checking oil JEEP GRAND CHEROKEE 2003 WJ / 2.G User Guide

(26) Remove bolts holding the upper transmission
bending braces to the torque converter housing and
the overdrive unit (Fig. 20).
(27) Remove all remaining converter housing bolts.
(28) Carefully work transmission and torque con-
verter assembly rearward off engine block dowels.
(29) Hold torque converter in place during trans-
mission removal.
(30) Lower transmission and remove assembly
from under the vehicle.
(31) To remove torque converter, carefully slide
torque converter out of the transmission.
DISASSEMBLY
(1) Clean transmission exterior with steam gun or
with solvent. Wear eye protection during cleaning
operations.
(2) Place transmission in a vertical position.(3) Measure input shaft end play as follows (Fig.
21).
(a) Attach Adapter 8266-6 to Handle 8266-8.
(b) Attach dial indicator C-3339 to Handle
8266-8.
(c) Install the assembled tool onto the input
shaft of the transmission and tighten the retaining
screw on Adapter 8266-6 to secure it to the input
shaft.
(d) Position the dial indicator plunger against a
flat spot on the oil pump and zero the dial indica-
tor.
(e) Move the input shaft in and out. Record the
maximum travel for assembly reference.
(4) Remove shift and throttle levers from valve
body manual lever shaft.
(5) Place transmission in horizontal position.
(6) Remove transmission oil pan and gasket.
(7) Remove filter from valve body (Fig. 22). Keep
filter screws separate from other valve body screws.
Filter screws are longer and should be kept with fil-
ter.
(8) Remove park/neutral position switch.
(9) Remove hex head bolts attaching valve body to
transmission case (Fig. 23). A total of 10 bolts are
used. Note different bolt lengths for assembly refer-
ence.
Fig. 19 Remove NV242 Transfer Case
1 - NV242 TRANSFER CASE
Fig. 20 Remove Upper Transmission Bending
Braces
1 - TRANSMISSION BENDING BRACES
Fig. 21 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-6
3 - TOOL C-3339
WJAUTOMATIC TRANSMISSION - 42RE 21 - 29
AUTOMATIC TRANSMISSION - 42RE (Continued)

(27) Install oil pump (Fig. 57). Align and position
pump on pilot studs. Slide pump down studs and
work it into front clutch hub and case by hand. Then
install 2 or 3 pump bolts to hold pump in place.
(28) Remove pilot stud tools and install remaining
oil pump bolts. Tighten bolts alternately in diagonal
pattern to 20 N´m (15 ft. lbs.).
(29) Measure input shaft end play (Fig. 58).
NOTE: If end play is incorrect, transmission is
incorrectly assembled, or the intermediate shaft
thrust washer is incorrect. The intermediate shaft
thrust washer is selective.
(a) Attach Adapter 8266-6 to Handle 8266-8.
(b) Attach dial indicator C-3339 to Handle
8266-8.
(c) Install the assembled tool onto the input
shaft of the transmission and tighten the retaining
screw on Adapter 8266-6 to secure it to the input
shaft.
(d) Position the dial indicator plunger against a
flat spot on the oil pump and zero the dial indica-
tor.
(e) Move input shaft in and out and record read-
ing. End play should be 0.56-2.31 mm (0.022-0.091
in.). Adjust as necessary.
(30) Install accumulator piston and inner and
outer springs (Fig. 59).
(31) Verify that valve body solenoid harness is
secured in 3-4 accumulator housing cover plate.
Fig. 57 Installing Oil Pump
1 - OIL PUMP
2 - PILOT STUD TOOL
3 - PILOT STUD TOOL
Fig. 58 Checking Input Shaft End Play
1 - TOOL 8266-8
2 - TOOL 8266-6
3 - TOOL C-3339
Fig. 59 Accumulator Piston And Springs
1 - GOVERNOR PRESSURE SENSOR
2 - VALVE BODY
3 - PARK ROD
4 - ACCUMULATOR PISTON
5 - GOVERNOR PRESSURE SOLENOID
21 - 40 AUTOMATIC TRANSMISSION - 42REWJ
AUTOMATIC TRANSMISSION - 42RE (Continued)

(32) Install valve body as follows:
(a) Align and carefully insert park rod into pawl.
Rod will make click noise as it enters pawl. Move
rod slightly to check engagement.
(b) Align and seat valve body on case. Be sure
manual lever shaft and overdrive connector are
fully seated in case. Also be sure valve body wiring
is not pinched or kinked.
(c) Install and start all valve body attaching
bolts by hand. Then tighten bolts evenly, in a diag-
onal pattern to 12 N´m (105 in. lbs.) torque. Do not
overtighten valve body bolts. This could result in
distortion and cross leakage after installation.
CAUTION: It is possible for the park rod to displace
into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into the cavity.
(33) Install new filter on valve body. Tighten filter
screws to 4 N´m (35 in. lbs.).
(34) Adjust front and rear bands.
(35) Install seal on park/neutral position switch.
Then install and tighten switch to 34 N´m (25 ft.
lbs.).
(36) Install magnet in oil pan. Magnet goes on
small protrusion at corner of pan.
(37) Position new oil pan gasket on case and
install oil pan. Tighten pan bolts to 17 N´m (13 ft.
lbs.).
(38) Install new valve body manual shaft seal in
case (Fig. 60). Lubricate seal lip and manual shaft
with petroleum jelly. Start seal over shaft and into
case. Seat seal with 15/16 inch, deep well socket.
(39) Install throttle valve and shift selector levers
on valve body manual lever shaft.INSTALLATION
(1) Check torque converter hub and hub drive
notches for sharp edges burrs, scratches, or nicks.
Polish the hub and notches with 320/400 grit paper
and crocus cloth if necessary. The hub must be
smooth to avoid damaging pump seal during installa-
tion.
(2) Lubricate oil pump seal lip with transmission
fluid.
(3) Align converter and oil pump.
(4) Carefully insert converter in oil pump. Then
rotate converter back and forth until fully seated in
pump gears.
(5) Check converter seating with steel scale and
straightedge (Fig. 61). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con-
verter is fully seated.
(6) Temporarily secure converter with C-clamp.
(7) Position transmission on jack and secure it
with chains.
(8) Check condition of converter driveplate.
Replace the plate if cracked, distorted or damaged.
Also be sure transmission dowel pins are seated in
engine block and protrude far enough to hold trans-
mission in alignment.
(9) Apply a light coating of MopartHigh Temp
grease to the torque converter hub pocket in the rear
of the crankshaft
(10) Raise transmission and align converter with
drive plate and converter housing with engine block.
Fig. 60 Installing Manual Lever Shaft Seal
1 - 15/1688SOCKET
2 - SEAL
Fig. 61 Checking Torque Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
WJAUTOMATIC TRANSMISSION - 42RE 21 - 41
AUTOMATIC TRANSMISSION - 42RE (Continued)

(1) A result of restricted fluid flow through the
main and/or auxiliary cooler. This condition is usu-
ally the result of a faulty or improperly installed
drainback valve, a damaged main cooler, or severe
restrictions in the coolers and lines caused by debris
or kinked lines.
(2) Heavy duty operation with a vehicle not prop-
erly equipped for this type of operation. Trailer tow-
ing or similar high load operation will overheat the
transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary
transmission fluid cooler, a heavy duty cooling sys-
tem, and the engine/axle ratio combination needed to
handle heavy loads.
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION
Transmission fluid contamination is generally a
result of:
²adding incorrect fluid
²failure to clean dipstick and fill tube when
checking level
²engine coolant entering the fluid
²internal failure that generates debris
²overheat that generates sludge (fluid break-
down)
²failure to reverse flush cooler and lines after
repair
²failure to replace contaminated converter after
repair
The use of non-recommended fluids can result in
transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and eventual failure
due to fluid breakdown and sludge formation. Avoid
this condition by using recommended fluids only.
The dipstick cap and fill tube should be wiped
clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall
into the tube if not removed beforehand. Take the
time to wipe the cap and tube clean before withdraw-
ing the dipstick.
Engine coolant in the transmission fluid is gener-
ally caused by a cooler malfunction. The only remedy
is to replace the radiator as the cooler in the radiator
is not a serviceable part. If coolant has circulated
through the transmission, an overhaul is necessary.
The transmission cooler and lines should be
reverse flushed whenever a malfunction generates
sludge and/or debris. The torque converter should
also be replaced at the same time.
Failure to flush the cooler and lines will result in
recontamination. Flushing applies to auxiliary coolers
as well. The torque converter should also be replaced
whenever a failure generates sludge and debris. This
is necessary because normal converter flushing proce-
dures will not remove all contaminants.
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transmssion has too much fluid, the
geartrain churns up foam and cause the same condi-
tions which occur with a low fluid level.
In either case, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can
interfere with normal valve, clutch, and accumulator
operation. Foaming can also result in fluid escaping
from the transmission vent where it may be mis-
taken for a leak.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
The transmission has a dipstick to check oil level.
It is located on the right side of the engine. Be sure
to wipe all dirt from dipstick handle before removing.
Fluid level is checked with the engine running at
curb idle speed, the transmission in NEUTRAL and
the transmission fluid at normal operating tempera-
ture.The engine should be running at idle
speed for at least one minute, with the vehicle
on level ground.
The transmission fluid level can be checked two
ways.
PROCEDURE ONE
(1) Transmission fluid must be at normal operat-
ing temperature for accurate fluid level check. Drive
vehicle if necessary to bring fluid temperature up to
normal hot operating temperature of 82ÉC (180ÉF).
(2) Position vehicle on level surface.
(3) Start and run engine at curb idle speed.
(4) Apply parking brakes.
(5) Shift transmission momentarily into all gear
ranges. Then shift transmission back to NEUTRAL.
(6) Clean top of filler tube and dipstick to keep
dirt from entering tube.
(7) Remove dipstick (Fig. 87) and check fluid level
as follows:
(a) Correct acceptable level is in crosshatch area.
(b) Correct maximum level is to MAX arrow
mark.
(c) Incorrect level is at or below MIN line.
(d) If fluid is low, add only enough MopartAT F
+4, type 9602, to restore correct level. Do not over-
fill.
21 - 70 AUTOMATIC TRANSMISSION - 42REWJ
FLUID AND FILTER (Continued)

PROCEDURE TWO
(1) Start engine and apply parking brake.
(2) Shift the transmission into DRIVE for approxi-
mately 2 seconds.
(3) Shift the transmission into REVERSE for
approximately 2 seconds.
(4) Shift the transmission into PARK.
(5) Hook up DRBtscan tool and select engine.
(6) Select sensors.
(7) Read the transmission temperature value.
(8) Compare the fluid temperature value with the
figure. (Fig. 88)
(9) Adjust transmission fluid level shown on the
dipstick according to the figure.NOTE: After adding any fluid to the transmission,
wait a minimum of 2 minutes for the oil to fully
drain from the fill tube into the transmission before
rechecking the fluid level.
(10) Check transmission for leaks.
STANDARD PROCEDURE - FLUID AND FILTER
REPLACEMENT
For proper service intervals (Refer to LUBRICA-
TION & MAINTENANCE/MAINTENANCE SCHED-
ULES - DESCRIPTION). The service fluid fill after a
filter change is approximately 3.8 liters (4.0 quarts).
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 (Fig. 89).
(4) Loosen bolts holding rear of pan to transmis-
sion.
(5) Slowly separate front of pan and gasket away
from transmission allowing the fluid to drain into
drain pan.
(6) Hold up pan and remove remaining bolt hold-
ing pan to transmission.
Fig. 88 42/44RE Fluid Fill Graph
Fig. 87 Dipstick Fluid Level Marks - Typical
1 - DIPSTICK
2 - MAXIMUM CORRECT FLUID LEVEL
3 - ACCEPTABLE FLUID LEVEL
WJAUTOMATIC TRANSMISSION - 42RE 21 - 71
FLUID AND FILTER (Continued)

TORQUE CONVERTER CLUTCH (TCC)
The torque converter clutch is hydraulically
applied and is released when fluid is vented from the
hydraulic circuit by the torque converter control
(TCC) solenoid on the valve body. The torque con-
verter clutch is controlled by the Powertrain Control
Module (PCM). The torque converter clutch engages
in fourth gear, and in third gear under various con-
ditions, such as when the O/D switch is OFF, when
the vehicle is cruising on a level surface after the
vehicle has warmed up. The torque converter clutch
will disengage momentarily when an increase in
engine load is sensed by the PCM, such as when the
vehicle begins to go uphill or the throttle pressure is
increased.
REMOVAL
(1) Remove transmission and torque converter
from vehicle.
(2) Place a suitable drain pan under the converter
housing end of the transmission.
CAUTION: Verify that transmission is secure on the
lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) Pull the torque converter forward until the cen-
ter hub clears the oil pump seal.
(4) Separate the torque converter from the trans-
mission.
INSTALLATION
Check converter hub and drive notches for sharp
edges, burrs, scratches, or nicks. Polish the hub and
notches with 320/400 grit paper or crocus cloth if nec-
essary. The hub must be smooth to avoid damaging
the pump seal at installation.
(1) Lubricate oil pump seal lip with transmission
fluid.
(2) Place torque converter in position on transmis-
sion.
CAUTION: Do not damage oil pump seal or bushing
while inserting torque converter into the front of the
transmission.
(3) Align torque converter to oil pump seal open-
ing.
(4) Insert torque converter hub into oil pump.
(5) While pushing torque converter inward, rotate
converter until converter is fully seated in the oil
pump gears.
(6) Check converter seating with a scale and
straightedge (Fig. 253). Surface of converter lugs
should be 1/2 in. to rear of straightedge when con-
verter is fully seated.
(7) If necessary, temporarily secure converter with
C-clamp attached to the converter housing.
(8) Install the transmission in the vehicle.
(9) Fill the transmission with the recommended
fluid.
Fig. 252 Stator Operation
1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
AGAINST STATOR VANES
Fig. 253 Checking Torque Converter Seating -
Typical
1 - SCALE
2 - STRAIGHTEDGE
WJAUTOMATIC TRANSMISSION - 42RE 21 - 133
TORQUE CONVERTER (Continued)

AUTOMATIC TRANSMISSION - 545RFE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 545RFE
DESCRIPTION........................178
OPERATION..........................179
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION.....................179
DIAGNOSIS AND TESTING - PRELIMINARY . 180
DIAGNOSIS AND TESTING - ROAD
TESTING...........................180
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST....................181
DIAGNOSIS AND TESTING - AIR CHECKING
TRANSMISSION CLUTCH OPERATION....182
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK................182
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR.....................183
REMOVAL............................183
DISASSEMBLY........................185
CLEANING...........................190
INSPECTION.........................190
ASSEMBLY...........................190
INSTALLATION........................197
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS.............199
SPECIFICATIONS
TRANSMISSION.....................220
SPECIAL TOOLS
RFE TRANSMISSION.................221
4C RETAINER/BULKHEAD
DISASSEMBLY........................224
ASSEMBLY...........................224
ADAPTER HOUSING SEAL
REMOVAL............................225
INSTALLATION........................225
BRAKE TRANSMISSION SHIFT INTERLOCK
MECHANISM
DESCRIPTION........................226
OPERATION..........................226
DIAGNOSIS AND TESTING - BRAKE
TRANSMISSION SHIFT INTERLOCK......226
ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK...................227
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL.............228
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID.......................228DIAGNOSIS AND TESTING - FLUID
CONTAMINATION....................228
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK............................229
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT...............230
STANDARD PROCEDURE - TRANSMISSION
FILL...............................230
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE.............................231
REMOVAL............................231
INSTALLATION........................231
ADJUSTMENTS - GEARSHIFT CABLE......232
HOLDING CLUTCHES
DESCRIPTION........................233
OPERATION..........................234
INPUT CLUTCH ASSEMBLY
DESCRIPTION........................235
OPERATION..........................235
DISASSEMBLY........................237
ASSEMBLY...........................238
INPUT SPEED SENSOR
DESCRIPTION........................244
OPERATION..........................244
REMOVAL............................244
INSTALLATION........................244
LINE PRESSURE (LP) SENSOR
DESCRIPTION........................245
OPERATION..........................245
REMOVAL............................245
INSTALLATION........................245
LOW/REVERSE CLUTCH
DISASSEMBLY........................246
CLEANING...........................247
INSPECTION.........................247
ASSEMBLY...........................247
OIL PUMP
DESCRIPTION........................248
OPERATION..........................248
STANDARD PROCEDURE - OIL PUMP
VOLUME CHECK.....................249
DISASSEMBLY........................250
CLEANING...........................252
INSPECTION.........................252
ASSEMBLY...........................253
OIL PUMP FRONT SEAL
REMOVAL............................253
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 177

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)

NOTE: The 545RFE utilizes closed loop control of
pump line pressure. The pressure readings may
therefore vary greatly but should always follow line
pressure.
Some common pressures that can be measured to
evaluate pump and clutch performance are the
upshift/downshift pressures and the garage shift
pressures. The upshift/downshift pressure for all
shifts except the 4-5 shift is 120 psi. The upshift
pressure for the 4-5 shift is 130 psi. The garage shift
pressure when performing a N-R shift is 220 psi. The
garage shift pressure for the R-N and N-1 shifts is
120 psi.
DIAGNOSIS AND TESTING - AIR CHECKING
TRANSMISSION CLUTCH OPERATION
Air-pressure testing can be used to check transmis-
sion clutch operation. The test can be conducted with
the transmission either in the vehicle or on the work
bench, as a final check.
Air-pressure testing requires that the oil pan and
valve body be removed from the transmission. The
clutch apply passages are shown (Fig. 6).
NOTE: The air supply which is used must be free of
moisture and dirt. Use a pressure of 30 psi to test
clutch operation.Apply air pressure at each port. If the clutch is
functioning, a soft thump will be heard as the clutch
is applied. The clutch application can also be felt by
touching the appropriate element while applying air
pressure. As the air pressure is released, the clutch
should also release.
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK
When diagnosing converter housing fluid leaks,
two items must be established before repair.
(1) Verify that a leak condition actually exists.
(2) Determined the true source of the leak.
Some suspected converter housing fluid leaks may
not be leaks at all. They may only be the result of
residual fluid in the converter housing, or excess
fluid spilled during factory fill or fill after repair.
Converter housing leaks have several potential
sources. Through careful observation, a leak source
can be identified before removing the transmission
for repair. Torque converter seal leaks tend to move
along the drive hub and onto the rear of the con-
verter. Pump cover seal tend to run down the cover
and the inside surface of the bellhousing.
Some leaks, or suspected leaks, may be particu-
larly difficult to locate. If necessary, a Mopart
approved dye may be used to locate a leak.
Fig. 5 Valve Body Pressure Tap Adapter 8258-A
1 - 545RFE TRANSMISSION
2 - TOOL 8258-A
Fig. 6 Air Pressure Test Passages
1 - LOW REVERSE CLUTCH
2 - 4TH CLUTCH
3 - 2ND CLUTCH
4 - OVERDRIVE CLUTCH
5 - UNDERDRIVE CLUTCH
6 - REVERSE CLUTCH
21 - 182 AUTOMATIC TRANSMISSION - 545RFEWJ
AUTOMATIC TRANSMISSION - 545RFE (Continued)

(5) Carefully insert converter in oil pump. Then
rotate converter back and forth until fully seated in
pump gears.
(6) Check converter seating with steel scale and
straightedge (Fig. 52). Surface of converter lugs
should be at least 13 mm (1/2 in.) to rear of straight-
edge when converter is fully seated.
(7) Temporarily secure converter with C-clamp.
(8) Position transmission on jack and secure it
with chains.
(9) Check condition of converter driveplate.
Replace the plate if cracked, distorted or damaged.
Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
hold transmission in alignment.
(10) Apply a light coating of MopartHigh Temp
Grease to the torque converter hub pocket in the rear
pocket of the engine's crankshaft.
(11) Raise transmission and align the torque con-
verter with the drive plate and the transmission con-
verter housing with the engine block.
(12) Move transmission forward. Then raise, lower,
or tilt transmission to align the converter housing
with the engine block dowels.
(13) Carefully work transmission forward and over
engine block dowels until converter hub is seated in
crankshaft. Verify that no wires, or the transmission
vent hose, have become trapped between the engine
block and the transmission.
(14) Install two bolts to attach the transmission to
the engine.(15) Install remaining torque converter housing to
engine bolts. Tighten to 68 N´m (50 ft.lbs.).
(16) Install rear transmission crossmember.
Tighten crossmember to frame bolts to 68 N´m (50
ft.lbs.).
(17) Install rear support to transmission. Tighten
bolts to 47 N´m (35 ft.lbs.).
(18) Lower transmission onto crossmember and
install bolts attaching transmission mount to cross-
member. Tighten clevis bracket to crossmember bolts
to 47 N´m (35 ft.lbs.). Tighten the clevis bracket to
rear support bolt to 68 N´m (50 ft.lbs.).
(19) Remove engine support fixture.
(20) Install new plastic retainer grommet on any
shift cable that was disconnected. Grommets should
not be reused. Use pry tool to remove rod from grom-
met and cut away old grommet. Use pliers to snap
new grommet into cable and to snap grommet onto
lever.
(21) Connect gearshift cable to transmission.
(22) Connect wires to solenoid and pressure switch
assembly connector, input and output speed sensors,
and line pressure sensor. Be sure transmission har-
nesses are properly routed.
CAUTION: It is essential that correct length bolts be
used to attach the converter to the driveplate. Bolts
that are too long will damage the clutch surface
inside the converter.
(23) Install all torque converter-to-driveplate bolts
by hand.
(24) Verify that the torque converter is pulled
flush to the driveplate. Tighten bolts to 31 N´m (270
in. lbs.).
(25) Install starter motor and cooler line bracket.
(26) Connect cooler lines to transmission.
(27) Install transmission fill tube.
(28) Install exhaust components.
(29) Install transfer case. Tighten transfer case
nuts to 35 N´m (26 ft.lbs.).
(30) Install the transfer case shift cable to the
cable support bracket and the transfer case shift
lever.
(31) Install the transmission collar onto the trans-
mission and the engine. Tighten the bolts to 54 N´m
(40 ft.lbs.).
(32) Align and connect propeller shaft(s).
(33) Adjust gearshift cable if necessary.
(34) Lower vehicle.
(35) Fill transmission with MopartATF +4, type
9602, Automatic Transmission fluid.
Fig. 52 Checking Torque Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
21 - 198 AUTOMATIC TRANSMISSION - 545RFEWJ
AUTOMATIC TRANSMISSION - 545RFE (Continued)