Check transmission JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual

STANDARD PROCEDURE - FLUID AND FILTER
REPLACEMENT
For proper service intervals (Refer to LUBRICA-
TION & MAINTENANCE/MAINTENANCE SCHED-
ULES - DESCRIPTION).
REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Place a large diameter shallow drain pan
beneath the transmission pan.
(3) Remove bolts holding front and sides of pan to
transmission.
(4)
Loosen bolts holding rear of pan to transmission.
(5) Slowly separate front of pan away from trans-
mission allowing the fluid to drain into drain pan.
(6) Hold up pan and remove remaining bolts hold-
ing pan to transmission.
(7) While holding pan level, lower pan away from
transmission.
(8) Pour remaining fluid in pan into drain pan.
(9)
Remove screw holding filter to valve body (Fig. 60).
(10) Separate filter from valve body and oil pump
and pour fluid in filter into drain pan.
(11) Remove and discard the oil filter seal from the
bottom of the oil pump.
(12) If replacing the cooler return filter, use Oil
Filter Wrench 8321 to remove the filter from the
transmission.
(13) Dispose of used trans fluid and filter(s) prop-
erly.
INSPECTION
Inspect bottom of pan and magnet for excessive
amounts of metal. A light coating of clutch material
on the bottom of the pan does not indicate a problemunless accompanied by a slipping condition or shift
lag. If fluid and pan are contaminated with excessive
amounts of debris, refer to the diagnosis section of
this group.
CLEANING
(1) Using a suitable solvent, clean pan and mag-
net.
(2) Using a suitable gasket scraper, clean original
sealing material from surface of transmission case
and the transmission pan.
INSTALLATION
(1) Install a new primary oil filter seal in the oil
pump inlet bore. Seat the seal in the bore with the
butt end of a hammer, or other suitable tool.
CAUTION: The primary oil filter seal MUST be fully
installed flush against the oil pump body. DO NOT
install the seal onto the filter neck and attempt to
install the filter and seal as an assembly. Damage to
the transmission will result.
(2) Place replacement filter in position on valve
body and into the oil pump.
(3) Install screw to hold filter to valve body (Fig.
60). Tighten screw to 4.5 N´m (40 in. lbs.) torque.
(4) Install new cooler return filter onto the trans-
mission, if necessary. Torque the filter to 14.12 N´m
(125 in.lbs.).
(5) Place bead of MopartRTV sealant onto the
transmission case sealing surface.
(6) Place pan in position on transmission.
(7) Install bolts to hold pan to transmission.
Tighten bolts to 11.8 N´m (105 in. lbs.) torque.
(8) Lower vehicle and fill transmission with
MopartATF +4, type 9602 fluid.
STANDARD PROCEDURE - TRANSMISSION
FILL
To avoid overfilling transmission after a fluid
change or overhaul, perform the following procedure:
(1) Remove dipstick and insert clean funnel in
transmission fill tube.
(2) Add following initial quantity of MopartAT F
+4 to transmission:
(a) If only fluid and filter were changed, add10
pints (5 quarts)of ATF +4 to transmission.
(b) If transmission was completely overhauled,
torque converter was replaced or drained, and
cooler was flushed, add24 pints (12 quarts)of
ATF +4 to transmission.
(3) Check the transmission fluid (Refer to 21 -
TRANSMISSION/TRANSAXLE/AUTOMATIC -
45RFE/FLUID - STANDARD PROCEDURE) and
adjust as required.
Fig. 60 Transmission Filters - 4X4 Shown
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
21 - 230 AUTOMATIC TRANSMISSION - 545RFEWJ
FLUID AND FILTER (Continued)

(3) Install nuts to hold seal plate to floor pan.
Tighten nuts to 7 N´m (65 in.lbs.).
(4) Install the shift cable to the shifter assembly
bracket. Push cable into the bracket until secure.
(5) Place the floor shifter lever in PARK position.
(6) Loosen the adjustment screw on the shift cable.
(7) Snap the shift cable onto the shift lever pin.
(8) Raise the vehicle.
(9) Install the shift cable to the shift cable support
bracket.
(10) Shift the transmission into PARK. PARK is
the rearmost detent position on the transmission
manual shift lever.
(11) Snap the shift cable onto the transmission
manual shift lever.
(12) Lower vehicle.
(13) Verify that the shift lever is in the PARK posi-
tion.
(14) Tighten the adjustment screw to 7 N´m (65
in.lbs.).
(15) Verify correct shifter operation.
(16) Install any console parts removed for access to
shift lever assembly and shift cable. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE - INSTALLA-
TION)
ADJUSTMENTS - GEARSHIFT CABLE
Check adjustment by starting the engine in PARK
and NEUTRAL. Adjustment is CORRECT if the
engine starts only in these positions. Adjustment is
INCORRECT if the engine starts in one but not both
positions. If the engine starts in any position other
than PARK or NEUTRAL, or if the engine will not
start at all, the park/neutral position switch or TRS
may be faulty.
(1) Shift transmission into PARK.
(2) Remove floor console as necessary for access to
the shift cable adjustment. (Refer to 23 - BODY/IN-
TERIOR/FLOOR CONSOLE - REMOVAL)
(3) Loosen the shift cable adjustment screw (Fig.
64).
(4) Raise vehicle.
(5) Unsnap cable eyelet from transmission shift
lever (Fig. 65).
(6) Verify transmission shift lever is in PARK
detent by moving lever fully rearward. Last rearward
detent is PARK position.
(7) Verify positive engagement of transmission
park lock by attempting to rotate propeller shaft.
Shaft will not rotate when park lock is engaged.
(8) Snap cable eyelet onto transmission shift lever.
(9) Lower vehicle
(10) Tighten the shift cable adjustment screw to 7
N´m (65 in.lbs.).
(11) Verify correct operation.(12) Install any floor console components removed
for access. (Refer to 23 - BODY/INTERIOR/FLOOR
CONSOLE - INSTALLATION)
Fig. 64 Shift Cable at the Shifter
1 - SHIFT LEVER PIN
2 - ADJUSTMENT SCREW
3 - SHIFT CABLE
4 - SHIFTER ASSEMBLY BRACKET
Fig. 65 Shift Cable at Transmission
1 - TRANSMISSION SHIFTER CABLE
2 - THROTTLE VALVE CABLE
3 - TRANSFER CASE SHIFTER CABLE
4 - TRANSFER CASE SHIFTER CABLE BRACKET RETAINING
BOLT(S)
5 - THROTTLE VALVE CABLE BRACKET RETAINING BOLT
6 - ELECTRICAL CONNECTORS
7 - TRANSMISSION FLUID LINES
21 - 232 AUTOMATIC TRANSMISSION - 545RFEWJ
GEARSHIFT CABLE (Continued)

INPUT CLUTCH ASSEMBLY
DESCRIPTION
Three hydraulically applied input clutches are used
to drive planetary components. The underdrive, over-
drive, and reverse clutches are considered input
clutches and are contained within the input clutch
assembly (Fig. 68) and (Fig. 69). The input clutch
assembly also contains:
²Input shaft
²Input hub
²Clutch retainer
²Underdrive piston²Overdrive/reverse piston
²Overdrive hub
²Underdrive hubOPERATION
The three input clutches are responsible for driving
different components of the planetary geartrain.
UNDERDRIVE CLUTCH
The underdrive clutch is hydraulically applied in
first, second, second prime, and third (direct) gears
by pressurized fluid against the underdrive piston.
Fig. 68 Input Clutch Assembly - Part 1
1 - INPUT CLUTCH HUB 11 - UD CLUTCH
2 - O-RING SEALS 12 - PLATE
3 - SEAL 13 - CLUTCH RETAINER
4 - SNAP-RING 14 - SEAL
5 - SNAP-RING 15 - OD/REV PISTON
6 - UD BALANCE PISTON 16 - BELLEVILLE SPRING
7 - SNAP-RING 17 - SNAP-RING
8 - UD PISTON 18 - SEAL RINGS
9 - SPRING 19 - INPUT SHAFT
10 - DISC 20 - LUBRICATION CHECK VALVE AND SNAP-RING
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 235

(9) Remove the number 2 bearing from the input
clutch hub.
(10) Remove the overdrive clutch wave snap-ring
from the input clutch retainer.
(11) Remove the UD/OD reaction plate tapered
snap-ring from the input clutch retainer.
(12) Remove the UD/OD reaction plate from the
input clutch retainer.
(13) Remove the UD/OD reaction plate flat snap-
ring from the input clutch retainer (Fig. 70).
(14) Remove the underdrive clutch pack from the
input clutch retainer (Fig. 72).
(15) Using Spring Compressor 8251, compress the
UD/OD balance piston and remove the snap-ring
from the input clutch hub (Fig. 71).
(16) Remove the UD/OD balance piston and piston
return spring from the input clutch retainer (Fig. 72).
(17) Remove the underdrive piston from the input
clutch retainer (Fig. 72).NOTE: Both the UD/OD balance piston and the
underdrive piston have seals molded onto them. If
the seal is damaged, do not attempt to install a new
seal onto the piston. The piston/seal must be
replaced as an assembly.
(18) Remove the input clutch retainer tapered
snap-ring.
(19) Separate input clutch retainer from input
clutch hub.
(20) Separate OD/reverse piston from input clutch
hub retainer (Fig. 72).
(21) Remove all seals and o-rings from the input
shaft and input hub. The o-rings on the input hub
are color coded. Be sure to make note of which o-ring
belongs in which location.
ASSEMBLY
(1) Install all new seals and o-rings onto the input
shaft and input hub. The o-rings on the input hub
are color coded. Be sure to install the correct o-ring
in the correct location.
(2) Check the transmission lubrication check valve
located in the input shaft using shop air. The valve
should only allow air flow in one direction. If the
valve allows no air flow, or air flow in both direc-
tions, the valve will need to be replaced.
(3) Lubricate all seals with MopartATF +4, type
9602, prior to installation.
(4) Assemble the OD/reverse piston onto the input
clutch hub (Fig. 73).
(5) Assemble the input clutch retainer onto the
input clutch hub.
(6) Install the input clutch retainer tapered snap-
ring with tapered side up onto the input clutch hub.
Fig. 71 Compressing UD/OD Balance Piston Using
Tool 8251
1 - PRESS
2 - TOOL 8251
3 - BALANCE PISTON
21 - 238 AUTOMATIC TRANSMISSION - 545RFEWJ
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 72 Input Clutch Assembly - Part 1
1 - INPUT CLUTCH HUB 11 - UD CLUTCH
2 - O-RING SEALS 12 - PLATE
3 - SEAL 13 - CLUTCH RETAINER
4 - SNAP-RING 14 - SEAL
5 - SNAP-RING 15 - OD/REV PISTON
6 - UD BALANCE PISTON 16 - BELLEVILLE SPRING
7 - SNAP-RING 17 - SNAP-RING
8 - UD PISTON 18 - SEAL RINGS
9 - SPRING 19 - INPUT SHAFT
10 - DISC 20 - LUBRICATION CHECK VALVE AND SNAP-RING
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 239
INPUT CLUTCH ASSEMBLY (Continued)

Fig. 73 Input Clutch Assembly - Part I
1 - INPUT CLUTCH HUB 11 - UD CLUTCH
2 - O-RING SEALS 12 - PLATE
3 - SEAL 13 - CLUTCH RETAINER
4 - SNAP-RING 14 - SEAL
5 - SNAP-RING 15 - OD/REV PISTON
6 - UD BALANCE PISTON 16 - BELLEVILLE SPRING
7 - SNAP-RING 17 - SNAP-RING
8 - UD PISTON 18 - SEAL RINGS
9 - SPRING 19 - INPUT SHAFT
10 - DISC 20 - LUBRICATION CHECK VALVE AND SNAP-RING
21 - 240 AUTOMATIC TRANSMISSION - 545RFEWJ
INPUT CLUTCH ASSEMBLY (Continued)

holding the Belleville spring into the low/reverse
clutch retainer.
(10) Remove the low/reverse clutch Belleville
spring and piston from the low/reverse clutch
retainer. Use 20 psi of air pressure to remove the pis-
ton if necessary.
CLEANING
Clean the overrunning clutch assembly, clutch cam,
and low-reverse clutch retainer. Dry them with com-
pressed air after cleaning.
INSPECTION
Inspect condition of each clutch part after cleaning.
Replace the overrunning clutch roller and spring
assembly if any rollers or springs are worn or dam-
aged, or if the roller cage is distorted, or damaged.
Replace the cam if worn, cracked or damaged.
Replace the low-reverse clutch retainer if the
clutch race, roller surface or inside diameter is
scored, worn or damaged.
ASSEMBLY
(1) Check the bleed orifice to ensure that it is not
plugged or restricted.
(2) Install a new seal on the low/reverse piston.
Lubricate the seal with MopartATF +4, type 9602,
prior to installation.
(3) Install the low/reverse piston into the low/re-
verse clutch retainer.
(4) Position the low/reverse piston Belleville spring
on the low/reverse piston.
(5) Using Spring Compressor 8285 and a suitable
shop press (Fig. 86), compress the low/reverse piston
Belleville spring and install the split retaining ring
to hold the Belleville spring into the low/reverse
clutch retainer.
(6) Install the lower overrunning clutch snap-ring
(Fig. 85).
(7) Assemble the inner and outer races of the over-
running clutch (Fig. 85).
(8) Position the overrunning clutch spacer on the
overrunning clutch.
(9) Install the upper overrunning clutch snap-ring
(Fig. 85).
(10) Assemble and install the low/reverse clutch
pack into the low/reverse clutch retainer (Fig. 84).
(11) Install the low/reverse reaction plate into the
low/reverse clutch retainer (Fig. 84). The reaction
plate is directional and must be installed with the
flat side down.
(12) Install the low/reverse clutch pack snap-ring
(Fig. 84). The snap-ring is selectable and should be
chosen to give the correct clutch pack clearance.
(13) Measure the low/reverse clutch pack clearance
and adjust as necessary. The correct clutch clearance
is 1.00-1.74 mm (0.039-0.075 in.).
(14) Install the overrunning clutch into the low/re-
verse clutch retainer making sure that the index
splines are aligned with the retainer.
(15) Install the overrunning clutch inner snap-
ring.
Fig. 85 Overrunning Clutch
1 - SNAP-RING
2 - OUTER RACE
3 - OVERRUNNING CLUTCH
4 - SPACER
Fig. 86 Compress Low/Reverse Belleville Spring
Using Tool 8285
1 - PRESS
2 - TOOL 8285
3 - BELLEVILLE SPRING
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 247
LOW/REVERSE CLUTCH (Continued)

OIL PUMP
DESCRIPTION
The oil pump (Fig. 87) is located at the front of the
transmission inside the bell housing and behind the
transmission front cover. The oil pump consists of
two independent pumps (Fig. 88), a number of valves
(Fig. 89), a front seal (Fig. 90), and a bolt on reaction
shaft. The converter clutch switch and regulator
valves, pressure regulator valve, and converter pres-
sure limit valve are all located in the oil pump valve
body.
OPERATION
As the torque converter rotates, the converter hub
rotates the oil pump drive gear. As the drive gear
rotates both driven gears, a vacuum is created when
the gear teeth come out of mesh. This suction draws
fluid through the pump inlet from the oil pan. As the
gear teeth come back into mesh, pressurized fluid is
forced into the pump outlet and to the oil pump
valves.
At low speeds, both sides of the pump supply fluid
to the transmission. As the speed of the torque con-
verter increases, the flow from both sides increases
until the flow from the primary side alone is suffi-
cient to meet system demands. At this point, the
check valve located between the two pumps closes.
The secondary side is shut down and the primary
side supplies all the fluid to the transmission.
CONVERTER CLUTCH SWITCH VALVE
The converter clutch switch valve is used to control
the hydraulic pressure supplied to the front (OFF)
side of the torque converter clutch.
CONVERTER CLUTCH REGULATOR VALVE
The converter clutch regulator valve is used to con-
trol the hydraulic pressure supplied to the back (ON)
side of the torque converter clutch.
TORQUE CONVERTER LIMIT VALVE
The torque converter limit valve serves to limit the
available line pressure to the torque converter clutch
to approximately 120 psi.
Fig. 87 Oil Pump
1 - OIL PUMP TO CASE BOLT (6)
2 - OIL PUMP
Fig. 88 Oil Pump Gears
1 - PUMP HOUSING
2 - DRIVE GEAR
3 - DRIVEN GEARS
Fig. 89 Oil Pump Valves
1 - TORQUE CONVERTER CLUTCH ACCUMULATOR VALVE
2 - TORQUE CONVERTER CLUTCH CONTROL VALVE
3 - TORQUE CONVERTER CLUTCH SWITCH VALVE
4 - PUMP VALVE BODY
5 - PRESSURE REGULATOR VALVE
6 - TORQUE CONVERTER CLUTCH LIMIT VALVE
21 - 248 AUTOMATIC TRANSMISSION - 545RFEWJ

STANDARD PROCEDURE - OIL PUMP VOLUME
CHECK
Measuring the oil pump output volume will deter-
mine if sufficient oil flow to the transmission oil
cooler exists, and whether or not an internal trans-
mission failure is present.
Verify that the transmission fluid is at the proper
level. Refer to the Fluid Level Check procedure in
this section. If necessary, fill the transmission to the
proper level with MopartATF +4, type 9602, Auto-
matic Transmission Fluid.
(1) Disconnect theTo coolerline at the cooler
inlet and place a collecting container under the dis-
connected line.CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter-
nal damage to the transmission may occur.
(2) Run the engineat 1800 rpm, with the shift
selector in neutral. Verify that the transmission fluid
temperature is below 104.5É C (220É F) for this test.
(3) If one quart of transmission fluid is collected in
the container in 30 seconds or less, oil pump flow vol-
ume is within acceptable limits. If fluid flow is inter-
mittent, or it takes more than 30 seconds to collect
one quart of fluid, refer to the Hydraulic Pressure
tests in this section for further diagnosis.
(4) Re-connect theTo coolerline to the transmis-
sion cooler inlet.
Fig. 90 Oil Pump Reaction Shaft
1 - PUMP HOUSING 4 - SEAL RING (5)
2 - SEAL 5 - REACTION SHAFT SUPPORT
3 - OIL FILTER SEAL 6 - PUMP VALVE BODY
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 249
OIL PUMP (Continued)

(5) Remove the screws holding the separator plate
onto the oil pump body (Fig. 92).
(6) Remove the separator plate from the oil pump
body (Fig. 92).
(7) Mark all gears for location. The gears are
select fit and if the oil pump is to be reused, the
gears must be returned to their original locations.
(8) Remove the oil pump gears from the oil pump
case (Fig. 92).
Fig. 92 Oil Pump Housing and Gears
1 - SEPARATOR PLATE 5 - DOWEL (2)
2 - DRIVEN GEAR (2) 6 - DRIVE GEAR
3 - CHECK VALVE 7 - SCREW
4 - PUMP HOUSING
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 251
OIL PUMP (Continued)