Prop JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual

PARK LOCK CABLE
REMOVAL
(1) Place the shifter in the PARK position.
(2) Lower the steering column cover.
(3) With the ignition switch in the ªRUNº position
depress the park lock cable locking tab, located on
top of the cable connector at the steering column and
pull the park lock cable straight out.
(4) Remove the park lock cable from steering col-
umn (Fig. 97).
(5) Remove the floor console and related trim.
(Refer to 23 - BODY/INTERIOR/FLOOR CONSOLE -
REMOVAL)
(6) Disconnect the park lock cable from the shift
BTSI lever and remove the cable from the shifter
assembly bracket.
(7) Release the park lock cable from any remaining
clips.
(8) Remove park lock cable from the vehicle.
INSTALLATION
NOTE: The gearshift cable must be secured into
position and properly adjusted before the installa-
tion of the Park Lock Cable.
(1) Verify that the shifter is in the PARK position.
(2) Push the park lock cable straight into the
square mounting hole in the steering column until
cable snaps in place.
(3) Route park lock cable to the shifter mecha-
nism.
(4) Install the park lock cable end fitting into
shifter BTSI lever.
(5) Pull rearward on the cable housing to snap
park lock cable adjuster ears into floor shifter
bracket.
(6) Place the ignition key cylinder in the ACCES-
SORY position.
(7) Push the cable adjuster lock clamp downward
to lock it.
(8) Test the park lock cable operation.
(9) Install the floor console and related trim.
(Refer to 23 - BODY/INTERIOR/FLOOR CONSOLE -
INSTALLATION)
Fig. 97 Brake Transmission Shift Interlock
1 - SHIFT MECHANISM 4 - STEERING COLUMN ASSEMBLY
2 - SHIFTER BTSI LEVER 5 - INTERLOCK CABLE
3 - ADJUSTMENT CLIP
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 255

position, the clutch will engage after the shift to
third gear, at approximately 56 km/h (35 mph) at
light throttle.
The TCM controls the torque converter by way of
internal logic software. The programming of the soft-
ware provides the TCM with control over the L/R-CC
Solenoid. There are four output logic states that can
be applied as follows:
²No EMCC
²Partial EMCC
²Full EMCC
²Gradual-to-no EMCC
NO EMCC
Under No EMCC conditions, the L/R Solenoid is
OFF. There are several conditions that can result in
NO EMCC operations. No EMCC can be initiated
due to a fault in the transmission or because the
TCM does not see the need for EMCC under current
driving conditions.
PARTIAL EMCC
Partial EMCC operation modulates the L/R Sole-
noid (duty cycle) to obtain partial torque converter
clutch application. Partial EMCC operation is main-
tained until Full EMCC is called for and actuated.
During Partial EMCC some slip does occur. Partial
EMCC will usually occur at low speeds, low load and
light throttle situations.
FULL EMCC
During Full EMCC operation, the TCM increases
the L/R Solenoid duty cycle to full ON after PartialEMCC control brings the engine speed within the
desired slip range of transmission input speed rela-
tive to engine rpm.
GRADUAL-TO-NO EMCC
This operation is to soften the change from Full or
Partial EMCC to No EMCC. This is done at mid-
throttle by decreasing the L/R Solenoid duty cycle.
REMOVAL
(1) Remove transmission and torque converter
from vehicle.
(2) Place a suitable drain pan under the converter
housing end of the transmission.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pull the torque converter forward until the cen-
ter hub clears the oil pump seal.
(4) Separate the torque converter from the trans-
mission.
INSTALLATION
Check converter hub and drive flats for sharp
edges, burrs, scratches, or nicks. Polish the hub and
flats with 320/400 grit paper or crocus cloth if neces-
sary. Verify that the converter hub o-ring is properly
installed and is free from debris. The hub must be
smooth to avoid damaging the pump seal at installa-
tion.
(1) Lubricate oil pump seal lip with transmission
fluid.
(2) Place torque converter in position on transmis-
sion.
CAUTION: Do not damage oil pump seal or con-
verter hub o-ring while inserting torque converter
into the front of the transmission.
(3) Align torque converter to oil pump seal open-
ing.
(4) Insert torque converter hub into oil pump.
(5) While pushing torque converter inward, rotate
converter until converter is fully seated in the oil
pump gears.
(6) Check converter seating with a scale and
straightedge (Fig. 117). Surface of converter lugs
should be at least 13 mm (1/2 in.) to rear of straight-
edge when converter is fully seated.
(7) If necessary, temporarily secure converter with
C-clamp attached to the converter housing.
Fig. 116 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 269
TORQUE CONVERTER (Continued)

(8) Install the transmission in the vehicle.
(9) Fill the transmission with the recommended
fluid.
TRANSMISSION CONTROL
RELAY
DESCRIPTION
The relay is supplied fused B+ voltage, energized
by the TCM, and is used to supply power to the sole-
noid pack when the transmission is in normal oper-
ating mode.
OPERATION
When the relay is ªoffº, no power is supplied to the
solenoid pack and the transmission is in ªlimp-inº
mode. After a controller reset, the TCM energizes the
relay. Prior to this, the TCM verifies that the con-
tacts are open by checking for no voltage at the
switched battery terminals. After this is verified, the
voltage at the solenoid pack pressure switches is
checked. After the relay is energized, the TCM mon-
itors the terminals to verify that the voltage is
greater than 3 volts.
TRANSMISSION RANGE
SENSOR
DESCRIPTION
The Transmission Range Sensor (TRS) is part of
the solenoid module, which is mounted to the top of
the valve body inside the transmission.
The Transmission Range Sensor (TRS) has five
switch contact pins that:
²Determine shift lever position
²Supply ground to the Starter Relay in Park and
Neutral only.
²Supply +12 V to the backup lamps in Reverse
only.
The TRS also has an integrated temperature sen-
sor (thermistor) that communicates transmission
temperature to the TCM and PCM.
OPERATION
The Transmission Range Sensor (TRS) communi-
cates shift lever position to the TCM as a combina-
tion of open and closed switches. Each shift lever
position has an assigned combination of switch states
(open/closed) that the TCM receives from four sense
circuits. The TCM interprets this information and
determines the appropriate transmission gear posi-
tion and shift schedule.
There are many possible combinations of open and
closed switches (codes). Seven of these possible codes
are related to gear position and five are recognized
as ªbetween gearº codes. This results in many codes
which shouldnever occur. These are called
ªinvalidº codes. An invalid code will result in a DTC,
and the TCM will then determine the shift lever
position based on pressure switch data. This allows
reasonably normal transmission operation with a
TRS failure.
GEAR C5 C4 C3 C2 C1
ParkCL OP OP CL CL
Temp 1CL OP OP CL OP
ReverseOP OP OP CL OP
Temp 2OP OP CL CL OP
Neutral 1OP OP CL CL CL
Neutral 2OP CL CL CL CL
Temp 3OP CL CL CL OP
DriveOP CL CL OP OP
Temp 4OP CL OP OP OP
Manual 2CL CL OP OP OP
Temp 5CL OP OP OP OP
Manual 1CL OP CL OP OP
Fig. 117 Checking Torque Converter Seating-Typical
1 - SCALE
2 - STRAIGHTEDGE
21 - 270 AUTOMATIC TRANSMISSION - 545RFEWJ
TORQUE CONVERTER (Continued)

REMOVAL
(1) Remove the valve body from the transmission
(Fig. 119).
(2) Remove the screws holding the transmission
solenoid/TRS assembly onto the valve body (Fig. 120).
(3) Separate the transmission solenoid/TRS assem-
bly from the valve body.
INSTALLATION
(1) Place TRS selector plate in the PARK position.
(2) Position the transmission solenoid/TRS assem-
bly onto the valve body. Be sure that both alignment
dowels are fully seated in the valve body and that
the TRS switch contacts are properly positioned in
the selector plate
(3) Install the screws to hold the transmission
solenoid/TRS assembly onto the valve body.
(4) Tighten the solenoid assembly screws adjacent
to the arrows cast into the bottom of the valve body
first. Tighten the screws to 5.7 N´m (50 in.lbs.).
(5) Tighten the remainder of the solenoid assembly
screws to 5.7 N´m (50 in.lbs.).
(6) Install the valve body into the transmission.
TRANSMISSION
TEMPERATURE SENSOR
DESCRIPTION
The transmission temperature sensor is a ther-
mistor that is integral to the Transmission Range
Sensor (TRS).
OPERATION
The transmission temperature sensor is used by
the TCM to sense the temperature of the fluid in the
sump. Since fluid temperature can affect transmis-
sion shift quality and convertor lock up, the TCM
requires this information to determine which shift
schedule to operate in.
Calculated Temperature
A failure in the temperature sensor or circuit will
result in calculated temperature being substituted for
actual temperature. Calculated temperature is a pre-
dicted fluid temperature which is calculated from a
combination of inputs:
²Battery (ambient) temperature
²Engine coolant temperature
²In-gear run time since start-up
Fig. 119 Valve Body Bolts
1 - VALVE BODY TO CASE BOLT (6)
Fig. 120 Ttransmission Solenoid/TRS Assembly
Screws
1 - SOLENOID PACK BOLTS (15)
21 - 272 AUTOMATIC TRANSMISSION - 545RFEWJ
TRANSMISSION SOLENOID/TRS ASSEMBLY (Continued)

Inspect all the valve and plug bores in the valve
body. Use a penlight to view the bore interiors.
Replace the valve body if any bores are distorted or
scored. Inspect all of the valve body springs. The
springs must be free of distortion, warpage or broken
coils.
Trial fit each valve and plug in its bore to check
freedom of operation. When clean and dry, the valves
and plugs should drop freely into the bores.
Valve body bores do not change dimensionally with
use. If the valve body functioned correctly when new,
it will continue to operate properly after cleaning and
inspection. It should not be necessary to replace a
valve body assembly unless it is damaged in han-
dling.
Inspect all the accumulator bores in the valve body.
Use a penlight to view the bore interiors. Replace the
valve body if any bores are distorted or scored.Inspect all of the accumulator springs. The springs
must be free of distortion, warpage or broken coils.
Inspect all the fluid seals on the valve body (Fig.
133). Replace any seals that are cracked, distorted, or
damaged in any way. These seals pass fluid pressure
directly to the clutches. Any pressure leak at these
points, may cause transmission performance prob-
lems.
ASSEMBLY
(1) Lubricate valves, springs, and the housing
valve bores with clean transmission fluid.
(2) Install solenoid switch valve, manual valve,
and the low/reverse switch valve into the valve body.
(3) Install the retainers to hold each valve into the
valve body.
(4) Install the valve body check balls into their
proper locations.
(5) Position the transfer plate onto the valve body.
(6) Install the screws to hold the transfer plate to
the valve body. Tighten the screws to 5.6 N´m (50 in.
lbs.).
(7) Install the accumulator pistons and springs
into the valve body in the location from which they
were removed. Note that all accumulators except the
overdrive have two springs. The overdrive accumula-
tor piston has only one spring.
Fig. 132 Valve Body Components
1 - SOLENOID SWITCH VALVE
2 - MANUAL VALVE
3 - LOW REVERSE SWITCH VALVE
4 - LOW REVERSE ACCUMULATOR
5 - 2ND CLUTCH ACCUMULATOR
6 - UNDERDRIVE ACCUMULATOR
7 - OVERDRIVE ACCUMULATOR
8 - 4TH CLUTCH ACCUMULATOR
9 - CHECK BALLS (7)
Fig. 133 Valve Body Seals
1 - UNDERDRIVE ACCUMULATOR (2 SPRINGS)
2 - 4TH CLUTCH ACCUMULATOR (2 SPRINGS)
3 - 2ND CLUTCH ACCUMULATOR (2 SPRINGS)
4 - LOW REVERSE ACCUMULATOR (2 SPRINGS)
5 - LOW/REVERSE PASSAGE SEAL
6 - 2ND CLUTCH PASSAGE SEAL
7 - 4TH CLUTCH PASSAGE SEAL
8 - OVERDRIVE ACCUMULATOR (1 SPRING)
21 - 278 AUTOMATIC TRANSMISSION - 545RFEWJ
VALVE BODY (Continued)

REMOVAL
(1) Shift transfer case into NEUTRAL.
(2) Raise vehicle.
(3) Remove transfer case drain plug and drain
transfer case lubricant.
(4) Mark front and rear propeller shaft yokes for
alignment reference.
(5) Support transmission with jack stand.
(6) Remove rear crossmember and skid plate, if
equipped (Fig. 3).
(7) Disconnect front/rear propeller shafts at trans-
fer case. (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(8) Disconnect transfer case cable from range
lever.
(9) Disconnect transfer case vent hose (Fig. 4) and
transfer case position sensor.
(10) Support transfer case with transmission jack.
(11) Secure transfer case to jack with chains.
(12) Remove nuts attaching transfer case to trans-
mission.(13) Pull transfer case and jack rearward to disen-
gage transfer case.
(14) Remove transfer case from under vehicle.
DISASSEMBLY
REAR RETAINER - NV242LD
(1) Remove output shaft boot. Spread band clamp
that secures boot on slinger with a suitable awl.
Then slide boot off shaft (Fig. 5).
Fig. 3 Crossmember Removal
1 - CROSSMEMBER
2 - REAR TRANSMISSION MOUNT
Fig. 4 Transfer Case Mounting
1 - NV242 TRANSFER CASE
Fig. 5 Output Boot - Typical
1 - SLINGER
2 - BOOT
3-AWL
4 - TRANSFER CASE
21 - 282 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail (Fig. 47). Minor nicks on the shift rail can
be smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear pads. The mode fork
pads are serviceable and can be replaced if necessary.
The range fork pads are also serviceable.
Check both of the sleeves for wear or damage,
especially on the interior teeth. Replace the sleeves if
wear or damage is evident.
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT
Inspect the retainer components (Fig. 48). Replace
the bearing if rough or noisy. Check the retainer for
cracks or wear in the bearing bore. Clean the
retainer sealing surfaces with a scraper and 3M all
purpose cleaner. This will ensure proper adhesion of
the sealer during reassembly.
Replace the slinger and seal outright; do not reuse
either part.
Replace any part if distorted, bent, or broken. Also
replace the boot if cut or torn. Replace the boot band
clamps, do not reuse them.
Fig. 48 Rear Retainer - Typical
1 - REAR RETAINER 5 - BAND CLAMPS
2 - REAR BEARING I.D. MAINSHAFT RETAINING RING 6 - REAR SLINGER
3 - REAR SEAL 7 - REAR BEARING O.D. RETAINING RING
4 - BOOT 8 - REAR BEARING
Fig. 47 Shift Fork And Wear Pad Locations
1 - MODE FORK
2 - RANGE FORK
3 - WEAR PADS (SERVICEABLE)
4 - WEAR PADS (SERVICEABLE)
21 - 294 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condition of the seal contact surfaces of the
yoke slinger (Fig. 49). This surface must be clean and
smooth to ensure proper seal life. Replace the yoke
nut and seal washer as neither part should be
reused.
Inspect the shaft threads, sprocket teeth, and bear-
ing surfaces. Minor nicks on the teeth can be
smoothed with an oilstone. Use 320-400 grit emery to
smooth minor scratches on the shaft bearing sur-
faces. Rough threads on the shaft can be chased if
necessary. Replace the shaft if the threads are dam-
aged, bearing surfaces are scored, or if any sprocket
teeth are cracked or broken.
Examine the drive chain and shaft bearings.
Replace the chain and both sprockets if the chain is
stretched, distorted, or if any of the links bind.
Replace the bearings if rough, or noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear condition carefully. The gear
is only serviced as part of the front case. If the gear
is damaged, it will be necessary to replace the gear
and front case as an assembly. Do not attempt to
remove the gear (Fig. 50)
FRONT-REAR CASES AND FRONT RETAINER
Inspect the cases and retainer for wear and dam-
age. Clean the sealing surfaces with a scraper and
3M all purpose cleaner. This will ensure proper
sealer adhesion at assembly. Replace the input
retainer seal; do not reuse it.Check case condition. If leaks were a problem, look
for gouges and severe scoring of case sealing sur-
faces. Also make sure the front case mounting studs
are in good condition.
Check the front case mounting studs and vent
tube. The tube can be secured with LoctiteŸ 271 or
680 if loose. The stud threads can be cleaned up with
a die if necessary. Also check condition of the fill/
drain plug threads in the rear case. The threads can
be repaired with a thread chaser or tap if necessary.
Or the threads can be repaired with HelicoilŸ stain-
less steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the
pump if any part appears to be worn or damaged. Do
not disassemble the pump as individual parts are not
available. The pump is only available as a complete
assembly. The pickup screen, hose, and tube are the
only serviceable parts and are available separately.
ASSEMBLY
Lubricate transfer case components with automatic
transmission fluid or petroleum jelly (where indi-
cated) during assembly.
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
Fig. 49 Seal Contact Surface Of Yoke Slinger
1 - FRONT SLINGER (PART OF YOKE)
2 - SEAL CONTACT SURFACE MUST BE CLEAN AND SMOOTH
Fig. 50 Low Range Annulus Gear
1 - FRONT CASE
2 - LOW RANGE ANNULUS GEAR
WJTRANSFER CASE - NV242 21 - 295
TRANSFER CASE - NV242 (Continued)

NV242HD REAR RETAINER
(1) Apply bead of MopartSealer, or LoctiteŸ
Ultra Gray, to mating surface of rear retainer. Sealer
bead should be a maximum of 3/16 in.
(2) Install rear retainer on rear case. Tighten
retainer bolts to 20-27 N´m (15-20 ft. lbs.) torque.
(3) Install new output shaft bearing snap-ring
(Fig. 91). Lift mainshaft slightly to seat snap-ring in
shaft groove, if necessary.
(4) Apply 3 mm (1/8 in.) wide bead of Mopartgas-
ket maker or silicone adhesive sealer to mounting
surface of extension housing. Allow sealer to set-up
slightly before proceeding.(5) Install extension housing on rear retainer.
(6) Install extension housing bolts and tighten to
35-46 N´m (26-34 ft. lbs.).
COMPANION FLANGE
(1) Lubricate companion flange hub with transmis-
sion fluid and install flange on front shaft.
(2) Install new seal washer on front shaft.
(3) Install flange on front shaft and tighten nut to
122-176 N´m (90-130 ft. lbs.).
INSTALLATION
(1) Mount transfer case on a transmission jack.
(2) Secure transfer case to jack with chains.
(3) Position transfer case under vehicle.
(4) Align transfer case and transmission shafts
and install transfer case on transmission.
(5) Install and tighten transfer case attaching nuts
to 35 N´m (26 ft. lbs.) torque (Fig. 4).
(6) Align and connect propeller shafts. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(7) Fill transfer case with correct fluid. Check
transmission fluid level. Correct as necessary.
(8) Install rear crossmember and skid plate, if
equipped. Tighten crossmember bolts to 41 N´m (30
ft. lbs.) torque.
(9) Remove transmission jack and support stand.
(10) Connect shift rod to transfer case range lever.
(11) Connect transfer case vent hose and transfer
case position sensor.
(12) Adjust transfer case shift cable.
(13) Lower vehicle and verify transfer case shift
operation.
Fig. 91 Install Output Bearing Snap-ring
1 - REAR RETAINER
2 - SNAP-RING
3 - REAR BEARING
WJTRANSFER CASE - NV242 21 - 307
TRANSFER CASE - NV242 (Continued)

FLUID
STANDARD PROCEDURE - FLUID DRAIN/
REFILL
The fill and drain plugs are both in the rear case
(Fig. 92).
(1) Raise vehicle.
(2) Position drain pan under transfer case.
(3) Remove drain and fill plugs and drain lubri-
cant completely.
(4) Install drain plug. Tighten plug to 20-34 N´m
(15-25 ft. lbs.).
(5) Remove drain pan.
(6) Fill transfer case to bottom edge of fill plug
opening with MopartTransfer Case Lubricant.
(7) Install and tighten fill plug to 20-34 N´m
(15-25 ft. lbs.).
(8) Lower vehicle.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Raise vehicle.
(2) Remove front propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Remove front output shaft companion flange.
(4) Remove seal from front case with pry tool (Fig.
93).
INSTALLATION
(1) Install new front output seal in front case with
Installer Tool 6952-A as follows:
(a) Place new seal on tool. Garter spring on seal
goes toward interior of case.
(b) Start seal in bore with light taps from ham-
mer (Fig. 94). Once seal is started, continue tap-
ping seal into bore until installer tool seats against
case.
(2) Install companion flange and tighten nut to
122-176 (90-130 ft. lbs.) torque.
(3) Install front propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - INSTALLATION)
Fig. 92 Fill/Drain Plug and I.D. Tag Location -
Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
Fig. 93 Remove Front Output Shaft Seal
1 - OUTPUT SHAFT SEAL
2 - PRYBAR
Fig. 94 Front Output Seal Installation
1 - INSTALLER 6952-A
2 - TRANSFER CASE
21 - 310 TRANSFER CASE - NV242WJ