axle seal front JEEP GRAND CHEROKEE 2003 WJ / 2.G Owner's Manual

(1) Apply Mopar Door Ease or equivalent lubricant
to outside surface of pinion bearing cups.
(2) Install pinion rear bearing cup with Installer
C-4308 and Driver Handle C-4171 (Fig. 80) and ver-
ify cup is seated.
(3) Install pinion front bearing cup with Installer
D-129 and Handle C-4171 (Fig. 81) and verify cup is
seated.(4) Install pinion front bearing and oil slinger, if
equipped.
(5) Apply a light coating of gear lubricant on the
lip of pinion seal. Install seal with an appropriate
(Fig. 82).
(6) Install depth shim on the pinion gear.
(7) Install rear bearing on the pinion gear with
Installer 6448 and a press (Fig. 83).
Fig. 80 Rear Pinion Bearing Cup
1 - INSTALLER
2 - HANDLE
Fig. 81 FRONT PINION BEARING CUP
1 - INSTALLER
2 - HANDLE
Fig. 82 PINION SEAL INSTALLER
1 - HANDLE
2 - INSTALLER
Fig. 83 REAR PINION BEARING
1 - PRESS
2 - INSTALLER
3 - PINION GEAR
4 - PINION BEARING
WJREAR AXLE - 226RBA 3 - 127
PINION GEAR/RING GEAR (Continued)

BRAKE PADS / SHOES
DESCRIPTION
DESCRIPTION - FRONT DISC BRAKE SHOES
The calipers are twin piston type. The calipers are
free to slide laterally on the anchor, this allows con-
tinuous compensation for lining wear.
DESCRIPTION - REAR DISC BRAKE SHOES
The rear disc brakes consist of single piston float-
ing-type calipers and solid rotors. The rear caliper is
mounted on an anchor attached to an adapter
attached the rear axle tube flange. The anchors are
secured to the adapters with mounting bolts. The
disc brake rotor splash shield is part of the adaptor.
The disc brake rotor has a built in brake drum used
for the parking brakes (Fig. 6). The parking brake
shoes are mounted to the adaptor.
OPERATION
OPERATION - FRONT DISC BRAKE SHOES
When the brakes are applied fluid pressure is
exerted against the caliper pistons. The fluid pres-
sure is exerted equally and in all directions. This
means pressure exerted against the caliper pistons
and within the caliper bores will be equal (Fig. 7).
Fluid pressure applied to the pistons is transmit-
ted directly to the inboard brake shoe. This forces the
shoe lining against the inner surface of the disc
brake rotor. At the same time, fluid pressure within
the piston bores forces the caliper to slide inward on
the slide pins. This action brings the outboard brake
shoe lining into contact with the outer surface of the
disc brake rotor.
Fluid pressure acting simultaneously on the pis-
tons and caliper to produces a strong clamping
action. When sufficient force is applied, friction will
stop the rotors from turning and bring the vehicle to
a stop.Application and release of the brake pedal gener-
ates only a very slight movement of the caliper and
pistons. Upon release of the pedal, the caliper and
pistons return to a rest position. The brake shoes do
not retract an appreciable distance from the rotor. In
fact, clearance is usually at, or close to zero. The rea-
sons for this are to keep road debris from getting
between the rotor and lining and in wiping the rotor
surface clear each revolution.
The caliper piston seals control the amount of pis-
ton extension needed to compensate for normal lining
wear.
During brake application, the seals are deflected
outward by fluid pressure and piston movement (Fig.
8). When the brakes (and fluid pressure) are
released, the seals relax and retract the pistons.
The front outboard brake shoes have wear indica-
tors.
OPERATION - REAR DISC BRAKE SHOES
When the brakes are applied fluid pressure is
exerted against the caliper pistons. The fluid pres-
sure is exerted equally and in all directions. This
means pressure exerted against the caliper pistons
and within the caliper bores will be equal (Fig. 7).
Fluid pressure applied to the pistons is transmit-
ted directly to the inboard brake shoe. This forces the
Fig. 6 Rear Disc Brake Rotor
1 - PARKING BRAKE DRUM SURFACE
2 - REAR DISC BRAKE ROTOR
Fig. 7 Brake Caliper Operation
1 - CALIPER
2 - PISTON
3 - PISTON BORE
4 - SEAL
5 - INBOARD SHOE
6 - OUTBOARD SHOE
5 - 10 BRAKES - BASEWJ

ELECTRIC BRAKE
DESCRIPTION
The electronic brake distribution (EBD) functions
like a rear proportioning valve. The EBD system uses
the ABS system to control the slip of the rear wheels
in partial braking range. The braking force of the
rear wheels is controlled electronically by using the
inlet and outlet valves located in the HCU.
OPERATION
Upon entry into EBD the inlet valve for the rear
brake circuit is switched on so that the fluid supply
from the master cylinder is shut off. In order to
decrease the rear brake pressure the outlet valve for
the rear brake circuit is pulsed. This allows fluid to
enter the low pressure accumulator (LPA) in the
HCU resulting in a drop in fluid pressure to the rear
brakes. In order to increase the rear brake pressure
the outlet valve is switched off and the inlet valve is
pulsed. This increases the pressure to the rear
brakes. This will continue until the required slip dif-
ference is obtained. At the end of EBD braking (no
brake application) the fluid in the LPA drains back to
the master cylinder by switching on the outlet valve
and draining through the inlet valve check valve. At
the same time the inlet valve is switched on to pre-
vent a hydraulic short circiut in case of another
brake application.
The EBD will remain functional during many ABS
fault modes. If the red and amber warning lamps are
illuminated the EBD may have a fault.
FRONT WHEEL SPEED
SENSOR
DESCRIPTION
A wheel speed sensor is used at each wheel. The
front sensors are mounted to the steering knuckles.
The rear sensors are mounted at the outboard end of
the axle. Tone wheels are mounted to the outboard
ends of the front and rear axle shafts. The gear type
tone wheel serves as the trigger mechanism for each
sensor.
OPERATION
The sensors convert wheel speed into a small digi-
tal signal. The CAB sends 12 volts to the sensors.
The sensor has an internal magneto resistance
bridge that alters the voltage and amperage of the
signal circuit. This voltage and amperage is changed
by magnetic induction when the toothed tone wheel
passes the wheel speed sensor. This digital signal issent to the CAB. The CAB measures the voltage and
amperage of the digital signal for each wheel.
REMOVAL
(1) Raise and support the vehicle.
(2) Remove the front wheel sensor mounting bolt
(Fig. 1).
(3) Remove the sensor from the steering knuckle.
(4) Disengage the sensor wire from the brackets
(Fig. 1)on the steering knuckle.
(5) Disconnect the sensor from the sensor harness
(Fig. 2)and (Fig. 3).
(6) Remove the sensor and wire.
INSTALLATION
(1) Install the sensor on the steering knuckle.
(2) Apply Mopar Lock N' Seal or Loctitet242 to
the sensor mounting bolt. Use new sensor bolt if orig-
inal bolt is worn or damaged.
(3) Install the sensor mounting bolt and tighten
bolt to 12-14 N´m (106-124 in. lbs.).
(4) Engage the grommets on the sensor wire to the
steering knuckle brackets.
(5) Connect the sensor wire to the harness connec-
tor.
(6) Check the sensor wire routing. Be sure the
wire is clear of all chassis components and is not
twisted or kinked at any spot.
(7) Remove the support and lower vehicle.
Fig. 1 Sensor Location
1 - BRACKET
2 - BRACKET
3 - WHEEL SPEED SENSOR
4 - MOUNTING BOLT
WJBRAKES - ABS 5 - 43

(3) Install intake manifold on the cylinder head
dowels.
(4) Install washer and fastener Numbers 1, 2, 4, 5,
8, 9, 10 and 11 (Fig. 84).
(5) Install washer and fastener Numbers 6 and 7
(Fig. 84).
(6) Tighten the fasteners in sequence and to the
specified torque (Fig. 84).
²Fastener Numbers 1 through 5ÐTighten to 33
N´m (24 ft. lbs.) torque.
²Fastener Numbers 6 and 7ÐTighten to 31 N´m
(23 ft. lbs.) torque.
²Fastener Numbers 8 through 11ÐTighten to 33
N´m (24 ft. lbs.) torque.
(7) Install the power steering pump to the intake
manifold.
(8) Install the accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(9) Install the fuel system supply line to the fuel
rail assembly.
(10) Connect all electrical connections on the
intake manifold.
(11) Connect the vacuum hoses previously
removed.
(12) Install throttle cable, vehicle speed control
cable (if equipped).
(13) Install the transmission line pressure cable (if
equipped) (Refer to 21 - TRANSMISSION/TRANS-
AXLE/AUTOMATIC - AW4/THROTTLE VALVE
CABLE - INSTALLATION).
(14) Install air cleaner assembly.
(15) Connect air inlet hose to the resonator assem-
bly.
(16) Raise the vehicle.
(17) Connect the exhaust pipes to the engine
exhaust manifolds. Tighten the bolts to 31 N´m (23
ft. lbs.)
(18) Lower the vehicle.(19) Connect the battery negative cable.
(20) Start the engine and check for leaks.
EXHAUST MANIFOLD
DESCRIPTION
The two exhaust manifolds (Fig. 85) are log style
and are made of high silicon molybdenum cast iron.
The exhaust manifolds share a common gasket with
the intake manifold. The exhaust manifolds also
incorporate ball flange outlets for improved sealing
and strain free connections.
REMOVAL
The intake and engine exhaust manifolds on the
4.0L engine must be removed together. The manifolds
use a common gasket at the cylinder head.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE
MANIFOLD - REMOVAL).
INSTALLATION
(1) The exhaust manifold and the intake manifold
must be installed together using a common gasket.
(2) (Refer to 9 - ENGINE/MANIFOLDS/INTAKE
MANIFOLD - INSTALLATION).
TIMING BELT / CHAIN
COVER(S)
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove the vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(3) Remove the fan, hub assembly and fan shroud
(Refer to 7 - COOLING/ENGINE/RADIATOR FAN -
REMOVAL).
(4) Remove the accessory drive brackets that are
attached to the timing case cover.
(5) Remove the A/C compressor (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING/A/C
COMPRESSOR - REMOVAL) (if equipped) and gen-
erator bracket assembly from the engine cylinder
head and move to one side.
(6) Remove the oil pan-to-timing case cover bolts
and timing case cover-to-cylinder block bolts.
(7) Remove the timing case cover and gasket from
the engine.
(8) Pry the crankshaft oil seal from the front of the
timing case cover (Fig. 86).
INSTALLATION
Clean the timing case cover, oil pan and cylinder
block gasket surfaces.
Fig. 84 Intake and Exhaust Manifolds Installation
9 - 58 ENGINE - 4.0LWJ
INTAKE MANIFOLD (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
NO DRIVE RANGE
(REVERSE OK)1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable
Loose/Misadjusted.2. Repair or replace linkage components.
3. Rear Clutch Burnt. 3. Remove and disassemble transmission and
rear clutch and seals. Repair/replace worn or
damaged parts as needed.
4. Valve Body Malfunction. 4. Remove and disassemble valve body. Replace
assembly if any valves or bores are damaged.
5. Transmission Overrunning
Clutch Broken.5. Remove and disassemble transmission.
Replace overrunning clutch.
6. Input Shaft Seal Rings
Worn/Damaged.6. Remove and disassemble transmission.
Replace seal rings and any other worn or
damaged parts.
7. Front Planetary Failed Broken. 7. Remove and repair.
NO DRIVE OR
REVERSE (VEHICLE
WILL NOT MOVE)1. Fluid Level Low. 1. Add fluid and check for leaks if drive is
restored.
2. Gearshift Linkage/Cable
Loose/Misadjusted.2. Inspect, adjust and reassemble linkage as
needed. Replace worn/damaged parts.
3. U-Joint/Axle/Transfer Case
Broken.3. Perform preliminary inspection procedure for
vehicle that will not move. Refer to procedure in
diagnosis section.
4. Filter Plugged. 4. Remove and disassemble transmission. Repair
or replace failed components as needed. Replace
filter. If filter and fluid contained clutch material or
metal particles, an overhaul may be necessary.
Perform lube flow test. Flush oil. Replace cooler
as necessary.
5. Oil Pump Damaged. 5. Perform pressure test to confirm low pressure.
Replace pump body assembly if necessary.
6. Valve Body Malfunctioned. 6. Check and inspect valve body. Replace valve
body (as assembly) if any valve or bore is
damaged. Clean and reassemble correctly if all
parts are in good condition.
7. Transmission Internal
Component Damaged.7. Remove and disassemble transmission. Repair
or replace failed components as needed.
8. Park Sprag not Releasing -
Check Stall Speed, Worn/
Damaged/Stuck.8. Remove, disassemble, repair.
9. Torque Converter Damage. 9. Inspect and replace as required.
21 - 18 AUTOMATIC TRANSMISSION - 42REWJ
AUTOMATIC TRANSMISSION - 42RE (Continued)

(12) Install new oil seal in pump with Special Tool
C-4193 and Tool Handle C-4171 (Fig. 122). Be sure
seal lip faces inward.
(13) Install new seal ring around pump housing.
Be sure seal is properly seated in groove.
(14) Lubricate lip of pump oil seal and O-ring seal
with transmission fluid.
OUTPUT SHAFT FRONT
BEARING
REMOVAL
(1) Remove overdrive unit from the vehicle.
(2) Remove overdrive geartrain from housing.
(3) Remove snap-ring holding output shaft front
bearing to overdrive geartrain. (Fig. 123).
(4) Pull bearing from output shaft.
INSTALLATION
(1) Place replacement bearing in position on
geartrain with locating retainer groove toward the
rear.
(2) Push bearing onto shaft until the snap-ring
groove is visible.
(3) Install snap-ring to hold bearing onto output
shaft.
(4) Install overdrive geartrain into housing.
(5) Install overdrive unit in vehicle.
OUTPUT SHAFT REAR
BEARING
REMOVAL
(1) Remove overdrive unit from the vehicle. (Refer
to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC/
OVERDRIVE - REMOVAL)
(2) Remove overdrive geartrain from housing.
(3) Remove snap-ring holding output shaft rear
bearing into overdrive housing (Fig. 124).
(4) Using a suitable driver inserted through the
rear end of housing, drive bearing from housing.
INSTALLATION
(1) Place replacement bearing in position in hous-
ing.
(2) Using a suitable driver, drive bearing into
housing until the snap-ring groove is visible.
(3) Install snap-ring to hold bearing into housing
(Fig. 124).
(4) Install overdrive geartrain into housing.
(5) Install overdrive unit in vehicle.
Fig. 122 Pump Oil Seal Installation
1 - PUMP BODY
2 - PUMP SEAL
3 - SPECIAL TOOL C-4193
Fig. 123 Output Shaft Front Bearing
1 - OUTPUT SHAFT FRONT BEARING
2 - SNAP-RING
3 - OUTPUT SHAFT
4 - GROOVE TO REAR
5 - OVERDRIVE GEARTRAIN
Fig. 124 Output Shaft Rear Bearing
1 - OUTPUT SHAFT REAR BEARING
2 - OVERDRIVE HOUSING
3 - SNAP-RING
WJAUTOMATIC TRANSMISSION - 42RE 21 - 85
OIL PUMP (Continued)

TORQUE CONVERTER LEAK POINTS
Possible sources of converter leaks are:
(1) Leaks at the weld joint around the outside
diameter weld (Fig. 7).
(2) Leaks at the converter hub weld (Fig. 7).
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-CoilsŸ, or equivalent. This repair con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-CoilŸ tap, or
equivalent, and installing a Heli-CoilŸ insert, or
equivalent, into the hole. This brings the hole back to
its original thread size.
Heli-CoilŸ, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
REMOVAL
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo-
nent damage. The converter driveplate, converter
hub o-ring, or oil seal can be damaged if the con-
verter is left attached to the driveplate during
removal. Be sure to remove the transmission and
converter as an assembly.
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle
(3) Mark propeller shaft and axle yokes for assem-
bly alignment.
(4) Remove the rear propeller shaft
(5) Remove the front propeller shaft.
(6) Remove the engine to transmission collar (Fig.
8).
(7) Remove the exhaust support bracket from the
rear of the transmission.
(8) Disconnect and lower or remove any necessary
exhaust components.
(9) Remove the starter motor.
(10) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.
(11) Disconnect wires from solenoid and pressure
switch assembly, input and output speed sensors, and
line pressure sensor.
Fig. 7 Torque Converter Assembly
1 - TURBINE ASSEMBLY
2-STATOR
3 - CONVERTER HUB
4 - O-RING
5 - IMPELLER ASSEMBLY
6 - CONVERTER CLUTCH PISTON
7 - TURBINE HUB
Fig. 8 Transmission Collar
1 - ENGINE
2 - ENGINE TO TRANSMISSION COLLAR
3 - TRANSMISSION
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 183
AUTOMATIC TRANSMISSION - 545RFE (Continued)

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)

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