Battery cable JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual

KEY-IN IGNITION SWITCH
DESCRIPTION
The key-in ignition switch is concealed within and
integral to the ignition switch, which is mounted on
the steering column. The key-in ignition switch is
actuated by the ignition lock cylinder mechanism,
and is hard wired between a body ground and the
Body Control Module (BCM) through the instrument
panel wire harness.
The key-in ignition switch cannot be adjusted or
repaired and, if faulty or damaged, the entire igni-
tion switch unit must be replaced,(Refer to 19 -
STEERING/COLUMN/LOCK CYLINDER HOUSING
- REMOVAL). For complete circuit diagrams, refer to
Body Control Modulein the Contents of Wiring
Diagrams.
OPERATION
The key-in ignition switch closes a path to ground
for the BCM when the ignition key is inserted in the
ignition lock cylinder, and opens the ground path
when the key is removed from the ignition lock cyl-
inder. The BCM monitors the key-in ignition switch
status through an internal pull-up, then sends the
proper switch status messages to other electronic
modules over the Programmable Communications
Interface (PCI) data bus network. The key-in ignition
switch status is also used by the BCM as an input
for chime warning system operation.
DIAGNOSIS AND TESTING
KEY-IN IGNITION SWITCH
For complete circuit diagrams, refer toBody Con-
trol Modulein the Contents of Wiring Diagrams.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO GROUP 8M - PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.(1) Disconnect and isolate the battery negative
cable. Disconnect the instrument panel wire harness
connector from the key-in ignition switch connector
receptacle on the ignition switch. Check for continu-
ity between the key-in ignition switch sense and
ground terminals of the key-in ignition switch con-
nector receptacle. There should be continuity with
the key inserted in the ignition lock cylinder, and no
continuity with the key removed from the ignition
lock cylinder. If OK, go to Step 2. If not OK, replace
the faulty ignition switch unit.
(2) Check for continuity between the ground cir-
cuit cavity of the instrument panel wire harness con-
nector for the key-in ignition switch and a good
ground. There should be continuity. If OK, go to Step
3. If not OK, repair the open ground circuit to ground
as required.
(3) Disconnect the gray 26-way instrument panel
wire harness connector from the Body Control Mod-
ule (BCM) connector receptacle. Check for continuity
between the key-in ignition switch sense circuit cav-
ity of the instrument panel wire harness connector
for the key-in ignition switch and a good ground.
There should be no continuity. If OK, go to Step 4. If
not OK, repair the shorted key-in ignition switch
sense circuit as required.
(4) Check for continuity between the key-in igni-
tion switch sense circuit cavities of the instrument
panel wire harness connector for the key-in ignition
switch and the gray 26-way instrument panel wire
harness connector for the BCM. There should be con-
tinuity. If OK, use a DRB scan tool and the proper
Diagnostic Procedures manual to test the BCM. If
not OK, repair the open key-in ignition switch sense
circuit as required.
LOCK CYLINDER
REMOVAL
The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before removing ignition switch.
(1) Disconnect negative battery cable at battery.
(2) If equipped with an automatic transmission,
place shifter in PARK position.
(3) Rotate key to ON position.
19 - 14 COLUMNWJ

(4) A release tang is located on bottom of key cyl-
inder (Fig. 18).(5) Position a small screwdriver or pin punch into
tang access hole on bottom of steering column lower
cover (Fig. 19).
(6) Push the pin punch up while pulling key cylin-
der from steering column.
INSTALLATION
The ignition key must be in the key cylinder for
cylinder removal. The key cylinder must be removed
first before removing ignition switch.
(1) If equipped with an automatic transmission,
place shifter in PARK position.
(2) Position key cylinder into steering column as it
would normally be in the ON position.
(3) Press key cylinder into column until it snaps
into position.
(4) Check mechanical operation of switch.Auto-
matic Transmission:Be sure transmission lever is
locked in PARK position after key removal. If key is
difficult to rotate or is difficult to remove, the shift
lever-to-steering column cable may be out of adjust-
ment or defective. Refer to Transmission for proce-
dures.Manual Transmission:Be sure key cannot
be removed until release lever is operated. If key can
be removed, release lever mechanism may be defec-
tive. Release lever mechanism is not serviced sepa-
rately. If repair is necessary, the steering column
must be replaced,(Refer to 19 - STEERING/COL-
UMN - REMOVAL).
(5) Connect negative cable to battery.
(6) Check electrical operation of switch.
STEERING WHEEL
REMOVAL
For steering wheel removal procedure,(Refer to 8 -
ELECTRICAL/RESTRAINTS/CLOCKSPRING -
REMOVAL).
INSTALLATION
For steering wheel installation procedure,(Refer to
8 - ELECTRICAL/RESTRAINTS/CLOCKSPRING -
INSTALLATION).
Fig. 18 Key Cylinder Release Tang
1 - KEY CYLINDER
2 - RELEASE TANG
Fig. 19 Key Cylinder and Cover Removal
1 - LOWER COVER
2 - ACCESS HOLE
3 - PIN PUNCH
4 - COVER SCREWS (3)
WJCOLUMN 19 - 15
LOCK CYLINDER (Continued)

SPECIAL TOOLS
POWER STEERING PUMP
FLUID COOLER
DESCRIPTION
4.7L models of this vehicle are equipped with a
cooler for the power steering system fluid. The power
steering fluid cooler is located at the front of the
vehicle. It is mounted to the radiator support just
forward of the air-conditioning condenser and just
rearward of the front fascia (Fig. 6). The cooler is
positioned so it is in the air flow through the front
fascia of the vehicle.
REMOVAL
(1) Disconnect negative battery cable at battery.
(2) Drain the power steering fluid out of the reser-
voir.
(3) Remove the front fascia grille assembly,(Refer
to 13 - FRAMES & BUMPERS/BUMPERS/FRONT
FASCIA - REMOVAL).
(4) Remove the grille opening reinforcement panel
(5) Place a drain pan under the cooler.
(6) Disconnect the lower hose at cooler (Fig. 6).
(7) Disconnect the upper hose at cooler (Fig. 6).
(8) Remove the three cooler mounting bolts (Fig.
6).
(9) Remove the cooler from the vehicle.
Analyzer Set, Power Steering Flow/Pressure 6815
Adapters, Power Steering Flow/Pressure Tester
6893
4.7L HYDRAULIC POWER STEERING TEST
ADAPTER KIT - 8630
Puller C-4333
Installer, Power Steering Pulley C-4063B
Fig. 6 POWER STEERING FLUID COOLER
1 - POWER STEERING COOLER
2 - POWER STEERING COOLER LINES CLIP
19 - 36 PUMPWJ
PUMP (Continued)

INSTALLATION
(1) Position and install the power steering cooler
to the vehicle.
(2) Install the three mounting bracket bolts (Fig.
6).
(3) Reconnect the upper hose at cooler (Fig. 6).
(4) Reconnect the lower hose at cooler (Fig. 6).
(5) Connect negative battery cable to battery.
(6) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
(7) Start engine and check for leaks.
(8) Install the grille opening reinforcement panel
(9) Install the front fascia grille,(Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- INSTALLATION).
HOSES - 4.0L
DESCRIPTION
DESCRIPTION - PRESSURE LINE
The hose consists of two metal ends and rubber
center section that contains a tuning cable. The
pump end uses a quick connect fitting. Lubircation
must be used on the quick connect nut and o-ring
when installing.
DESCRIPTION - RETURN LINE
Power steering return line is a hose which is
clamped at the pump and the gear.
OPERATION
OPERATION - PRESSURE LINE
Power steering pressure line, is used to transfer
high pressure power steering fluid, from the power
steering pump to the power steering gear on the
4.0L. The 4.7L power steering pressure line, is used
to transfer high pressure power steering fluid, from
the power steering pump to the engine cooling fan
and the steering gear.
OPERATION - RETURN LINE
Power steering return line, is used to transfer low
pressure power steering fluid, from the power steer-
ing gear to the power steering pump.
REMOVAL
(1) Drain the power steering fluid from the reser-
voir.
(2) Remove the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(3) Disconnect the power steering pressure hose
from the power steering pump and then the power
steering gear (Fig. 7).
(4) Disconnect the power steering return hose from
the power steering cooler and the reservoir.
(5) Remove the hoses from the vehicle.
INSTALLATION
(1) Install the hoses to the vehicle.
(2) Reconnect the power steering return hose to
the power steering cooler and the reservoir.
(3) Reconnect the power steering pressure hose to
the power steering pump and then the power steer-
ing gear.
(4) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(5) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
Fig. 7 POWER STEERING HOSES
1 - RETURN HOSE
2 - HIGH PRESSURE HOSE
3 - STEERING GEAR
WJPUMP 19 - 37
FLUID COOLER (Continued)

(5) Disconnect the rubber hose from the power
steering reservoir (Fig. 12).
(6) Remove the hose from the vehicle.
REMOVAL - 3/8(GEAR OUTLET HOSE
(1) Drain the power steering fluid from the reser-
voir.
(2) Remove the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(3) Raise and support the vehicle.
(4) Disconnect the rubber hose from the steering
cooler inlet tube (Fig. 11).
(5) Disconnect the metal tube from the power
steering gear (Fig. 11).
(6) Remove the hose from the vehicle.
REMOVAL - INLET COOLER HOSE
(1) Disconnect negative battery cable at battery.
(2) Drain the power steering fluid out of the reser-
voir.
(3) Remove the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(4) Remove the front fascia grille assembly,(Refer
to 13 - FRAMES & BUMPERS/BUMPERS/FRONT
FASCIA - REMOVAL).
(5) Remove the grille opening reinforcement panel
(6) Place a drain pan under the cooler.
(7) Disconnect the lower hose at cooler (Fig. 6).
(8) Disconnect the cooler hose at the gear.
(9) Remove the bracket holding the cooler hoses
(Fig. 13).
(10) Remove the cooler hose from the vehicle.
REMOVAL - OUTLET COOLER HOSE
(1) Disconnect negative battery cable at battery.
(2) Drain the power steering fluid out of the reser-
voir.
(3) Remove the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(4) Remove the front fascia grille assembly,(Refer
to 13 - FRAMES & BUMPERS/BUMPERS/FRONT
FASCIA - REMOVAL).
(5) Remove the grille opening reinforcement panel
(6) Place a drain pan under the cooler.
(7) Disconnect the upper hose at cooler (Fig. 6).
(8) Disconnect the cooler hose at the reservoir.
(9) Remove the bracket holding the cooler hoses
(Fig. 13).
(10) Remove the cooler hose from the vehicle.
INSTALLATION
INSTALLATION - 1/2(PRESSURE HOSE
NOTE: Lubrication and a new o-ring must be used
when reinstalling.
(1) Install the hoses to the vehicle.
(2) Reconnect the high pressure hose to the power
steering pump (Fig. 8) Tighten the hose to 22.5 N´m
(17 ft.lbs.).
(3) Reconnect the high pressure hose to the
hydraulic fan motor (Fig. 8) Tighten the hose to 22.5
N´m (17 ft.lbs.).
(4) Install the hose to the clipped position on the
fan shroud.
(5) Install the metal skid plate.
(6) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(7) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
INSTALLATION - 1/2(RETURN HOSE
(1) Install the hoses to the vehicle.
(2) Reconnect the rubber return hose to the power
steering reservoir (Fig. 9) Tighten the hose clamp.
(3) Reconnect the rubber return hose to the
hydraulic fan motor (Fig. 9) Tighten the hose.
(4) Install the metal skid plate.
(5) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(6) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
Fig. 13 COOLER HOSES MOUNTING BRACKET
1 - RADIATOR
2 - COOLER HOSES MOUNTING BRACKET
2 - COOLER HOSE
19 - 40 PUMPWJ
HOSES - 4.7L (Continued)

INSTALLATION - 3/8(PRESSURE HOSE
NOTE: Lubrication and a new o-ring must be used
when reinstalling.
(1) Install the hoses to the vehicle.
(2) Reconnect the high pressure hose to the
hydraulic fan motor (Fig. 10) Tighten the hose to
22.5 N´m (17 ft.lbs.).
(3) Reconnect the high pressure hose to the power
steering gear (Fig. 10) Tighten the hose to 22.5 N´m
(17 ft.lbs.).
(4) Install the hose to the clipped position on the
fan shroud.
(5) Install the metal skid plate.
(6) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(7) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
INSTALLATION - 3/8(RETURN HOSE
(1) Install the hoses to the vehicle.
(2) Reconnect the rubber hose to the steering
cooler outlet tube (Fig. 12) Tighten the hose clamp.
(3) Reconnect the rubber hose to the power steer-
ing reservoir (Fig. 12) Tighten the hose clamp.
(4) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(5) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
INSTALLATION - 3/8(GEAR OUTLET HOSE
NOTE: Lubrication and a new o-ring must be used
when reinstalling.
(1) Install the hoses to the vehicle.
(2) Reconnect the rubber hose to the steering
cooler inlet tube (Fig. 11) Tighten the hose clamp.
(3)
Reconnect the metal tube to the power steering
gear (Fig. 11) Tighten the hose to 22.5 N´m (17 ft.lbs.).
(4) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(5) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
INSTALLATION - INLET COOLER HOSE
(1) Install the cooler hose to the vehicle.
(2) Reconnect the cooler hose at the gear.
(3) Reconnect the lower hose at cooler (Fig. 6).
Tighten the hose to 22.5 N´m (17 ft.lbs.)
(4) Install the bracket holding the cooler hoses
(Fig. 13).(5) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(6) Install the grille opening reinforcement panel
(7) Install the front fascia grille assembly, (Refer to
13 - FRAMES & BUMPERS/BUMPERS/FRONT
FASCIA - INSTALLATION).
(8) Reconnect negative battery cable at battery.
(9) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
INSTALLATION - OUTLET COOLER HOSE
(1) Install the cooler hose to the vehicle.
(2) Reconnect the cooler hose at the reservoir.
(3) Reconnect the upper hose at the cooler (Fig. 6).
Tighten the hose to 22.5 N´m (17 ft. lbs.)
(4) Install the bracket holding the cooler hoses
(Fig. 13). Tighten the bracket to 22.5 N´m (17 ft. lbs.)
(5) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(6) Install the grille opening reinforcement panel
(7) Install the front fascia grille assembly, (Refer to
13 - FRAMES & BUMPERS/BUMPERS/FRONT
FASCIA - INSTALLATION).
(8) Reconnect negative battery cable at battery.
(9) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
PULLEY
DESCRIPTION
POWER STEERING PUMP PULLEY - 3.1L
DIESEL
To service the power steering pump pulley on the
3.1L turbo diesel engine. Refer to the power steering
pump removal and installation procedure in this
group. The pulley must be removed to service the
pump assembly. Detailed instructions are provided in
the pump procedure.
REMOVAL
CAUTION: On vehicles equipped with the 4.0L or
4.7L, Do not reuse the old power steering pump
pulley it is not intended for reuse. A new pulley
must be installed if removed.
(1) Remove pump assembly.
(2) Remove pulley from pump with Puller C-4333
or equivalent puller (Fig. 14).
WJPUMP 19 - 41
HOSES - 4.7L (Continued)

REMOVAL
The overdrive unit can be removed and serviced
separately. It is not necessary to remove the entire
transmission assembly to perform overdrive unit
repairs.
If only the overdrive unit requires service, refer to
Overdrive Removal for proper procedures.
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo-
nent damage. The converter driveplate, pump bush-
ing, or oil seal can be damaged if the converter is
left attached to the driveplate during removal. Be
sure to remove the transmission and converter as
an assembly.
(1) Disconnect battery negative cable.
(2) Disconnect and lower or remove necessary
exhaust components.
(3) Disconnect fluid cooler lines at transmission.
(4) Remove starter motor. (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - REMOVAL)
(5) Disconnect and remove crankshaft position sen-
sor. (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION/CRANKSHAFT POSITION SENSOR -
REMOVAL) Retain sensor attaching bolts.
CAUTION: The crankshaft position sensor will be
damaged if the transmission is removed, or
installed, while the sensor is still bolted to the
engine block, or transmission (4.0L only). To avoid
damage, be sure to remove the sensor before
removing the transmission.
(6) Remove the bolts holding the bell housing
brace to the transmission.
(7) Remove nut holding the bell housing brace to
the engine to transmission bending brace.
(8) Remove the bell housing brace from the trans-
mission (Fig. 13).
(9) Remove the bolt holding the torque converter
cover to the transmission.
(10) Remove the torque converter cover from the
transmission.
(11) If transmission is being removed for overhaul,
remove transmission oil pan, drain fluid and reinstall
pan.
(12) Remove fill tube bracket bolts and pull tube
out of transmission. Retain fill tube seal. On4x4
models, it will also be necessary to remove bolt
attaching transfer case vent tube to converter hous-
ing.
(13) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.(14) Mark propeller shaft and axle yokes for
assembly alignment. Then disconnect and remove
propeller shaft. On4x4models, remove both propel-
ler shafts.
(15) Disconnect wires from park/neutral position
switch and transmission solenoid.
(16) Disconnect gearshift cable from transmission
manual valve lever (Fig. 14).
Fig. 13 Bell Housing Brace and Converter Cover
1 - Transmission
2 - Torque Converter Cover
3 - Bellhousing Brace
Fig. 14 Transmission Shift Cable
1 - SHIFT CABLE
2 - MANUAL LEVER
3 - MANUAL LEVER
WJAUTOMATIC TRANSMISSION - 42RE 21 - 27
AUTOMATIC TRANSMISSION - 42RE (Continued)

ASSEMBLY
(1) Lubricate piston and guide seals (Fig. 235)
with petroleum jelly. Lubricate other servo parts with
MopartATF +4, type 9602, transmission fluid.
(2) Install new seal ring on servo piston.
(3) Assemble piston, plug, spring and new snap-
ring.
(4) Lubricate piston seal lip with petroleum jelly.
SHIFT MECHANISM
DESCRIPTION
The gear shift mechanism provides six shift posi-
tions which are:
²PARK (P)
²REVERSE (R)
²NEUTRAL (N)
²DRIVE (D)
²Manual SECOND (2)
²Manual LOW (1)
OPERATION
Manual LOW (1) range provides first gear only.
Overrun braking is also provided in this range. Man-
ual SECOND (2) range provides first and second gear
only.
DRIVE range provides first, second third and over-
drive fourth gear ranges. The shift into overdrive
fourth gear range occurs only after the transmission
has completed the shift into D third gear range. No
further movement of the shift mechanism is required
to complete the 3-4 shift.
The fourth gear upshift occurs automatically when
the overdrive selector switch is in the ON position.
No upshift to fourth gear will occur if any of the fol-
lowing are true:
²The transmission fluid temperature is below 10É
C (50É F) or above 121É C (250É F).
²The shift to third is not yet complete.
²Vehicle speed is too low for the 3-4 shift to occur.
²Battery temperature is below -5É C (23É F).
REMOVAL
(1) Remove any necessary console parts for access
to shift lever assembly and shifter cables. (Refer to
23 - BODY/INTERIOR/FLOOR CONSOLE -
REMOVAL)
(2) Shift transmission into PARK.
(3) Disconnect the transmission shift cable at shift
lever and shifter assembly bracket (Fig. 236).
(4) Disconnect the park lock cable from the shifter
BTSI lever and the shifter assembly bracket. (Fig.
237)
(5) Disconnect the transfer case shift cable from
the transfer case shift lever pin (Fig. 238), if
equipped.
(6) Remove the clip holding the transfer case shift
cable to the shifter assembly bracket, if equipped.
(7) Remove the transfer case shift cable from the
shifter assembly bracket, if equipped.
Fig. 234 Rear Servo Components
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
Fig. 235 Rear Servo Components
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
WJAUTOMATIC TRANSMISSION - 42RE 21 - 123
REAR SERVO (Continued)

TORQUE CONVERTER LEAK POINTS
Possible sources of converter leaks are:
(1) Leaks at the weld joint around the outside
diameter weld (Fig. 7).
(2) Leaks at the converter hub weld (Fig. 7).
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-CoilsŸ, or equivalent. This repair con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-CoilŸ tap, or
equivalent, and installing a Heli-CoilŸ insert, or
equivalent, into the hole. This brings the hole back to
its original thread size.
Heli-CoilŸ, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
REMOVAL
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo-
nent damage. The converter driveplate, converter
hub o-ring, or oil seal can be damaged if the con-
verter is left attached to the driveplate during
removal. Be sure to remove the transmission and
converter as an assembly.
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle
(3) Mark propeller shaft and axle yokes for assem-
bly alignment.
(4) Remove the rear propeller shaft
(5) Remove the front propeller shaft.
(6) Remove the engine to transmission collar (Fig.
8).
(7) Remove the exhaust support bracket from the
rear of the transmission.
(8) Disconnect and lower or remove any necessary
exhaust components.
(9) Remove the starter motor.
(10) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.
(11) Disconnect wires from solenoid and pressure
switch assembly, input and output speed sensors, and
line pressure sensor.
Fig. 7 Torque Converter Assembly
1 - TURBINE ASSEMBLY
2-STATOR
3 - CONVERTER HUB
4 - O-RING
5 - IMPELLER ASSEMBLY
6 - CONVERTER CLUTCH PISTON
7 - TURBINE HUB
Fig. 8 Transmission Collar
1 - ENGINE
2 - ENGINE TO TRANSMISSION COLLAR
3 - TRANSMISSION
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 183
AUTOMATIC TRANSMISSION - 545RFE (Continued)

leak area. If the hose cannot be positioned without
being held, have someone help do the water test.
Some water leaks must be tested for a considerable
length of time to become apparent. When a leak
appears, find the highest point of the water track or
drop. The highest point usually will show the point of
entry. After leak point has been found, repair the
leak and water test to verify that the leak has
stopped.
Locating the entry point of water that is leaking
into a cavity between panels can be difficult. The
trapped water may splash or run from the cavity,
often at a distance from the entry point. Most water
leaks of this type become apparent after accelerating,
stopping, turning, or when on an incline.
MIRROR INSPECTION METHOD
When a leak point area is visually obstructed, use
a suitable mirror to gain visual access. A mirror can
also be used to deflect light to a limited-access area
to assist in locating a leak point.
BRIGHT LIGHT LEAK TEST METHOD
Some water leaks in the luggage compartment can
be detected without water testing. Position the vehi-
cle in a brightly lit area. From inside the darkened
luggage compartment inspect around seals and body
seams. If necessary, have a helper direct a drop light
over the suspected leak areas around the luggage
compartment. If light is visible through a normally
sealed location, water could enter through the open-
ing.
PRESSURIZED LEAK TEST METHOD
When a water leak into the passenger compart-
ment cannot be detected by water testing, pressurize
the passenger compartment and soap test exterior of
the vehicle. To pressurize the passenger compart-
ment, close all doors and windows, start engine, and
set heater control to high blower in HEAT position. If
engine can not be started, connect a charger to the
battery to ensure adequate voltage to the blower.
With interior pressurized, apply dish detergent solu-
tion to suspected leak area on the exterior of the
vehicle. Apply detergent solution with spray device or
soft bristle brush. If soap bubbles occur at a body
seam, joint, seal or gasket, the leak entry point could
be at that location.
WIND NOISE
Wind noise is the result of most air leaks. Air leaks
can be caused by poor sealing, improper body compo-
nent alignment, body seam porosity, or missing plugs
in the engine compartment or door hinge pillar areas.
All body sealing points should be airtight in normal
driving conditions. Moving sealing surfaces will notalways seal airtight under all conditions. At times,
side glass or door seals will allow wind noise to be
noticed in the passenger compartment during high
cross winds. Over compensating on door or glass
adjustments to stop wind noise that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After a repair pro-
cedure has been performed, test vehicle to verify
noise has stopped before returning vehicle to use.
Wind noise can also be caused by improperly fitted
exterior moldings or body ornamentation. Loose
moldings can flutter, creating a buzzing or chattering
noise. An open cavity or protruding edge can create a
whistling or howling noise. Inspect the exterior of the
vehicle to verify that these conditions do not exist.
VISUAL INSPECTION BEFORE TESTS
Verify that floor and body plugs are in place and
body components are aligned and sealed. If compo-
nent alignment or sealing is necessary, refer to the
appropriate section of this group for proper proce-
dures.
ROAD TESTING WIND NOISE
(1) Drive the vehicle to verify the general location
of the wind noise.
(2) Apply 50 mm (2 in.) masking tape in 150 mm
(6 in.) lengths along weatherstrips, weld seams or
moldings. After each length is applied, drive the vehi-
cle. If noise goes away after a piece of tape is applied,
remove tape, locate, and repair defect.
POSSIBLE CAUSE OF WIND NOISE
²Moldings standing away from body surface can
catch wind and whistle.
²Gaps in sealed areas behind overhanging body
flanges can cause wind-rushing sounds.
²Misaligned movable components.
²Missing or improperly installed plugs in pillars.
²Weld burn through holes.
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY LUBRICATION
All mechanisms and linkages should be lubricated
when necessary. This will maintain ease of operation
and provide protection against rust and excessive
wear. The weatherstrip seals should be lubricated to
prolong their life as well as to improve door sealing.
All applicable exterior and interior vehicle operat-
ing mechanisms should be inspected and cleaned.
Pivot/sliding contact areas on the mechanisms should
then be lubricated.
(1) When necessary, lubricate the operating mech-
anisms with the specified lubricants.
23 - 2 BODYWJ
BODY (Continued)