545rfe JEEP GRAND CHEROKEE 2002 WJ / 2.G Service Manual

545RFE HYDRAULIC SCHEMATIC
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545RFE HYDRAULIC SCHEMATIC
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545RFE HYDRAULIC SCHEMATIC
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545RFE HYDRAULIC SCHEMATIC
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545RFE HYDRAULIC SCHEMATIC
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SPECIFICATIONS
TRANSMISSION
GENERAL
Component Metric Inch
Output Shaft End Play 0.22-0.55
mm0.009-0.021
in.
Input Shaft End Play 0.46-0.89
mm0.018-0.035
in.
2C Clutch Pack
Clearance0.455-1.335
mm0.018-0.053
in.
4C Clutch Pack
Clearance0.770-1.390
mm0.030-0.055
in.
L/R Clutch Pack
Clearance1.00-1.74
mm0.039-0.069
in.
OD Clutch Pack
Clearance1.103-1.856
mm0.043-0.073
in.
Component Metric Inch
UD Clutch Pack
Clearance0.84-1.54
mm0.033-0.061
in.
Reverse Clutch Pack
Clearance0.81-1.24
mm0.032-0.049
in.
Recommended fluid MoparTATF +4, type 9602
GEAR RATIOS
1ST 3.00:1
2ND 1.67:1
2ND Prime 1.50:1
3RD 1.0:1
4TH 0.75:1
5TH 0.67:1
REVERSE 3.00:1
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Fitting, cooler line at trans 17.5 - 155
Bolt, torque convertor 31 23 -
Bolt/nut, crossmember 68 50 -
Bolt, driveplate to crankshaft 75 55 -
Bolt, oil pan 11.8 - 105
Screw, primary fluid filter 4.5 - 40
Bolt, oil pump 28.2 - 250
Bolt, oil pump body to cover 4.5 - 40
Screw, plate to oil pump body 4.5 - 40
Bolt, valve body to case 11.8 - 105
Plug, pressure test port 5.1 - 45
Bolt, reaction shaft support 11.8 - 105
Screw, valve body to transfer plate 5.6 - 50
Screw, solenoid module to transfer plate 5.7 - 50
Screw, accumulator cover 4.5 - 40
Screw, detent spring 4.5 - 40
Bolt, input speed sensor 11.8 - 105
Bolt, output speed sensor 11.8 - 105
Bolt, line pressure sensor 11.8 - 105
Bolt, extension housing 54 40 -
Valve, cooler return filter bypass 4.5 - 40
Screw, manual valve cam retaining 4.5 - 40
Bolt, manual lever 28.2 - 250
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SPECIAL TOOLS
RFE TRANSMISSION
Gauge, Oil Pressure - C-3292
Gauge, Oil Pressure - C-3293SP
Dial Indicator - C-3339
Installer, Seal - C-3860-A
Flusher, Oil Cooler - 6906-C
Compressor, Spring - 8249
Compressor, Spring - 8250
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Compressor, Spring - 8251
Installer, Piston - 8252
Installer, Seal - 8253
Installer, Seal - 8254
Installer, Snap-ring - 8255
Stand, Support - 8257
Adapter, Pressure Tap - 8258-A
Adapter, Line Pressure - 8259
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Fixture, Input Clutch Pressure - 8260
Plate, Alignment - 8261
End Play Set - 8266
Compressor, Spring - 8285
Installer, Bearing - 8320
Wrench, Filter - 8321
Installer, Piston - 8504
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4C RETAINER/BULKHEAD
DISASSEMBLY
(1) Remove the 2C piston belleville spring snap-
ring from the 4C retainer /bulkhead (Fig. 53).
(2) Remove the 2C piston Belleville spring from
the retainer/bulkhead (Fig. 53).
(3) Remove the 2C piston from the retainer/bulk-
head. Use 20 psi of air pressure to remove the piston
if necessary.
(4) Remove the 4C clutch snap-ring from the
retainer/bulkhead (Fig. 53).
(5) Remove the 4C clutch pack from the retainer/
bulkhead (Fig. 53).
(6) Using Spring Compressor 8250 and a suitable
shop press, compress the 4C piston return spring and
remove the snap-ring (Fig. 53).(7) Remove the 4C piston return spring and piston
from the retainer/bulkhead (Fig. 53). Use 20 psi of
air pressure to remove the piston if necessary.ASSEMBLY
(1) Clean and inspect all components. Replace any
components which show evidence of excessive wear
or scoring.
(2) Install new seals on the 2C and 4C pistons
(Fig. 53).
(3) Lubricate all seals with MopartATF +4, type
9602 prior to installation.
(4) Install the 4C piston into the 4C retainer/bulk-
head (Fig. 53).
(5) Position the 4C piston return spring onto the
4C piston.
Fig. 53 4C Retainer/Bulkhead Components
1 - SEAL 8 - REACTION PLATE
2 - 2C PISTON 9 - SNAP-RING
3 - PLATE 10 - RETURN SPRING
4 - DISC 11 - SEAL
5 - 2C BELLEVILLE SPRING 12 - 4C PISTON
6 - SNAP-RING 13 - 4C RETAINER/BULKHEAD
7 - SNAP-RING (SELECT)
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