torque specifications JEEP GRAND CHEROKEE 2002 WJ / 2.G Repair Manual

SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Power Steering Pump
Bracket Bolt-4.0L57 42 Ð
Power Steering Pump
Pump Bolts-4.0L28 21 250
Power Steering Pump
Pump Bolts-4.7L28 21 250
Power Steering Pump
Flow Control Valve75 55 Ð
Power Steering Pump
Pressure Line
4.0L20-38 14-28 Ð
Power Steering Pump
Pressure Line
4.7L47 35 416
Power Steering Pump
Return Line
4.0L & 4.7L20-38 14-28 Ð
High Pressure Inlet Hose
to Hydraulic Fan
DriveÐ1/2 inch Fitting49 36 Ð
High Pressure Outlet
Hose to Steering
GearÐ3/8 inch Fitting29 21.5 Ð
Power Steering Cooler
Lines
at the Cooler22.5 17 200
WJPUMP 19 - 35
PUMP (Continued)

PRESSURE TEST
Overdrive clutch Fourth gear only Pressure should be 469-496 kPa (68-72 psi) with
closed throttle and increase to 620-896 kPa (90-130
psi) at 1/2 to 3/4 throttle.
Line pressure (at
accumulator)Closed throttle 372-414 kPa (54-60 psi).
Front servo Third or Fourth gear only No more than 21 kPa (3 psi) lower than line pressure.
Rear servo 1 range No more than 21 kPa (3 psi) lower than line pressure.
R range 1103 kPa (160 psi) at idle, builds to 1862 kPa (270 psi)
at 1600 rpm.
Governor D range closed throttle Pressure should respond smoothly to changes in mph
and return to 0-7 kPa (0-1.5 psi) when stopped with
transmission in D, 1, 2. Pressure above 7 kPa (1.5 psi)
at stand still will prevent transmission from
downshifting.
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Fitting, cooler line at trans 18 13 -
Bolt, torque convertor 31 - 270
Bolt, clevis bracket to crossmember 47 35 -
Bolt, clevis bracket to rear support 68 50 -
Bolt, driveplate to crankshaft 75 55 -
Plug, front band reaction 17 13 -
Locknut, front band adj. 34 25 -
Switch, park/neutral 34 25 -
Bolt, fluid pan 17 13 -
Screws, fluid filter 4 - 35
Bolt, oil pump 20 15 -
Bolt, overrunning clutch cam 17 13 -
Bolt, O/D to trans. 34 25 -
Bolt, O/D piston retainer 17 13 -
Plug, pressure test port 14 10 -
Bolt, reaction shaft support 20 15 -
Locknut, rear band 41 30 -
Bolt, speedometer adapter 11 - 100
Screw, vehicle speed sensor 2.5 - 21
Bolt, valve body to case 12 - 100
Sensor, trans speed 27 20 -
Screw, solenoid wiring connector 4 - 35
Screw, solenoid to transfer plate 4 - 35
21 - 56 AUTOMATIC TRANSMISSION - 42REWJ
AUTOMATIC TRANSMISSION - 42RE (Continued)

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
21 - 220 AUTOMATIC TRANSMISSION - 545RFEWJ
AUTOMATIC TRANSMISSION - 545RFE (Continued)

TRANSFER CASE - NV242
TABLE OF CONTENTS
page page
TRANSFER CASE - NV242
DESCRIPTION........................280
OPERATION..........................281
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV242.......................281
REMOVAL............................282
DISASSEMBLY........................282
CLEANING...........................292
INSPECTION.........................293
ASSEMBLY...........................295
INSTALLATION........................307
SPECIFICATIONS
TRANSFER CASE - NV242.............308
SPECIAL TOOLS
TRANSFER CASE - NV242.............308
FLUID
STANDARD PROCEDURE - FLUID DRAIN/
REFILL............................310FRONT OUTPUT SHAFT SEAL
REMOVAL............................310
INSTALLATION........................310
POSITION SENSOR
DESCRIPTION........................311
OPERATION..........................311
REMOVAL............................312
INSTALLATION........................312
REAR RETAINER BUSHING AND SEAL -
NV242HD
REMOVAL............................312
INSTALLATION........................312
SHIFT CABLE
REMOVAL............................313
INSTALLATION........................313
TRANSFER CASE - NV242
DESCRIPTION
The NV242 is a full transfer case (Fig. 1). It pro-
vides full time 2-wheel, or 4-wheel drive operation.
A differential in the transfer case is used to control
torque transfer to the front and rear axles. A low
range gear provides increased low speed torque capa-
bility for off road operation. The low range provides a
2.72:1 reduction ratio.
The geartrain is mounted in two aluminum case
halves attached with bolts. The mainshaft front and
rear bearings are mounted in aluminum retainer
housings bolted to the case halves.
TRANSFER CASE IDENTIFICATION
Two versions of the NV242 are used in the WJ
vehicles, NV242LD and NV242HD. The two transfer
cases can be distinguished from one another by the
rear output shaft retainer. The NV242LD uses a rub-
ber boot to cover the rear output shaft, while the
NV242HD uses a cast aluminum housing. Other than
this difference, the two transfer cases are serviced
the same.
A circular ID tag is attached to the rear case of
each transfer case (Fig. 2). The ID tag provides the
transfer case model number, assembly number, serial
number, and low range ratio.The transfer case serial number also represents
the date of build.
SHIFT MECHANISM
Operating ranges are selected with a lever in the
floor mounted shifter assembly. The shift lever is con-
nected to the transfer case range lever by an adjust-
able cable. A straight line shift pattern is used.
Range positions are marked on the shifter bezel.
Fig. 1 NV242 Transfer Case
21 - 280 TRANSFER CASE - NV242WJ

SPECIFICATIONS
TRANSFER CASE - NV242
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 11.8-17.7 -
Bolt, Diff. Case 17-27 12.5-19.9 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Front Brg. Retainer 16-27 11.8-19.9 -
Bolt, Case Half 35-46 25.8-33.9 -
Nut, Front Yoke 122-176 90-130 -
Screw, Oil Pump 1.2-1.8 - 12-15
Nut, Range Lever 27-34 19.9-25 -
Bolt, Rear Retainer 35-46 25.8-33.9 -
Nuts, Mounting 35 25.8 -
Bolts, U-Joint 19 14 -
SPECIAL TOOLS
TRANSFER CASE - NV242
Installer, Seal - C-4076-B
Handle, Universal - C-4171
Remover, Bearing - C-4210
Puller, Slinger - MD-998056-A
Installer - MD-998323
Installer, Bearing - 5064
21 - 308 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (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)

TIRES/WHEELS
TABLE OF CONTENTS
page page
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND
WHEEL RUNOUT......................1
STANDARD PROCEDURE
STANDARD PROCEDURE - TIRE AND
WHEEL BALANCE......................2
STANDARD PROCEDURE - MATCH
MOUNTING...........................4
STANDARD PROCEDURE - TIRE ROTATION . 5
STANDARD PROCEDURE - WHEEL
INSTALLATION........................5
TIRES
DESCRIPTION
DESCRIPTION - TIRES..................6
DESCRIPTION - RADIAL±PLY TIRES.......6
DESCRIPTION - TIRE INFLATION
PRESSURES..........................6
DESCRIPTION - TIRE PRESSURE FOR
HIGH SPEED..........................7
DESCRIPTION - REPLACEMENT TIRES.....7
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - PRESSURE
GAUGES.............................8
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS..........................8
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS...........................8
DIAGNOSIS AND TESTING - TIRE NOISE
OR VIBRATION........................8STANDARD PROCEDURE - REPAIRING
LEAKS...............................8
CLEANING.............................9
SPECIFICATIONS
TIRES...............................9
SPECIFICATIONS -.....................9
SPARE TIRE
DESCRIPTION - SPARE / TEMPORARY TIRE . . 10
WHEELS
DESCRIPTION.........................10
DIAGNOSIS AND TESTING - WHEEL
INSPECTION.........................10
STANDARD PROCEDURE - WHEEL
REPLACEMENT.......................10
SPECIFICATIONS
TORQUE CHART......................11
STUDS
REMOVAL.............................11
INSTALLATION.........................11
TIRE PRESSURE MONITORING
DESCRIPTION.........................12
OPERATION...........................12
DIAGNOSIS AND TESTING - TIRE PRESSURE
MONITORING SYSTEM.................12
SENSOR
REMOVAL - TIRE PRESSURE SENSOR/
TRANSMITTER.......................12
INSTALLATION - TIRE PRESSURE SENSOR/
TRANSMITTER.......................13
TIRES/WHEELS
DIAGNOSIS AND TESTING - TIRE AND WHEEL
RUNOUT
Radial runout is the difference between the high
and low points on the tire or wheel (Fig. 1).
Lateral runout is thewobbleof the tire or wheel.
Radial runout of more than 1.5 mm (.060 inch)
measured at the center line of the tread may cause
the vehicle to shake.
Lateral runout of more than 2.0 mm (.080 inch)
measured near the shoulder of the tire may cause the
vehicle to shake.
Sometimes radial runout can be reduced. Relocate
the wheel and tire assembly on the mounting studs
(See Method 1). If this does not reduce runout to an
acceptable level, the tire can be rotated on the wheel.
(See Method 2).
METHOD 1 (RELOCATE WHEEL ON HUB)
(1) Drive vehicle a short distance to eliminate tire
flat spotting from a parked position.
(2) Check wheel bearings and adjust if adjustable
or replace if necessary.
(3) Check the wheel mounting surface.
(4) Relocate wheel on the mounting, two studs
over from the original position.
(5) Tighten wheel nuts until all are properly
torqued, to eliminate brake distortion.
(6) Check radial runout. If still excessive, mark
tire sidewall, wheel, and stud at point of maximum
runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL)
NOTE: Rotating the tire on wheel is particularly
effective when there is runout in both tire and
wheel.
WJTIRES/WHEELS 22 - 1

DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - PRESSURE
GAUGES
A quality air pressure gauge is recommended to
check tire pressure. After checking the air pressure,
replace valve cap finger tight.
DIAGNOSIS AND TESTING - TREAD WEAR
INDICATORS
Tread wear indicators are molded into the bottom
of the tread grooves. When tread depth is 1.6 mm
(1/16 in.), the tread wear indicators will appear as a
13 mm (1/2 in.) band (Fig. 15).
Tire replacement is necessary when indicators
appear in two or more grooves or if localized balding
occurs.
DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS
Under inflation will cause wear on the shoulders of
tire. Over inflation will cause wear at the center of
tire.
Excessive camber causes the tire to run at an
angle to the road. One side of tread is then worn
more than the other (Fig. 16).
Excessive toe-in or toe-out causes wear on the
tread edges and a feathered effect across the tread
(Fig. 16).
DIAGNOSIS AND TESTING - TIRE NOISE OR
VIBRATION
Radial-ply tires are sensitive to force impulses
caused by improper mounting, vibration, wheel
defects, or possibly tire imbalance.
To find out if tires are causing the noise or vibra-
tion, drive the vehicle over a smooth road at varying
speeds. Note the noise level during acceleration and
deceleration. The engine, differential and exhaust
noises will change as speed varies, while the tire
noise will usually remain constant.
STANDARD PROCEDURE - REPAIRING LEAKS
For proper repairing, a radial tire must be removed
from the wheel. Repairs should only be made if the
defect, or puncture, is in the tread area (Fig. 17). The
tire should be replaced if the puncture is located in
the sidewall.
Deflate tire completely before removing the tire
from the wheel. Use lubrication such as a mild soap
solution when dismounting or mounting tire. Use
tools free of burrs or sharp edges which could dam-
age the tire or wheel rim.
Before mounting tire on wheel, make sure all rust
is removed from the rim bead and repaint if neces-
sary.
Install wheel on vehicle, and tighten to proper
torque specification (Refer to 22 - TIRES/WHEELS/
WHEELS - SPECIFICATIONS).
Fig. 15 Tread Wear Indicators
1 - TREAD ACCEPTABLE
2 - TREAD UNACCEPTABLE
3 - WEAR INDICATOR
22 - 8 TIRES/WHEELSWJ

²Bent or dented
²Leak air through welds
²Have damaged bolt holes
Wheel repairs employing hammering, heating, or
welding are not allowed.
Original equipment wheels are available through
your dealer. Replacement wheels from any other
source should be equivalent in:
²Load carrying capacity
²Diameter
²Width²Offset
²Mounting configuration
Failure to use equivalent replacement wheels may
affect the safety and handling of your vehicle.
Replacement withusedwheels is not recommended.
Their service history may have included severe treat-
ment.
SPECIFICATIONS
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Lug Nut
1/2 X 20 with 60É Cone115-150 85-115 Ð
STUDS
REMOVAL
CAUTION: Do not use a hammer to remove wheel
studs.
(1) Raise and support vehicle.
(2) Remove wheel and tire assembly.
(3) Remove brake caliper, caliper adapter and
rotor,(Refer to 5 - BRAKES/HYDRAULIC/MECHAN-
ICAL/ROTORS - REMOVAL).
(4) Remove stud from hub with Remover C-4150A
(Fig. 19).
INSTALLATION
CAUTION: Do not use a hammer to remove wheel
studs.
(1) Install the new stud into the hub flange.
(2) Install the three washers onto the stud, then
install the lug nut with the flat side of the nut
against the washers.
(3) Tighten the lug nut until the stud is pulled
into the hub flange. Verify that the stud is properly
seated into the flange.
(4) Remove the lug nut and washers.
(5) Install the brake rotor, caliper adapter, and
caliper,(Refer to 5 - BRAKES/HYDRAULIC/ME-
CHANICAL/DISC BRAKE CALIPERS - INSTALLA-
TION).(6) Install the wheel and tire assembly, use new
lug nut on stud or studs that were replaced.
(7) Remove the support and lower vehicle.Fig. 19 Wheel Stud Removal
1 - REMOVER
2 - WHEEL STUD
WJTIRES/WHEELS 22 - 11
WHEELS (Continued)

BODY
TABLE OF CONTENTS
page page
BODY
DIAGNOSIS AND TESTING
WATER LEAKS........................1
WIND NOISE..........................2
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY
LUBRICATION.........................2
STANDARD PROCEDURE - DRILLING AND
WELDING............................3
SPECIFICATIONS
BODY LUBRICANTS....................3
SPECIFICATIONS - TORQUE.............4
SPECIAL TOOLS
BODY...............................4DECKLID/HATCH/LIFTGATE/TAILGATE........5
DOOR - FRONT.........................11
DOORS - REAR.........................19
EXTERIOR.............................25
HOOD.................................33
INSTRUMENT PANEL SYSTEM.............36
INTERIOR..............................69
PAINT.................................81
SEATS................................83
STATIONARY GLASS.....................93
SUNROOF.............................96
WEATHERSTRIP/SEALS..................105
BODY STRUCTURE.....................112
BODY
DIAGNOSIS AND TESTING
WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-
cle. For hoisting recommendations refer to Group 0,
Lubrication and Maintenance, General Information
section.
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
WJBODY 23 - 1