transmission fluid JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual

(15) Install new pickup tube O-ring in oil pump
(Fig. 63).
(16) Remove rear retainer bearing with Installer
8128 and Handle C-4171, NV242HD only.
(17) Install rear bearing in retainer with Handle
C-4171 and Installer 5064 (Fig. 64), NV242HD only.
DIFFERENTIAL
(1) Lubricate differential components with auto-
matic transmission fluid.
(2) Install sprocket gear in differential bottom case
(Fig. 65).(3) Install differential planet gears and new thrust
washers (Fig. 66).Be sure thrust washers are
installed at top and bottom of each planet gear.
(4) Install differential mainshaft gear (Fig. 66).
Fig. 63 Pickup Tube O-Ring Installation
1 - PICKUP TUBE O-RING
Fig. 64 Installing Rear Bearing In Retainer
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5064
3 - REAR RETAINER
Fig. 65 Installing Differential Sprocket Gear
1 - SPROCKET GEAR
2 - BOTTOM CASE
Fig. 66 Installing Mainshaft And Planet Gears
1 - MAINSHAFT GEAR
2 - THRUST WASHERS (12)
3 - PLANET GEARS (6)
WJTRANSFER CASE - NV242 21 - 299
TRANSFER CASE - NV242 (Continued)

(5) Align and position differential top case on bot-
tom case (Fig. 67). Align using scribe marks made at
disassembly.
(6) While holding differential case halves together,
invert the differential and start the differential case
bolts.
(7) Tighten differential case bolts to specified
torque.
INPUT GEAR/LOW RANGE ASSEMBLY
(1) Assemble low range gear, input gear thrust
washers, input gear and input gear retainer (Fig. 68).
(2) Install low range gear snap ring (Fig. 69).
(3) Lubricate input gear and low range gears with
automatic transmission fluid.
(4) Start input gear shaft into front case bearing.
(5) Press input gear shaft into front bearing.
(6) Install new input gear snap ring (Fig. 70).
(7) Apply 3 mm (1/8 in.) wide bead of Mopartgas-
ket maker or silicone adhesive sealer to seal surface
of front bearing retainer.
(8) Install front bearing retainer (Fig. 71). Tighten
retainer bolts to 16 ft. lbs. (21 N´m) torque.
SHIFT FORKS, SECTOR, AND MAINSHAFT
(1) Install the shift sector shaft o-ring and bush-
ing.
(2) Install shift sector.(3) Install new pads on low range fork, if neces-
sary.
(4) Assemble low range fork and sleeve.
Fig. 67 Differential Case Assembly
1 - TOP CASE
2 - BOTTOM CASE
3 - CASE ALIGNMENT MARKS
Fig. 68 Low Range And Input Gear Assembly
1 - THRUST WASHERS
2 - LOW RANGE GEAR
3 - INPUT GEAR
4 - RETAINER
Fig. 69 Install Low Range Gear Snap-Ring
1 - LOW RANGE GEAR SNAP-RING
21 - 300 TRANSFER CASE - NV242WJ
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)

(5) Install the rear propeller shaft. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(6) Verify proper fluid level.
(7) Lower vehicle.
SHIFT CABLE
REMOVAL
(1) Shift transfer case into NEUTRAL.
(2) Raise vehicle.
(3) Disconnect the shift cable eyelet from the
transfer case shift lever (Fig. 101).
(4) Remove shift cable from the cable support
bracket.
(5) Lower vehicle.
(6) Remove any necessary console parts for access
to shift lever assembly and shift cable.(7) Disconnect cable at shift lever and shifter
assembly bracket (Fig. 102).
(8) Remove the nuts holding the shift cable seal
plate to the floor pan (Fig. 103).
(9) Pull cable through floor panel opening.
(10) Remove transfer case shift cable from vehicle.
INSTALLATION
(1) Route cable through hole in floor pan.
(2) Install seal plate to studs in floor pan.
(3) Install nuts to hold seal plate to floor pan (Fig.
103). Tighten nuts to 7 N´m (65 in.lbs.).
Fig. 100 Install Rear Retainer Seal
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-3995-A
Fig. 101 Transfer Case Shift Cable at Transfer Case
1 - TRANSFER CASE SHIFT LEVER
2 - TRANSFER CASE SHIFT CABLE
Fig. 102 Transfer Case Shift Cable at Shifter
1 - CLIP
2 - SHIFTER
3 - TRANSFER CASE SHIFT LEVER PIN
4 - TRANSFER CASE SHIFT CABLE
Fig. 103 Shift Cables at Floor Pan
1 - SEAL PLATES
2 - TRANSMISSION SHIFT CABLE
3 - TRANSFER CASE SHIFT CABLE
WJTRANSFER CASE - NV242 21 - 313
REAR RETAINER BUSHING AND SEAL - NV242HD (Continued)

(6) Connect front propeller shaft and install rear
propeller shaft. (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 (Fig. 71) and skid
plate, if equipped. Tighten crossmember bolts to 41
N´m (30 ft. lbs.) torque.
(9) Remove transmission jack and support stand.
(10) Verify transfer case is in NEUTRAL. Connect
shift cable to transfer case range lever.
(11) Lower vehicle and verify transfer case shift
operation.
(12) Adjust the transfer case shift cable, if neces-
sary.
SPECIFICATIONS
TRANSFER CASE - NV247
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt, crossmember 41-47 30.2-34.7 -
Plug, Detent 16-24 11.8-17.7 -
Plugs, drain/fill 20-34 15-25 -
Bolts, front brg. retainer 16-24 11.8-17.7 -
Bolts, case half 27-34 19.9-25 -
Nut, companion flange 122-176 90-130 -
Bolts, rear extension 27-34 19.9-25 -
Lock-nut, shift 27-34 19.9-25 -
Nuts, T-case mount stud 33-41 24.3-30.2 -
Fig. 71 Crossmember Installation
1 - CROSSMEMBER
2 - REAR TRANSMISSION MOUNT
21 - 336 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)

(11) Remove the bolts that secure the upper con-
denser and transmission cooler.
(12) Carefully lift the condenser out of the vehicle.
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
CAUTION: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
condenser and radiator. The air seals must be rein-
stalled in their proper locations in order for the air
conditioning and engine cooling systems to per-
form as designed.
(1) Carefully position the condenser in the vehicle.
(2) Install the bolts that secure the upper con-
denser and transmission cooler.
(3) Remove the tape or plugs from the refrigerant
line fittings on the condenser inlet and the discharge
line. Connect the discharge line to the condenser
inlet. Tighten the retaining nut to 28 N´m (250 in.
lbs.).
(4) Remove the tape or plugs from the refrigerant
line fittings on the condenser outlet and the liquid
line. Connect the liquid line to the condenser outlet.
Tighten the retaining nut to 28 N´m (250 in. lbs.).
(5) Install the headlamp mounting module and
front fascia. Refer to Body for the procedure.
(6) Install the engine air filter inlet duct.
(7) Install the bolts that secure the radiator to the
upper crossmember.(8) Install the nuts that secure the hood latch and
brace to the upper crossmember.
(9) Install the headlamps in their mounts.
(10) Install the screws attaching the grille and
headlamp mounting module to the upper crossmem-
ber of the vehicle. Refer to Body for this and further
steps in the procedure.
(11) Evacuate and Recharge the refrigerant sys-
tem. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM EVACUATE) (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
(12) Connect the battery negative cable.
NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT OIL - DESCRIPTION)
A/C DISCHARGE LINE
REMOVAL
REMOVAL - 2.7L TURBO DIESEL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the negative battery
cable.
(2) Recover the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY)
(3) Remove both headlamps from the vehicle. Refer
to Lamps/Lighting for the procedure.
(4) Remove the a/c high pressure transducer(Refer
to 24 - HEATING & AIR CONDITIONING/CON-
TROLS/A/C PRESSURE TRANSDUCER - REMOV-
AL).
(5) Remove the front fascia from the vehicle. Refer
to Front Fascia for the procedure (Fig. 7).
(6) Remove the refrigerant line retaining fastener
from the condenser inlet fitting. Remove the line and
cap the condenser inlet tube to prevent contamina-
tion of the system.
WJPLUMBING 24 - 63
A/C CONDENSER (Continued)

(M)Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded
(depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G)Generator lamp illuminated
Generic Scan
Tool P-CodeDRB Scan Tool Display Brief Description of DTC
P0545 A/C Clutch Relay Circuit Problem detected in air conditioning clutch relay control
circuit.
P0551 Power Steering Switch Failure Incorrect input state detected for the power steering
switch circuit. PL: High pressure seen at high speed.
P0562 Charging System Voltage Too Low Supply voltage sensed at ECM too low.
P0563 Charging System Voltage Too High Supply voltage sensed at ECM too high.
P0572 Brake Switch Input #1 Signal
Missing
P0573 Brake Switch Input #2 Signal
Missing
P0575 Cruise Control Switch Voltage Low
P0576 Cruise Control Switch Voltage High
P0577 Cruise Control Switch Voltage High
P0600 PCM Failure SPI Communications No communication detected between co-processors in the
control module.
P0601 (M) Internal Controller Failure Internal control module fault condition (check sum)
detected.
P0602 (M) ECM Fueling Calibration Error ECM Internal fault condition detected.
P0604 RAM Check Failure Transmission control module RAM self test fault detected.
-Aisin transmission
P0605 ROM Check Falure Transmission control module ROM self test fault detected
-Aisin transmission
P0606 (M) ECM Failure ECM Internal fault condition detected.
P0615 Starter Relay Control Circuit An open or shorted condition detected in the starter relay
control circuit.
P0622 (G) Generator Field Not Switching
ProperlyAn open or shorted condition detected in the generator
field control circuit.
P0645 A/C Clutch Relay Circuit An open or shorted condition detected in the A/C clutch
relay control circuit.
P0700 EATX Controller DTC Present This SBEC III or JTEC DTC indicates that the EATX or
Aisin controller has an active fault and has illuminated the
MIL via a CCD (EATX) or SCI (Aisin) message. The
specific fault must be acquired from the EATX via CCD or
from the Aisin via ISO-9141.
P0703 Brake Switch Stuck Pressed or
ReleasedIncorrect input state detected in the brake switch circuit.
(Changed from P1595)
P0703 Brake Switch Sense Circuit
P0711 (M) Trans Temp Sensor, No Temp Rise
After StartRelationship between the transmission temperature and
overdrive operation and/or TCC operation indicates a
failure of the Transmission Temperature Sensor. OBD II
Rationality. Was MIL code 37.
P0712 Trans Temp Sensor Voltage Too Low Transmission fluid temperature sensor input below
acceptable voltage. Was MIL code 37.
WJEMISSIONS CONTROL 25 - 9
EMISSIONS CONTROL (Continued)

(M)Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded
(depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
(G)Generator lamp illuminated
Generic Scan
Tool P-CodeDRB Scan Tool Display Brief Description of DTC
P0712 (M) Trans Temp Sensor Voltage Too Low Voltage less than 1.55 volts (4-speed auto. trans. only).
P0713 Trans Temp Sensor Voltage Too
HighTransmission fluid temperature sensor input above
acceptable voltage. Was MIL code 37.
P0713 (M) Trans Temp Sensor Voltage Too
HighVoltage greater than 3.76 volts (4-speed auto. trans.
only).
P0720 (M) Low Output SPD Sensor RPM,
Above 15 MPHThe relationship between the Output Shaft Speed Sensor
and vehicle speed is not within acceptable limits.
P0720 (M) Low Output Spd Sensor RPM Above
15 mphOutput shaft speed is less than 60 rpm with vehicle speed
above 15 mph (4-speed auto. trans. only).
P0740 (M) Torq Con Clu, No RPM Drop at
LockupRelationship between engine and vehicle speeds
indicated failure of torque convertor clutch lock-up system
(TCC/PTU solenoid)
P0743 (M) Torque Converter Clutch Solenoid/
Trans Relay CircuitsAn open or shorted condition detected in the torque
converter clutch (part throttle unlock) solenoid control
circuit. Shift solenoid C electrical fault - Aisin transmission
P0743 (M) Torque Converter Clutch Solenoid/
Trans Relay CircuitsAn open or shorted condition detected in the torque
converter part throttle unlock solenoid control circuit (3 or
4-speed auto. trans. only).
P0748 (M) Governor Pressur Sol Control/Trans
Relay CircuitsAn open or shorted condition detected in the Governor
Pressure Solenoid circuit or Trans Relay Circuit in JTEC
RE transmissions.
P0748 (M) Governor Pressure Sol Control/Trans
Relay CircuitsAn open or shorted condition detected in the governor
pressure solenoid or relay circuits (4-speed auto. trans.
only).
P0751 (M) O/D Switch Pressed (Lo) More Than
5 MinutesOverdrive override switch input is in a prolonged
depressed state.
P0751 (M) O/D Switch Pressed (LO) More Than
5 MinOverdrive Off switch input too low for more than 5
minutes (4-speed auto. trans. only).
P0753 (M) Trans 3-4 Shift Sol/Trans Relay
CircuitsAn open or shorted condition detected in the overdrive
solenoid control circuit or Trans Relay Circuit in JTEC RE
transmissions. Was MIL code 45.
P0753 (M) Trans 3-4 Shift Sol/Trans Relay
CircuitsAn open or shorted condition detected in the transmission
2-4 shift solenoid circuit (4-speed auto. trans. only).
P0756 AW4 Shift Sol B (2-3) Functional
FailureShift solenoid B (2-3) functional fault - Aisin transmission
P0783 (M) 3-4 Shift Sol, No RPM Drop at
LockupThe overdrive solenoid is unable to engage the gear
change from 3rd gear to the overdrive gear.
P0801 Reverse Gear Lockout Circuit Open
or ShortAn open or shorted condition detected in the transmission
reverse gear lock-out solenoid control circuit.
P0830 Clutch Depressed Switch Circuit Problem detected in clutch switch circuit.
P0833 Clutch Released Switch Circuit Problem detected in clutch switch circuit.
P0836 4WD Mux Switch Circuit
P0837 4WD Mux Switch Performance
25 - 10 EMISSIONS CONTROLWJ
EMISSIONS CONTROL (Continued)