cli JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual

(5) Install the manual selector shaft and retaining
screw. Tighten the manual selector shaft retaining
screw to 28 N´m (250 in.lbs.).
(6) Install the park pawl, spring, and shaft (Fig.
32).
(7) Install the park rod and e-clip (Fig. 32).
(8) Install the park rod guide and snap-ring (Fig.
32).
(9) Install a new dipstick tube seal using Seal
Installer 8254 (Fig. 33).
NOTE: Before final assembly of transmission cen-
terline, the 2C/4C clutch components should be
installed into position and measured as follows:
(10) Install the 2C reaction plate into the trans-
mission case (Fig. 34). The reaction plate is direc-
tional. The plate must be installed with the flat side
toward the front of the transmission.
(11) Install the 2C clutch pack into the transmis-
sion case (Fig. 34).(12) Install the flat 2C clutch snap-ring into the
transmission case (Fig. 34).
(13) Install the 4C retainer/bulkhead into the
transmission case. Make sure that the oil feed holes
are pointing toward the valve body area.
(14) Install the 4C retainer/bulkhead tapered
snap-ring into the transmission case. Make sure that
the open ends of the snap-ring are located in the case
opening toward the valve body area.
Fig. 32 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
Fig. 33 Install Dipstick Tube Seal Using Tool 8254
1 - TOOL 8254
2 - SEAL
Fig. 34 Install 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 191
AUTOMATIC TRANSMISSION - 545RFE (Continued)

BRAKE TRANSMISSION SHIFT
INTERLOCK MECHANISM
DESCRIPTION
The Brake Transmission Shifter/Ignition Interlock
(BTSI), is a cable and solenoid operated system. It
interconnects the automatic transmission floor
mounted shifter to the steering column ignition
switch (Fig. 57).
OPERATION
The system locks the shifter into the PARK posi-
tion. The interlock system is engaged whenever the
ignition switch is in the LOCK or ACCESSORY posi-
tion. An additional electrically activated feature will
prevent shifting out of the PARK position unless the
brake pedal is depressed approximately one-half an
inch. A magnetic holding device in the shifter assem-
bly is energized when the ignition is in the RUN
position. When the key is in the RUN position and
the brake pedal is depressed, the shifter is unlocked
and will move into any position. The interlock system
also prevents the ignition switch from being turned
to the LOCK or ACCESSORY position, unless the
shifter is fully locked into the PARK position.
DIAGNOSIS AND TESTING - BRAKE
TRANSMISSION SHIFT INTERLOCK
(1) Verify that the key can only be removed in the
PARK position
(2) When the shift lever is in PARK And the shift
handle pushbutton is in the ªOUTº position, the igni-
tion key cylinder should rotate freely from OFF to
LOCK. When the shifter is in any other gear or neu-
tral position, the ignition key cylinder should not
rotate to the LOCK position.
(3) Shifting out of PARK should not be possible
when the ignition key cylinder is in the OFF posi-
tion.
(4) Shifting out of PARK should not be possible
while applying normal pushbutton force and ignition
key cylinder is in the RUN or START positions
unless the foot brake pedal is depressed approxi-
mately 1/2 inch (12mm).
(5) Shifting out of PARK should not be possible
when the ignition key cylinder is in the ACCESSORY
or LOCK positions.
(6) Shifting between any gears, NEUTRAL or into
PARK may be done without depressing foot brake
pedal with ignition switch in RUN or START posi-
tions.
Fig. 57 Ignition Interlock Cable
1 - SHIFT MECHANISM 4 - STEERING COLUMN ASSEMBLY
2 - SHIFTER BTSI LEVER 5 - INTERLOCK CABLE
3 - ADJUSTMENT CLIP
21 - 226 AUTOMATIC TRANSMISSION - 545RFEWJ

ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK
The park interlock cable is part of the brake/shift
lever interlock system. Correct cable adjustment is
important to proper interlock operation. The gear
shift and park lock cables must both be correctly
adjusted in order to shift out of PARK.
ADJUSTMENT PROCEDURE
(1) Remove floor console as necessary for access to
the brake transmission shift interlock cable. (Refer to
23 - BODY/INTERIOR/FLOOR CONSOLE -
REMOVAL)
(2) Shift the transmission into the PARK position.
(3) Turn ignition switch to LOCK position.Be
sure ignition key cylinder is in the LOCK posi-
tion. Cable will not adjust correctly in any
other position.
(4) Pull cable lock button up to release cable (Fig.
58).
(5) Ensure that the cable is free to self-adjust by
pushing cable rearward and releasing.
(6) Push lock button down until it snaps in place.
BTSI FUNCTION CHECK
(1) Verify removal of ignition key allowed in PARK
position only.
(2) When the shift lever is in PARK, and the shift
handle push-button is in the out position, the igni-
tion key cylinder should rotate freely from off to lock.
When the shifter is in any other position, the ignition
key should not rotate from off to lock.
(3) Shifting out of PARK should be possible when
the ignition key cylinder is in the off position.
(4) Shifting out of PARK should not be possible
while applying normal push-button force, and igni-
tion key cylinder is in the run or start positions,
unless the foot brake pedal is depressed approxi-
mately 1/2 inch (12mm).
(5) Shifting out of PARK should not be possible
when the ignition key cylinder is in the accessory or
lock position.
(6) Shifting between any gear and NEUTRAL, or
PARK, may be done without depressing foot brake
with ignition switch in run or start positions.
(7) The floor shifter lever and gate positions
should be in alignment with all transmission detent
positions.
Fig. 58 Brake Transmission Shift Interlock Cable
1 - SHIFT MECHANISM 4 - STEERING COLUMN ASSEMBLY
2 - SHIFTER BTSI LEVER 5 - INTERLOCK CABLE
3 - ADJUSTMENT CLIP
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 227
BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM (Continued)

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

Replace the driving shell if worn, cracked or dam-
aged.
Replace planetary gear sets if gears, pinion pins, or
carrier are damaged in any way. Replace the annulus
gears and supports if either component is worn or
damaged.
Replace the output shaft if the machined surfaces
are scored, pitted, or damaged in any way. Also
replace the shaft if the splines are damaged, or
exhibits cracks at any location.
ASSEMBLY
(1) Clean and inspect all components. Replace any
components which show evidence of excessive wear
or scoring.
(2) Install the number 11 bearing into the input
planetary carrier so that the inner race will be
toward the front of the transmission (Fig. 104).
(3) Install the input sun gear into the input carrier
(Fig. 104).
(4) Install the number 10 bearing onto the rear of
the reverse planetary carrier with the inner race
toward the carrier (Fig. 104).
(5) Install the number 9 bearing onto the front of
the reverse planetary carrier with the outer race
toward the carrier and the inner race facing upward
(Fig. 104).
(6) Install the reverse planetary gear carrier into
the input carrier (Fig. 104).
(7) Install the input annulus gear into the input
carrier (Fig. 104).
(8) Install the snap-ring to hold the input annulus
gear into the input carrier (Fig. 104).
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.
MANUAL SECOND (2) range provides FIRST and
SECOND gear only.
DRIVE range provides FIRST, SECOND, THIRD
and OVERDRIVE FOURTH and FIFTH gear ranges.
The shift into OVERDRIVE FOURTH and FIFTH
gear range occurs only after the transmission hascompleted the shift into D THIRD gear range. No
further movement of the shift mechanism is required
to complete the 3-4 or 4-5 shifts.
The FOURTH and FIFTH gear upshifts occurs
automatically when the overdrive selector switch is
in the ON position. An upshift to FOURTH and
FIFTH gears may not occur or may be delayed in
some of the possible shift schedules. (Refer to 8 -
ELECTRICAL/ELECTRONIC CONTROL MOD-
ULES/TRANSMISSION CONTROL MODULE -
OPERATION)
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. 105).
(4) Disconnect the park lock cable from the shifter
BTSI lever and the shifter assembly bracket. (Fig.
106)
(5) Disconnect the transfer case shift cable from
the transfer case shift lever pin (Fig. 107), 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.
(8) Disengage all wiring connectors from the
shifter assembly.
(9) Remove all nuts holding the shifter assembly to
the floor pan (Fig. 108).
Fig. 105 Transmission Shift Cable
1 - SHIFT LEVER PIN
2 - ADJUSTMENT SCREW
3 - SHIFT CABLE
4 - SHIFTER ASSEMBLY BRACKET
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 261
PLANETARY GEARTRAIN (Continued)

(10) Remove the shifter assembly from the vehicle.
Fig. 106 Brake Transmission Interlock Cable
1 - SHIFT MECHANISM 4 - STEERING COLUMN ASSEMBLY
2 - SHIFTER BTSI LEVER 5 - INTERLOCK CABLE
3 - ADJUSTMENT CLIP
Fig. 107 Transfer Case Shift Cable
1 - CLIP
2 - SHIFTER
3 - TRANSFER CASE SHIFT LEVER PIN
4 - TRANSFER CASE SHIFT CABLE
Fig. 108 Shifter Assembly
1 - FLOOR PAN
2 - SHIFTER ASSEMBLY
21 - 262 AUTOMATIC TRANSMISSION - 545RFEWJ
SHIFT MECHANISM (Continued)

INSTALLATION
(1) Place the floor shifter lever in PARK position.
(2) Loosen the adjustment screw on the shift cable.
(3) Verify that the park lock cable adjustment tab
is pulled upward to the unlocked position.
(4) Install wiring harness to the shifter assembly
bracket. Engage any wire connectors removed from
the shifter assembly.
(5) Install the transfer case shift cable to the
shifter assembly bracket. Install clip to hold cable to
the bracket.
(6) Snap the transfer case shift cable, if equipped,
onto the transfer case shift lever pin.
(7) Install the park lock cable into the shifter
assembly bracket and into the shifter BTSI lever.(Re-
fer to 21 - TRANSMISSION/TRANSAXLE/AUTO-
MATIC/SHIFT INTERLOCK MECHANISM -
ADJUSTMENTS)
(8) Install the shift cable to the shifter assembly
bracket. Push cable into the bracket until secure.
(9) Install shifter assembly onto the shifter assem-
bly studs on the floor pan.
(10) Install the nuts to hold the shifter assembly
onto the floor pan. Tighten nuts to 28 N´m (250
in.lbs.).
(11) Snap the shift cable onto the shift lever pin.
(12) Verify that the shift lever is in the PARK posi-
tion.
(13) Tighten the adjustment screw to 7 N´m (65
in.lbs.).
(14) Place the key in the accessory position.
(15) Push downward on the park lock cable adjust-
ment tab to lock the adjustment.
(16) Verify correct shifter, park lock, and BTSI
operation.
(17) Install any console parts removed for access to
shift lever assembly and shift cables. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE - INSTALLA-
TION)
SOLENOID SWITCH VALVE
DESCRIPTION
The Solenoid Switch Valve (SSV) is located in the
valve body and controls the direction of the transmis-
sion fluid when the L/R-TCC solenoid is energized.
OPERATION
The Solenoid Switch Valve controls line pressure
from the LR-TCC solenoid. In 1st gear, the SSV will
be in the downshifted position, thus directing fluid to
the L/R clutch circuit. In 2nd, 3rd, 4th,and 5th gears,
the solenoid switch valve will be in the upshifted
position and directs the fluid into the torque con-
verter clutch (TCC) circuit.When shifting into 1st gear, a special hydraulic
sequence is performed to ensure SSV movement into
the downshifted position. The L/R pressure switch is
monitored to confirm SSV movement. If the move-
ment is not confirmed (the L/R pressure switch does
not close), 2nd gear is substituted for 1st. A DTC will
be set after three unsuccessful attempts are made to
get into 1st gear in one given key start.
SOLENOIDS
DESCRIPTION
The typical electrical solenoid used in automotive
applications is a linear actuator. It is a device that
produces motion in a straight line. This straight line
motion can be either forward or backward in direc-
tion, and short or long distance.
A solenoid is an electromechanical device that uses
a magnetic force to perform work. It consists of a coil
of wire, wrapped around a magnetic core made from
steel or iron, and a spring loaded, movable plunger,
which performs the work, or straight line motion.
The solenoids used in transmission applications
are attached to valves which can be classified asnor-
mally openornormally closed. Thenormally
opensolenoid valve is defined as a valve which
allows hydraulic flow when no current or voltage is
applied to the solenoid. Thenormally closedsole-
noid valve is defined as a valve which does not allow
hydraulic flow when no current or voltage is applied
to the solenoid. These valves perform hydraulic con-
trol functions for the transmission and must there-
fore be durable and tolerant of dirt particles. For
these reasons, the valves have hardened steel pop-
pets and ball valves. The solenoids operate the valves
directly, which means that the solenoids must have
very high outputs to close the valves against the siz-
able flow areas and line pressures found in current
transmissions. Fast response time is also necessary
to ensure accurate control of the transmission.
The strength of the magnetic field is the primary
force that determines the speed of operation in a par-
ticular solenoid design. A stronger magnetic field will
cause the plunger to move at a greater speed than a
weaker one. There are basically two ways to increase
the force of the magnetic field:
1. Increase the amount of current applied to the
coil or
2. Increase the number of turns of wire in the coil.
The most common practice is to increase the num-
ber of turns by using thin wire that can completely
fill the available space within the solenoid housing.
The strength of the spring and the length of the
plunger also contribute to the response speed possi-
ble by a particular solenoid design.
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 263
SHIFT MECHANISM (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)

(4) Install the transfer case shift cable to the
shifter assembly bracket. Seat cable in bracket and
install clip (Fig. 102).
(5) Verify the transfer case shift lever (at console)
is in the NEUTRAL position.
(6) Snap the cable onto the shift lever pin (Fig.
102).
(7) Raise the vehicle.
(8) Install the shift cable to the shift cable support
bracket and install clip (Fig. 101).(9) Verify that the transfer case is still in the
NEUTRAL position.
(10) Snap the shift cable onto the transfer case
shift lever (Fig. 101).
(11) Lower vehicle.
(12) Verify correct transfer case operation in all
ranges.
(13) Install any console parts removed for access to
transfer case shift cable.
21 - 314 TRANSFER CASE - NV242WJ
SHIFT CABLE (Continued)

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. 78).
(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. 79).
(8) Remove the nuts holding the shift cable seal
plate to the floor pan (Fig. 80).
(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.
80). Tighten nuts to 7 N´m (65 in.lbs.).
(4) Install the transfer case shift cable to the
shifter assembly bracket. Seat cable in bracket and
install clip (Fig. 79).
(5) Verify the transfer case shift lever (at console)
is in the NEUTRAL position.
(6) Snap the cable onto the shift lever pin (Fig.
79).
(7) Raise the vehicle.(8) Install the shift cable to the shift cable support
bracket and install clip (Fig. 78).
(9) Verify that the transfer case is still in the
NEUTRAL position.
(10) Snap the shift cable onto the transfer case
shift lever (Fig. 78).
(11) Lower vehicle.
(12) Verify correct transfer case operation in all
ranges.
(13) Install any console parts removed for access to
transfer case shift cable.
Fig. 78 Transfer Case Shift Cable at Transfer Case
1 - TRANSFER CASE SHIFT LEVER
2 - TRANSFER CASE SHIFT CABLE
Fig. 79 Transfer Case Shift Cable at Shifter
1 - CLIP
2 - SHIFTER
3 - TRANSFER CASE SHIFT LEVER PIN
4 - TRANSFER CASE SHIFT CABLE
Fig. 80 Shift Cables at Floor Pan
1 - SEAL PLATES
2 - TRANSMISSION SHIFT CABLE
3 - TRANSFER CASE SHIFT CABLE
21 - 340 TRANSFER CASE - NV247WJ