ECU JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual

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)

DISASSEMBLY
CAUTION: Do not clamp any valve body component
in a vise. This practice can damage the component
resulting in unsatisfactory operation after assembly
and installation. Do not use pliers to remove any of
the valves, plugs or springs and do not force any of
the components out or into place. The valves and
valve body housings will be damaged if force is
used. Tag or mark the valve body springs for refer-
ence as they are removed. Do not allow them to
become intermixed.
(1) Disconnect wires from governor pressure sen-
sor and solenoid.
(2) Remove screws attaching governor body and
retainer plate to transfer plate.
(3) Remove retainer plate, governor body and gas-
ket from transfer plate.
(4) Remove governor pressure sensor from gover-
nor body.
(5) Remove governor pressure solenoid by pulling
it straight out of bore in governor body. Remove and
discard solenoid O-rings if worn, cut, or torn.
(6) Remove small shoulder bolt that secures sole-
noid harness case connector to 3-4 accumulator hous-
ing (Fig. 281). Retain shoulder bolt. Either tape it toharness or thread it back into accumulator housing
after connector removal.
(7) Unhook overdrive/converter solenoid harness
from 3-4 accumulator cover plate (Fig. 282).
(8) Turn valve body over and remove screws that
attach overdrive/converter solenoid assembly to valve
body (Fig. 283).
(9) Remove solenoid and harness assembly from
valve body (Fig. 284).
(10) Remove boost valve cover (Fig. 285).
(11) Remove boost valve retainer, valve spring and
boost valve (Fig. 286).
Fig. 280 Valve Body
1 - VALVE BODY
2 - WIRE HARNESS
3 - PARK ROD
4 - GOVERNOR PRESSURE SOLENOID
5 - GOVERNOR PRESSURE SENSOR
Fig. 281 Solenoid Harness Case Connector
Shoulder Bolt
1 - SOLENOID HARNESS CASE CONNECTOR
2 - 3-4 ACCUMULATOR HOUSING
Fig. 282 Unhooking Solenoid Harness From
Accumulator Cover Plate
1 - OVERDRIVE/CONVERTER SOLENOID WIRE HARNESS
2 - 3-4 ACCUMULATOR COVER PLATE
WJAUTOMATIC TRANSMISSION - 42RE 21 - 155
VALVE BODY (Continued)

(12) Secure detent ball and spring with Retainer
Tool 6583 (Fig. 287).
(13) Remove park rod E-clip and separate rod from
manual lever (Fig. 288).
(14) Remove E-clip and washer that retains throt-
tle lever shaft in manual lever (Fig. 289).
(15) Remove manual lever and throttle lever (Fig.
290). Rotate and lift manual lever off valve body and
throttle lever shaft. Then slide throttle lever out of
valve body.
Fig. 283 Solenoid Assembly Screws
1 - OVERDRIVE/CONVERTER CLUTCH SOLENOID ASSEMBLY
2 - HARNESS
Fig. 284 Solenoid Assembly
1 - GOVERNOR SOLENOID WIRES
2 - CONVERTER CLUTCH SOLENOID
3 - SOLENOID SCREWS
4 - GOVERNOR SENSOR WIRES
5 - OVERDRIVE SOLENOID
6 - HARNESS
7 - CASE CONNECTOR
Fig. 285 Boost Valve
1 - BOOST VALVE HOUSING AND COVER
2 - BOOST VALVE TUBE
Fig. 286 Boost Valve Components
1 - SPRING AND VALVE RETAINER
2 - COVER SCREWS
3 - BOOST VALVE COVER
4 - BOOST VALVE PLUG
5 - BOOST VALVE
6 - BOOST VALVE SPRING
21 - 156 AUTOMATIC TRANSMISSION - 42REWJ
VALVE BODY (Continued)

VALVE BODY UPPER HOUSING
(1) Note location of check balls in valve body upper
housing (Fig. 305). Then remove the one large diam-
eter and the six smaller diameter check balls.
(2) Remove governor plug and shuttle valve covers
(Fig. 307).
(3) Remove E-clip that secures shuttle valve sec-
ondary spring on valve stem (Fig. 306).
(4) Remove throttle plug, primary spring, shuttle
valve, secondary spring, and spring guides (Fig. 307).
(5) Remove boost valve retainer, spring and valve
if not previously removed.
(6) Remove throttle plug and 1-2 and 2-3 governor
plugs (Fig. 294).
(7) Turn upper housing around and remove limit
valve and shift valve covers (Fig. 308).
(8) Remove limit valve housing. Then remove
retainer, spring, limit valve, and 2-3 throttle plug
from limit valve housing (Fig. 308).(9) Remove 1-2 shift control valve and spring (Fig.
308).
(10) Remove 1-2 shift valve and spring (Fig. 308).
(11) Remove 2-3 shift valve and spring from valve
body (Fig. 308).
(12) Remove pressure plug cover (Fig. 308).
(13) Remove line pressure plug, sleeve, throttle
pressure plug and spring (Fig. 308).
Fig. 305 Check Ball Locations In Upper Housing
1 - SMALL DIAMETER CHECK BALLS (6)
2 - LARGE DIAMETER CHECK BALL (1)
Fig. 306 Shuttle Valve E-Clip And Secondary Spring
Location
1 - E-CLIP
2 - SECONDARY SPRING AND GUIDES
3 - SHUTTLE VALVE
21 - 162 AUTOMATIC TRANSMISSION - 42REWJ
VALVE BODY (Continued)

BOOST VALVE TUBE AND BRACE
(1) Position valve body assembly so lower housing
is facing upward (Fig. 321).
(2) Lubricate tube ends and housing ports with
transmission fluid or petroleum jelly.
(3) Start tube in lower housing port first. Then
swing tube downward and work opposite end of tube
into upper housing port (Fig. 321).
(4) Insert and seat each end of tube in housings.
(5) Slide tube brace under tube and into alignment
with valve body screw holes (Fig. 322).
(6) Install and finger tighten three screws that
secure tube brace to valve body housings (Fig. 322).
(7) Bend tube brace tabs up and against tube to
hold it in position (Fig. 323).
(8) Tighten all valve body housing screws to 4 N´m
(35 in. lbs.) torque after tube and brace are installed.
Tighten screws in diagonal pattern starting at center
and working outward.
Fig. 321 Boost Valve Tube
1 - BOOST VALVE TUBE
2 - LOWER HOUSING
3 - DISENGAGE THIS END OF TUBE FIRST
4 - UPPER HOUSING
Fig. 322 Boost Valve Tube And Brace
1 - BOOST VALVE TUBE
2 - TUBE BRACE
Fig. 323 Securing Boost Valve Tube With Brace
Tabs
1 - BEND TABS UP AGAINST TUBE AS SHOWN
21 - 172 AUTOMATIC TRANSMISSION - 42REWJ
VALVE BODY (Continued)

(12) Disconnect gearshift cable from transmission
manual valve lever (Fig. 9).
(13) Disconnect transfer case shift cable from the
transfer case shift lever (Fig. 10).
(14) Remove the clip securing the transfer case
shift cable into the cable support bracket.
(15) Disconnect transmission fluid cooler lines at
transmission fittings and clips.
(16) Disconnect the transmission vent hose from
the transmission.
(17) Support rear of engine with safety stand or
jack.
(18) Raise transmission slightly with service jack
to relieve load on crossmember and supports.(19) Remove bolts securing rear support and cush-
ion to transmission and crossmember (Fig. 11).
(20) Remove bolts attaching crossmember to frame
and remove crossmember.
(21) Remove transfer case (Fig. 12) and (Fig. 13).
(22) Remove all remaining converter housing bolts.
(23) Carefully work transmission and torque con-
verter assembly rearward off engine block dowels.
(24) Hold torque converter in place during trans-
mission removal.
(25) Lower transmission and remove assembly
from under the vehicle.
Fig. 9 Transmission Shift Cable
1 - SHIFT CABLE
2 - MANUAL LEVER
3 - MANUAL LEVER
Fig. 10 Transfer Case Shift Cable
1 - TRANSFER CASE SHIFT LEVER
2 - TRANSFER CASE SHIFT CABLE
Fig. 11 Rear Transmission Crossmember
1 - CROSSMEMBER
2 - REAR TRANSMISSION MOUNT
Fig. 12 Remove NV247 Transfer Case
1 - NV247 TRANSFER CASE
21 - 184 AUTOMATIC TRANSMISSION - 545RFEWJ
AUTOMATIC TRANSMISSION - 545RFE (Continued)

NOTE: When measuring the input shaft end-play,
two(stops(will be felt. When the input shaft is
pushed inward and the dial indicator zeroed, the
first(stop(felt when the input shaft is pulled out-
ward is the movement of the input shaft in the input
clutch housing hub. This value should not be
included in the end-play measured value and there-
fore must be recorded and subtracted from the dial
indicator reading.
(9) Remove the bolts holding the transmission
extension/adapter housing to the transmission case.
(10) Remove the extension/adapter housing from
the transmission case.
(11) Using Alignment Plate 8261, Adapter 8266-17
from End-Play Tool Set 8266 and Dial Indicator
C-3339, measure and record the output shaft end-
play (Fig. 17).
(12) Remove the bolts holding the transmission oil
pan to the transmission case.
(13) Remove the transmission oil pan from the
transmission case.
(14) Remove the primary oil filter and the oil
cooler return filter (Fig. 18).
(15) Remove the cooler return filter bypass valve.(16) Remove the bolts holding the valve body to
the transmission case (Fig. 19).
(17) Remove the valve body from the transmission
case.
(18) Remove the outer snap-ring securing the
transmission front cover into the transmission case
(Fig. 20).
Fig. 17 Measure Output Shaft End Play
1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339
Fig. 18 Remove Primary Oil and Cooler Filters
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
Fig. 19 Remove Valve Body Assembly
1 - VALVE BODY TO CASE BOLT (6)
21 - 186 AUTOMATIC TRANSMISSION - 545RFEWJ
AUTOMATIC TRANSMISSION - 545RFE (Continued)

(19) Remove the inner snap-ring securing the
transmission front cover to the oil pump (Fig. 20).
(20) Reaching through a case opening in the valve
body area with a long blunted tool, remove the trans-
mission front cover from the transmission case.
(21) Remove the bolts holding the oil pump into
the transmission case (Fig. 21).
(22) Remove the oil pump. Hold inward on the
input shaft to prevent pulling the input clutch
assembly with the oil pump (Fig. 21).(23) Remove the number 1 bearing from the input
clutch assembly (Fig. 22).
(24) Remove the input clutch assembly from the
transmission case (Fig. 22).
(25) Remove the number 5 bearing and selective
thrust plate from the input clutch assembly (Fig. 22),
or the 4C clutch retainer/bulkhead.
(26)
Remove the 4C clutch retainer/bulkhead tapered
snap-ring from the transmission case (Fig. 23).
(27) Remove the 4C clutch retainer/bulkhead from
the transmission case (Fig. 23).
Fig. 20 Remove Transmission Front Cover
1 - INNER SNAP-RING
2 - TRANSMISSION COVER
3 - OUTER SNAP-RING
Fig. 21 Remove Oil Pump
1 - OIL PUMP TO CASE BOLT (6)
2 - OIL PUMP
Fig. 22 Remove Input Clutch Assembly
1 - BEARING NUMBER 5
2 - THRUST PLATE (SELECT)
3 - INPUT CLUTCH ASSEMBLY
4 - BEARING NUMBER 1
Fig. 23 Remove 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 187
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)

(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)