluxe Master Rebuild kit with new clutches and steels, Solenoid Service and Upgrade Kit and upgraded valve body with a Transgo SK TFODJR Shift Kit.
Took my time and followed manual and videos, double or triple checked end play measurements for intermediate shaft spacer and for overdrive piston spacer.
Here is my issue: transmission won't shift into overdrive.
I have adjusted shift cable.
OD override button on dash appears to work fine.
There are no trouble codes.
Transmission will shift 1-3 but not into overdrive. I did adjust cable all the way out and when I got to about 50 mph transmission seemed to shift to neutral and engine rev'd higher.
I believe this was actually OD shift but OD did not engage.
I know this could be a solenoid/electrical issue, however, one thing keeps popping into my head. When I measured for OD piston spacer the manual called for a .155 thickness spacer but the original spacer was 3 sizes thicker at .198.
So, since I seemed to get trans to shift into but not actually engage OD I am wondering if a thicker or original spacer would fix issue.
Since this is my first transmission rebuild I am hoping that someone on forum has had this issue when they rebuilt their transmission and can help me fix OD issue.
Any help pointing me in the right direction would be greatly appreciated.
hmmrhead is offline  
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