545rfe JEEP GRAND CHEROKEE 2002 WJ / 2.G User Guide

(26) To remove torque converter, carefully slide
torque converter out of the transmission.
DISASSEMBLY
(1) Drain fluid from transmission.
(2) Clean exterior of transmission with suitable
solvent or pressure washer.
(3) Remove the torque converter from the trans-
mission.
(4) Remove the manual shift lever from the trans-
mission.
(5) Remove the input, output, and line pressure
sensors from the transmission case (Fig. 14).(6) Inspect the ends of the sensors for debris,
which may indicate the nature of the transmission
failure.
(7) Install Support Stand 8257 onto the transmis-
sion case (Fig. 15).
(8) Using Adapter 8266-1 from End-Play Tool Set
8266 and Dial Indicator C-3339, measure and record
the input shaft end-play (Fig. 16).
Fig. 13 Remove NV242 Transfer Case
1 - NV242 TRANSFER CASE
Fig. 14 Remove Input, Output, and Line Pressure
Sensors
1 - OUTPUT SPEED SENSOR
2 - LINE PRESSURE SENSOR
3 - INPUT SPEED SENSOR
Fig. 15 Install Support Stand - Tool 8257
1 - TOOL 8257
Fig. 16 Measure Input Shaft End Play
1 - TOOL 8266
2 - TOOL C-3339
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 185
AUTOMATIC TRANSMISSION - 545RFE (Continued)

NOTE: When measuring the input shaft end-play,
two(stops(will be felt. When the input shaft is
pushed inward and the dial indicator zeroed, the
first(stop(felt when the input shaft is pulled out-
ward is the movement of the input shaft in the input
clutch housing hub. This value should not be
included in the end-play measured value and there-
fore must be recorded and subtracted from the dial
indicator reading.
(9) Remove the bolts holding the transmission
extension/adapter housing to the transmission case.
(10) Remove the extension/adapter housing from
the transmission case.
(11) Using Alignment Plate 8261, Adapter 8266-17
from End-Play Tool Set 8266 and Dial Indicator
C-3339, measure and record the output shaft end-
play (Fig. 17).
(12) Remove the bolts holding the transmission oil
pan to the transmission case.
(13) Remove the transmission oil pan from the
transmission case.
(14) Remove the primary oil filter and the oil
cooler return filter (Fig. 18).
(15) Remove the cooler return filter bypass valve.(16) Remove the bolts holding the valve body to
the transmission case (Fig. 19).
(17) Remove the valve body from the transmission
case.
(18) Remove the outer snap-ring securing the
transmission front cover into the transmission case
(Fig. 20).
Fig. 17 Measure Output Shaft End Play
1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339
Fig. 18 Remove Primary Oil and Cooler Filters
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
Fig. 19 Remove Valve Body Assembly
1 - VALVE BODY TO CASE BOLT (6)
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AUTOMATIC TRANSMISSION - 545RFE (Continued)

(19) Remove the inner snap-ring securing the
transmission front cover to the oil pump (Fig. 20).
(20) Reaching through a case opening in the valve
body area with a long blunted tool, remove the trans-
mission front cover from the transmission case.
(21) Remove the bolts holding the oil pump into
the transmission case (Fig. 21).
(22) Remove the oil pump. Hold inward on the
input shaft to prevent pulling the input clutch
assembly with the oil pump (Fig. 21).(23) Remove the number 1 bearing from the input
clutch assembly (Fig. 22).
(24) Remove the input clutch assembly from the
transmission case (Fig. 22).
(25) Remove the number 5 bearing and selective
thrust plate from the input clutch assembly (Fig. 22),
or the 4C clutch retainer/bulkhead.
(26)
Remove the 4C clutch retainer/bulkhead tapered
snap-ring from the transmission case (Fig. 23).
(27) Remove the 4C clutch retainer/bulkhead from
the transmission case (Fig. 23).
Fig. 20 Remove Transmission Front Cover
1 - INNER SNAP-RING
2 - TRANSMISSION COVER
3 - OUTER SNAP-RING
Fig. 21 Remove Oil Pump
1 - OIL PUMP TO CASE BOLT (6)
2 - OIL PUMP
Fig. 22 Remove Input Clutch Assembly
1 - BEARING NUMBER 5
2 - THRUST PLATE (SELECT)
3 - INPUT CLUTCH ASSEMBLY
4 - BEARING NUMBER 1
Fig. 23 Remove 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 187
AUTOMATIC TRANSMISSION - 545RFE (Continued)

(28) Remove the front 2C clutch pack snap-ring
from the transmission case (Fig. 24).
(29) Remove the 2C clutch pack from the transmis-
sion case (Fig. 24).
(30) Remove the rear selective plate and number 6
bearing from the reaction annulus (Fig. 25).
(31) Remove the reaction annulus from the reac-
tion planetary carrier (Fig. 25).
(32) Remove the number 7 bearing (Fig. 25).
(33) Remove the reaction sun gear (Fig. 25).
(34) Remove the number 8 bearing from the reac-
tion planetary carrier (Fig. 25).
(35) Remove the reaction planetary carrier (Fig.
25). Note that this planetary gear set has three pin-
ion gears.
(36) Remove the number 9 bearing from the
reverse planetary gear set (Fig. 25).
Fig. 24 Remove 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
Fig. 25 Remove Reaction Annulus and Carrier
1 - BEARING NUMBER 8 5 - BEARING NUMBER 7
2 - BEARING NUMBER 9 6 - THRUST PLATE (SELECT)
3 - REACTION PLANETARY CARRIER 7 - BEARING NUMBER 6
4 - REACTION SUN GEAR 8 - REACTION ANNULUS
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AUTOMATIC TRANSMISSION - 545RFE (Continued)

(37) Remove the snap-ring holding the park sprag
gear onto the output shaft (Fig. 26).
(38) Remove the park sprag gear from the output
shaft (Fig. 27).
(39) Remove the input/reverse planetary assembly
(Fig. 28).
(40) Remove the number 12 bearing from the
input/reverse planetary assembly (Fig. 28).(41) Remove the snap-ring holding the low/reverse
clutch retainer into the transmission case (Fig. 29).
(42) Remove the low/reverse clutch retainer from
the transmission case (Fig. 29).
(43) Remove the park pawl rod and e-clip (Fig. 30).
(44) Remove the park pawl rod guide snap-ring
(Fig. 30).
(45) Remove the park pawl rod guide (Fig. 30).
(46) Remove the park pawl pivot shaft, park pawl,
and spring (Fig. 30).
(47) Remove the manual selector shaft (Fig. 30).
Fig. 26 Remove Park Sprag Snap-Ring
1 - SNAP-RING
Fig. 27 Remove Park Sprag Gear
1 - PARK SPRAG GEAR
Fig. 28 Remove Input/Reverse Planetary Assembly
1 - INPUT/REVERSE PLANETARY ASSEMBLY
2 - BEARING NUMBER 9
3 - BEARING NUMBER 12
Fig. 29 Remove Low/Reverse Clutch Retainer
1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
2 - SNAP-RING
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 189
AUTOMATIC TRANSMISSION - 545RFE (Continued)

(48) Remove the manual selector shaft seal.
(49) Remove the dipstick tube seal.
CLEANING
The use of crocus cloth is permissible where neces-
sary, providing it is used carefully. When used on
shafts, or valves, use extreme care to avoid rounding
off sharp edges. Sharp edges are vital as they pre-
vent foreign matter from getting between the valve
and valve bore.
Do not reuse oil seals, gaskets, seal rings, or
O-rings during overhaul. Replace these parts as a
matter of course. Also do not reuse snap rings or
E-clips that are bent or distorted. Replace these parts
as well.
Lubricate transmission parts with MopartATF +4,
Type 9602, transmission fluid during overhaul and
assembly. Use petroleum jelly, MopartDoor Ease, or
Ru-Glyde to prelubricate seals, O-rings, and thrust
washers. Petroleum jelly can also be used to hold
parts in place during reassembly.Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent.
Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
that all fluid passages are clear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.
INSPECTION
Inspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repaired with Helicoil thread inserts. However, the
case will have to be replaced if it exhibits any type of
damage or wear.
ASSEMBLY
(1) Clean and inspect all components. Replace any
components which show evidence of excessive wear
or scoring.
(2) Install the cooler filter bypass valve.
(3) Torque the bypass valve to specification. The
valve uses a tapered pipe thread and excessive
torque can damage the transmission case. Tighten
the cooler filter bypass valve to 4.5 N´m (40 in.lbs.).
(4) Install a new selector shaft seal using Seal
Installer 8253 (Fig. 31).
Fig. 30 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. 31 Install Selector Shaft
1 - SEAL
2 - TOOL 8253
21 - 190 AUTOMATIC TRANSMISSION - 545RFEWJ
AUTOMATIC TRANSMISSION - 545RFE (Continued)

(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
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AUTOMATIC TRANSMISSION - 545RFE (Continued)

(15) Using a feeler gauge through the opening in
the rear of the transmission case, measure the 2C
clutch pack clearance between the 2C reaction plate
and the transmission case at four different points.
The average of these measurements is the 2C clutch
pack clearance. The correct clutch clearance is 0.455-
1.335 mm (0.018-0.053 in.). The reaction plate is not
selective. If the clutch pack clearance is not within
specification, the reaction plate, all the friction discs,
and steels must be replaced.
(16) Remove the 4C retainer/bulkhead and all of
the 2C clutch components from the transmission
case.
(17) Install the low/reverse clutch assembly (Fig.
35). Make sure that the oil feed hole points toward
the valve body area and that the bleed orifice is
aligned with the notch in the rear of the transmis-
sion case.
(18) Install the snap-ring to hold the low/reverse
clutch retainer into the transmission case (Fig. 35).
The snap-ring is tapered and must be installed with
the tapered side forward. Once installed, verify that
the snap-ring is fully seated in the snap-ring groove.
(19) Air check the low/reverse clutch and verify
correct overrunning clutch operation.
(20) Install the number 12 bearing over the output
shaft and against the rear planetary gear set. The
flat side of the bearing goes toward the planetary
gearset and the raised tabs on the inner race should
face the rear of the transmission.(21) Install the reverse/input planetary assembly
through the low/reverse clutch assembly (Fig. 36).
(22) Install the park sprag onto the output shaft
(Fig. 37).
(23) Install the snap-ring to hold the park sprag
onto the output shaft (Fig. 38).
Fig. 35 Install Low/Reverse Clutch Retainer
1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
2 - SNAP-RING
Fig. 36 Install Input/Reverse Planetary Assembly
1 - INPUT/REVERSE PLANETARY ASSEMBLY
2 - BEARING NUMBER 9
3 - BEARING NUMBER 12
Fig. 37 Install Park Sprag Gear
1 - PARK SPRAG GEAR
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AUTOMATIC TRANSMISSION - 545RFE (Continued)

(24) Install the 2C reaction plate into the trans-
mission case (Fig. 39). The reaction plate is direc-
tional. The plate must be installed with the flat side
toward the front of the transmission.
(25) Install the 2C clutch pack into the transmis-
sion case (Fig. 39).(26) Install the number 8 bearing inside the reac-
tion carrier with the outer race against the reaction
planetary carrier.
(27) Install the reaction planetary gear set and the
number 9 bearing, with the inner race against the
reaction planetary carrier, into the transmission case
(Fig. 40).
(28) Install the flat 2C clutch snap-ring into the
transmission case (Fig. 39).
(29) Install the reaction sun gear into the reaction
planetary gear set.Make surethe small shoulder is
facing the front of the transmission (Fig. 40).
(30) Install the number 7 bearing onto the reaction
sun gear with the inner race against the sun gear
(Fig. 40).
(31) Install the output shaft selective thrust plate
onto the reaction annulus with the oil grooves facing
the annulus gear and the tabs and notches aligned as
shown in (Fig. 41).
(32) Install the number 6 bearing against the out-
put shaft selective thrust plate with the flat side
against the thrust plate (Fig. 40) and the raised tabs
on the inner race facing the front of the transmis-
sion.
(33) Install the reaction annulus into the reaction
planetary gear set (Fig. 40).
(34) Install the 4C retainer/bulkhead into the
transmission case. Make sure that the oil feed holes
are pointing toward the valve body area. Rotate the
reaction annulus during the installation of the 4C
retainer/bulkhead to ease installation.
(35) Install the 4C retainer/bulkhead tapered
snap-ring into the transmission case (Fig. 42) with
the taper toward the front of the case. Make sure
that the open ends of the snap-ring are located in the
case opening toward the valve body area.
(36) Air check the 2C and 4C clutch operation.
Fig. 38 Install Park Sprag Snap-Ring
1 - SNAP-RING
Fig. 39 Install 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
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AUTOMATIC TRANSMISSION - 545RFE (Continued)

Fig. 40 Install Reaction Annulus and Carrier
1 - BEARING NUMBER 8 5 - BEARING NUMBER 7
2 - BEARING NUMBER 9 6 - THRUST PLATE (SELECT)
3 - REACTION PLANETARY CARRIER 7 - BEARING NUMBER 6
4 - REACTION SUN GEAR 8 - REACTION ANNULUS
Fig. 41 Thrust Plate Alignment
1 - LOCATING LUG (3)
2 - THRUST PLATE
Fig. 42 Install 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
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AUTOMATIC TRANSMISSION - 545RFE (Continued)