Plugs JEEP GRAND CHEROKEE 2002 WJ / 2.G Repair Manual

²pressure adjusting screw and bracket assembly
²throttle lever
²manual lever and shaft seal
²throttle lever shaft seal, washer, and E-clip
²fluid filter and screws
²detent ball and spring
²valve body screws
²governor pressure solenoid
²governor pressure sensor and retaining clip
²park lock rod and E-clip
ASSEMBLY
CAUTION: Do not force valves or plugs into place
during reassembly. If the valve body bores, valves
and plugs are free of distortion or burrs, the valve
body components should all slide into place easily.
In addition, do not overtighten the transfer plate
and valve body screws during reassembly. Over-
tightening can distort the housings resulting in
valve sticking, cross leakage and unsatisfactory
operation. Tighten valve body screws to recom-
mended torque only.
LOWER HOUSING
(1) Lubricate valves, springs, and the housing
valve and plug bores with clean transmission fluid
(Fig. 309).
(2) Install 3-4 timing valve spring and valve in
lower housing.
(3) Install 3-4 quick fill valve in lower housing.
(4) Install 3-4 quick fill valve spring and plug in
housing.
(5) Install timing valve end plate. Tighten end
plate screws to 4 N´m (35 in. lbs.) torque.
3-4 ACCUMULATOR
(1) Lubricate accumulator piston, seals and hous-
ing piston bore with clean transmission fluid (Fig.
310).
(2) Install new seal rings on accumulator piston.
(3) Install piston and spring in housing.
(4) Install end plate on housing.
TRANSFER PLATE
(1) Install rear clutch and rear servo check balls in
transfer plate (Fig. 311).
(2) Install filter screen in upper housing separator
plate (Fig. 312).
(3) Align and position upper housing separator
plate on transfer plate (Fig. 313).
(4) Install brace plate (Fig. 313). Tighten brace
attaching screws to 4 N´m (35 in. lbs.) torque.
(5) Install remaining separator plate attaching
screws. Tighten screws to 4 N´m (35 in. lbs.) torque.
UPPER AND LOWER HOUSING
(1) Position upper housing so internal passages
and check ball seats are facing upward. Then install
check balls in housing (Fig. 314). Eight check balls
are used. The single large check ball is approxi-
mately 8.7 mm (11/32 in.) diameter. The single small
check ball is approximately 4.8 mm (3/16 in.) in
diameter. The remaining 6 check balls are approxi-
mately 6.3 mm (1/4 in.) in diameter.
(2) Position assembled transfer plate and upper
housing separator plate on upper housing (Fig. 315).
Be sure filter screen is seated in proper housing
recess.
Fig. 311 Rear Clutch And Rear Servo Check Ball
Locations
1 - REAR CLUTCH CHECK BALL
2 - REAR SERVO CHECK BALL
3 - TRANSFER PLATE
Fig. 312 Separator Plate Filter Screen Installation
1 - UPPER HOUSING SEPARATOR PLATE
2 - FILTER SCREEN
WJAUTOMATIC TRANSMISSION - 42RE 21 - 167
VALVE BODY (Continued)

UPPER HOUSING VALVE AND PLUG
Refer to (Fig. 318), (Fig. 319) and (Fig. 320) to per-
form the following steps.
(1) Lubricate valves, plugs, springs with clean
transmission fluid.
(2) Assemble regulator valve line pressure plug,
sleeve, throttle plug and spring. Insert assembly in
upper housing and install cover plate. Tighten cover
plate screws to 4 N´m (35 in. lbs.) torque.
(3) Install 1-2 and 2-3 shift valves and springs.
(4) Install 1-2 shift control valve and spring.
(5) Install retainer, spring, limit valve, and 2-3
throttle plug from limit valve housing.
Fig. 318 Shuttle And Boost Valve Components
1 - SPRING 8 - SHUTTLE VALVE COVER
2 - RETAINER 9 - SHUTTLE VALVE
3 - BOOST VALVE 10 - SHUTTLE VALVE PRIMARY SPRING
4 - BOOST VALVE PLUG 11 - GOVERNOR PLUG COVER
5 - SPRING GUIDES 12 - THROTTLE PLUG
6 - E-CLIP 13 - UPPER HOUSING
7 - SHUTTLE VALVE SECONDARY SPRING 14 - BOOST VALVE COVER
Fig. 317 Installing Lower Housing On Transfer Plate
And Upper Housing
1 - VALVE BODY SCREWS (13)
2 - LOWER HOUSING
3 - UPPER HOUSING
4 - TRANSFER PLATE
WJAUTOMATIC TRANSMISSION - 42RE 21 - 169
VALVE BODY (Continued)

(6) Install limit valve housing and cover plate.
Tighten screws to 4 N´m (35 in. lbs.).
(7) Install shuttle valve as follows:
(a) Insert plastic guides in shuttle valve second-
ary spring and install spring on end of valve.
(b) Install shuttle valve into housing.
(c) Hold shuttle valve in place.
(d) Compress secondary spring and install E-clip
in groove at end of shuttle valve.
(e) Verify that spring and E-clip are properly
seated before proceeding.(8) Install shuttle valve cover plate. Tighten cover
plate screws to 4 N´m (35 in. lbs.) torque.
(9) Install 1-2 and 2-3 valve governor plugs in
valve body.
(10) Install shuttle valve primary spring and
throttle plug.
(11) Align and install governor plug cover. Tighten
cover screws to 4 N´m (35 in. lbs.) torque.
Fig. 319 Upper Housing Control Valve Locations
1 - UPPER HOUSING 8 - MANUAL VALVE
2 - REGULATOR VALVE 9 - 1-2 GOVERNOR PLUG
3 - SWITCH VALVE 10 - GOVERNOR PLUG COVER
4 - REGULATOR VALVE SPRING 11 - THROTTLE PLUG
5 - KICKDOWN VALVE 12 - 2-3 GOVERNOR PLUG
6 - KICKDOWN DETENT 13 - SHUTTLE VALVE PRIMARY SPRING
7 - THROTTLE VALVE AND SPRING
21 - 170 AUTOMATIC TRANSMISSION - 42REWJ
VALVE BODY (Continued)

Diagnosis of these problems should always begin
by checking the easily accessible variables: fluid level
and condition, gearshift cable adjustment. Then per-
form a road test to determine if the problem has been
corrected or if more diagnosis is necessary. If the
problem persists after the preliminary tests and cor-
rections are completed, hydraulic pressure checks
should be performed.
DIAGNOSIS AND TESTING - PRELIMINARY
Two basic procedures are required. One procedure for
vehicles that are drivable and an alternate procedure for
disabled vehicles (will not back up or move forward).
VEHICLE IS DRIVABLE
(1) Check for transmission fault codes using DRBt
scan tool.
(2) Check fluid level and condition.
(3) Adjust gearshift cable if complaint was based
on delayed, erratic, or harsh shifts.
(4) Road test and note how transmission upshifts,
downshifts, and engages.
(5) Perform stall test if complaint is based on slug-
gish acceleration. Or, if abnormal throttle opening is
needed to maintain normal speeds with a properly
tuned engine.
(6) Perform hydraulic pressure test if shift prob-
lems were noted during road test.
(7)
Perform air-pressure test to check clutch operation.
VEHICLE IS DISABLED
(1) Check fluid level and condition.
(2)
Check for broken or disconnected gearshift cable.
(3) Check for cracked, leaking cooler lines, or loose
or missing pressure-port plugs.(4) Raise and support vehicle on safety stands,
start engine, shift transmission into gear, and note
following:
(a) If propeller shaft turns but wheels do not,
problem is with differential or axle shafts.
(b) If propeller shaft does not turn and transmis-
sion is noisy, stop engine. Remove oil pan, and
check for debris. If pan is clear, remove transmis-
sion and check for damaged driveplate, converter,
oil pump, or input shaft.
(c) If propeller shaft does not turn and transmis-
sion is not noisy, perform hydraulic-pressure test to
determine if problem is hydraulic or mechanical.
DIAGNOSIS AND TESTING - ROAD TESTING
Before road testing, be sure the fluid level and con-
trol cable adjustments have been checked and
adjusted if necessary. Verify that all diagnostic trou-
ble codes have been resolved.
Observe engine performance during the road test.
A poorly tuned engine will not allow accurate analy-
sis of transmission operation.
Operate the transmission in all gear ranges. Check
for shift variations and engine flare which indicates
slippage. Note if shifts are harsh, spongy, delayed,
early, or if part throttle downshifts are sensitive.
Slippage indicated by engine flare, usually means
clutch, overrunning clutch, or line presure problems.
A slipping clutch can often be determined by com-
paring which internal units are applied in the vari-
ous gear ranges. The Clutch Application chart
provides a basis for analyzing road test results.
CLUTCH APPLICATION CHART
SLP UD OD R 2C 4C L/R OVERRUNNING
P±PARKON
R±REVERSEON ON
N-NEUTRALON
D±OVERDRIVE
FIRSTON ON* ON
SECONDON ON
SECOND PRIMEON ON
THIRDON ON
FOURTHON ON
FIFTHON ON
LIMP-INON ON
2±FIRSTON ON* ON
SECONDON ON
LIMP-INON ON
1±LOWON ON ON
*L/R clutch is on only with the output shaft speed below 150 rpm.
21 - 180 AUTOMATIC TRANSMISSION - 545RFEWJ
AUTOMATIC TRANSMISSION - 545RFE (Continued)

DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST
An accurate tachometer and pressure test gauges
are required. Test Gauge C-3293-SP has a 300 psi
range and is used at all locations where pressures
exceed 100 psi.
Pressure Test Port Locations
Only two pressure ports are supplied on the trans-
mission case. The torque converter clutch apply and
release ports are located on the right side of the
transmission case (Fig. 2).
To determine the line pressure, there are two avail-
able methods. The DRBtscan tool can be used to
read line pressure from the line pressure sensor. The
second method is to install Line Pressure Adapter
8259 (Fig. 4) into the transmission case and then
install the pressure gauge and the original sensor
into the adapter. This will allow a comparison of the
DRBtreadings and the gauge reading to determe the
accuracy of the line pressure sensor. The DRBtline
pressure reading should match the gauge reading
within  10 psi.
In order to access any other pressure tap locations,
the transmission oil pan must be removed, the pres-
sure port plugs removed and Valve Body Pressure
Tap Adapter 8258-A (Fig. 5) installed. The extensions
supplied with Adapter 8258-A will allow the installa-
tion of pressure gauges to the valve body. Refer to
(Fig. 3) for correct pressure tap location identifica-
tion.
TEST PROCEDURE
All pressure readings should be taken with the
transmission fluid level full, transmission oil at the
normal operating temperature, and the engine at
1500 rpm. Check the transmission for proper opera-
tion in each gear position that is in question or if a
specific element is in question, check the pressure
readings in at least two gear positions that employ
that element. Refer to the Hydraulic Schematics at
the rear of this section to determine the correct pres-
sures for each element in a given gear position.
Fig. 2 Torque Converter Pressure Locations
1 - TCC RELEASE
2 - TO COOLER
3 - TCC APPLY
4 - FROM COOLER
5 - LINE PRESSURE SENSOR
Fig. 3 Pressure Tap Locations
Fig. 4 Line Pressure Adapter 8259
1 - LINE PRESSURE SENSOR PORT
2 - LINE PRESSURE SENSOR
3 - TOOL 8259
4 - PRESSURE TAP
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 181
AUTOMATIC TRANSMISSION - 545RFE (Continued)

(9) Remove the oil pump valve retainers and asso-
ciated valve and spring one at a time (Fig. 93) (Fig.
94). Mark the combination of components as a group
and tag them as to the location from which they were
removed.
CLEANING
Clean pump and support components with solvent
and dry them with compressed air.
INSPECTION
Check condition of the seal rings and thrust
washer on the reaction shaft support. The seal rings
do not need to be replaced unless cracked, broken, or
severely worn.
Inspect the pump and support components. Replace
the pump or support if the seal ring grooves or
machined surfaces are worn, scored, pitted, or dam-
aged. Replace the pump gears if pitted, worn
chipped, or damaged.Inspect the pump reaction shaft support bushings.
Replace either bushing only if heavily worn, scored or
damaged. It is not necessary to replace the bushings
unless they are actually damaged.
Inspect the valves and plugs for scratches, burrs,
nicks, or scores. Minor surface scratches on steel
valves and plugs can be removed with crocus cloth
butdo not round off the edges of the valve or
plug lands.Maintaining sharpness of these edges is
vitally important. The edges prevent foreign matter
from lodging between the valves and plugs and the
bore.
Inspect all the valve and plug bores in the oil
pump cover. Use a penlight to view the bore interi-
ors. Replace the oil pump if any bores are distorted
or scored. Inspect all of the valve 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.
Fig. 93 Oil Pump Valve Body
1 - T/C REGULATOR VALVE
2 - T/C LIMIT VALVE
3 - REGULATOR VALVE
4 - OIL PUMP VALVE BODY
Fig. 94 T/C Switch Valve
1 - RETAINER
2 - T/C SWITCH VALVE
3 - OIL PUMP VALVE BODY
21 - 252 AUTOMATIC TRANSMISSION - 545RFEWJ
OIL PUMP (Continued)

CLEANING
Clean the valve housings, valves, plugs, springs,
and separator plates with a standard parts cleaning
solution only. Do not use gasoline, kerosene, or any
type of caustic solution. (Fig. 131)
Do not immerse any of the electrical components in
cleaning solution. Clean the electrical components by
wiping them off with dry shop towels only.
Dry all except the electrical parts with compressed
air. Make sure all passages are clean and free from
obstructions.Do not use rags or shop towels to
dry or wipe off valve body components. Lint
from these materials can stick to valve body
parts, interfere with valve operation, and clog
filters and fluid passages.
INSPECTION
Inspect all of the valve body mating surfaces for
scratches, nicks, burrs, or distortion. Use a straight-edge to check surface flatness. Minor scratches may
be removed with crocus cloth using only very light
pressure.
Minor distortion of a valve body mating surface
may be corrected by smoothing the surface with a
sheet of crocus cloth. Position the crocus cloth on a
surface plate, sheet of plate glass or equally flat sur-
face. If distortion is severe or any surfaces are
heavily scored, the valve body will have to be
replaced.
Inspect the valves and plugs (Fig. 132) for
scratches, burrs, nicks, or scores. Minor surface
scratches on steel valves and plugs can be removed
with crocus cloth butdo not round off the edges
of the valve or plug lands.Maintaining sharpness
of these edges is vitally important. The edges prevent
foreign matter from lodging between the valves and
plugs and the bore.
Fig. 130 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. 131 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)
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 277
VALVE BODY (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)

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

(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)