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

(19) Attach solenoid case connector to 3-4 accumu-
lator with shoulder-type screw. Connector has small
locating tang that fits in dimple at top of accumula-
tor housing (Fig. 328). Seat tang in dimple before
tightening connector screw.
(20) Install solenoid assembly and gasket. Tighten
solenoid attaching screws to 8 N´m (72 in. lbs.)
torque.
(21) Verify that solenoid wire harness is properly
routed (Fig. 329). Solenoid harness must be clear of
manual lever and park rod and not be pinched
between accumulator housing and cover.
Fig. 326 Detent Ball Spring
1 - SPECIAL TOOL 6583 POSITIONED ON DETENT HOUSING
Fig. 327 Manual And Throttle Lever Alignment
1 - THROTTLE LEVER
2 - MANUAL LEVER VALVE ARM
3 - MANUAL VALVE
4 - KICKDOWN VALVE
Fig. 328 Solenoid Harness Case Connector
Shoulder Bolt
1 - SOLENOID HARNESS CASE CONNECTOR
2 - 3-4 ACCUMULATOR HOUSING
Fig. 329 Solenoid Harness Routing
1 - OVERDRIVE/CONVERTER SOLENOID WIRE HARNESS
2 - 3-4 ACCUMULATOR COVER PLATE
21 - 174 AUTOMATIC TRANSMISSION - 42REWJ
VALVE BODY (Continued)

GOVERNOR BODY, SENSOR AND SOLENOID
(1) Turn valve body assembly over so accumulator
side of transfer plate is facing down.
(2) Install new O-rings on governor pressure sole-
noid and sensor.
(3) Lubricate solenoid and sensor O-rings with
clean transmission fluid.
(4) Install governor pressure sensor in governor
body.
(5) Install governor pressure solenoid in governor
body. Push solenoid in until it snaps into place in
body.
(6) Position governor body gasket on transfer
plate.
(7) Install retainer plate on governor body and
around solenoid. Be sure solenoid connector is posi-
tioned in retainer cutout.
(8) Align screw holes in governor body and trans-
fer plate. Then install and tighten governor body
screws to 4 N´m (35 in. lbs.) torque.
(9) Connect harness wires to governor pressure
solenoid and governor pressure sensor.
(10) Install fluid filter and pan.
(11) Lower vehicle.
(12) Fill transmission with recommended fluid and
road test vehicle to verify repair.
INSTALLATION
(1) Check condition of O-ring seals on valve body
harness connector (Fig. 330). Replace seals on con-
nector body if cut or worn.
(2) Check condition of manual lever shaft seal in
transmission case. Replace seal if lip is cut or worn.
Install new seal with 15/16 deep well socket (Fig.
331).
(3) Check condition of seals on accumulator piston
(Fig. 332). Install new piston seals, if necessary.
(4) Place valve body manual lever in low (1 posi-
tion) so ball on park lock rod will be easier to install
in sprag.
(5) Lubricate shaft of manual lever with petroleum
jelly. This will ease inserting shaft through seal in
case.
(6) Lubricate seal rings on valve body harness con-
nector with petroleum jelly.
(7) Position valve body in case and work end of
park lock rod into and through pawl sprag. Turn pro-
peller shaft to align sprag and park lock teeth if nec-
essary. The rod will click as it enters pawl. Move rod
to check engagement.
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 this cavity.(8) Install accumulator springs and piston into
case. Then swing valve body over piston and outer
spring to hold it in place.
(9) Align accumulator piston and outer spring,
manual lever shaft and electrical connector in case.
(10) Then seat valve body in case and install one
or two bolts to hold valve body in place.
(11) Tighten valve body bolts alternately and
evenly to 11 N´m (100 in. lbs.) torque.
(12) Install new fluid filter on valve body. Tighten
filter screws to 4 N´m (35 in. lbs.) torque.
(13) Install throttle and gearshift levers on valve
body manual lever shaft.
(14) Check and adjust front and rear bands if nec-
essary.
(15) Connect solenoid case connector wires.
(16) Install oil pan and new gasket. Tighten pan
bolts to 13.6 N´m (125 in. lbs.) torque.
(17) Lower vehicle and fill transmission with
MopartATF +4, type 9602, fluid.
(18) Check and adjust gearshift and throttle valve
cables, if necessary.
ADJUSTMENTS - VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the
valve body;
²Line Pressure
²Throttle Pressure
Line and throttle pressures are interdependent
because each affects shift quality and timing. As a
result, both adjustments must be performed properly
and in the correct sequence. Adjust line pressure first
and throttle pressure last.
Fig. 330 Valve Body Harness Connector O-Ring Seal
1 - CONNECTOR O-RINGS
2 - VALVE BODY HARNESS CONNECTOR
3 - HARNESS
WJAUTOMATIC TRANSMISSION - 42RE 21 - 175
VALVE BODY (Continued)

TRANSMISSION IDENTIFICATION
Transmission identification numbers are stamped
on the left side of the case just above the oil pan
sealing surface (Fig. 1). Refer to this information
when ordering replacement parts. A label is attached
to the transmission case above the stamped numbers.
The label gives additional information which may
also be necessary for identification purposes.
GEAR RATIOS The 545RFE gear ratios are:
1st .................................3.00:1
2nd.................................1.67:1
2nd Prime............................1.50:1
3rd .................................1.00:1
4th .................................0.75:1
5th .................................0.67:1
Reverse..............................3.00:1
OPERATION
The 545RFE offers full electronic control of all auto-
matic up and downshifts, and features real-time adap-
tive closed-loop shift and pressure control. Electronic
shift and torque converter clutch controls help protect
the transmission from damage due to high tempera-
tures, which can occur under severe operating condi-
tions. By altering shift schedules, line pressure, and
converter clutch control, these controls reduce heat gen-
eration and increase transmission cooling.
To help reduce efficiency-robbing parasitic losses,
the transmission includes a dual-stage transmission
fluid pump with electronic output pressure control.
Under most driving conditions, pump output pres-
sure greatly exceeds that which is needed to keep the
clutches applied. The 545RFE pump-pressure controlsystem monitors input torque and adjusts the pump
pressure accordingly. The primary stage of the pump
works continuously; the second stage is bypassed
when demand is low. The control system also moni-
tors input and output speed and, if incipient clutch
slip is observed, the pressure control solenoid duty
cycle is varied, increasing pressure in proportion to
demand.
A high-travel torque converter damper assembly
allows earlier torque converter clutch engagement to
reduce slippage. Needle-type thrust bearings reduce
internal friction. The 545RFE is packaged in a one-
piece die-cast aluminum case. To reduce NVH, the
case has high lateral, vertical and torsional stiffness.
It is also designed to maximize the benefit of the
structural dust cover that connects the bottom of the
bell housing to the engine bedplate, enhancing over-
all power train stiffness. Dual filters protect the
pump and other components. A pump return filter is
added to the customary main sump filter. Indepen-
dent lubrication and cooler circuits assure ample
pressure for normal transmission operation even if
the cooler is obstructed or the fluid cannot flow due
to extremely low temperatures.
The hydraulic control system design (without elec-
tronic assist) provides the transmission with PARK,
REVERSE, NEUTRAL, SECOND, and THIRD gears,
based solely on driver shift lever selection. This
design allows the vehicle to be driven (in ªlimp-inº
mode) in the event of a electronic control system fail-
ure, or a situation that the Transmission Control
Module (TCM) recognizes as potentially damaging to
the transmission.
The TCM also performs certain self-diagnostic
functions and provides comprehensive information
(sensor data, DTC's, etc.) which is helpful in proper
diagnosis and repair. This information can be viewed
with the DRB scan tool.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION
CAUTION: Before attempting any repair on a
545RFE automatic transmission, check for Diagnos-
tic Trouble Codes with the DRBTscan tool.
Transmission malfunctions may be caused by these
general conditions:
²Poor engine performance
²Improper adjustments
²Hydraulic malfunctions
²Mechanical malfunctions
²Electronic malfunctions
Fig. 1 Transmission Part And Serial Number
Location
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 179
AUTOMATIC TRANSMISSION - 545RFE (Continued)

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)

DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST
An accurate tachometer and pressure test gauges
are required. Test Gauge C-3293-SP has a 300 psi
range and is used at all locations where pressures
exceed 100 psi.
Pressure Test Port Locations
Only two pressure ports are supplied on the trans-
mission case. The torque converter clutch apply and
release ports are located on the right side of the
transmission case (Fig. 2).
To determine the line pressure, there are two avail-
able methods. The DRBtscan tool can be used to
read line pressure from the line pressure sensor. The
second method is to install Line Pressure Adapter
8259 (Fig. 4) into the transmission case and then
install the pressure gauge and the original sensor
into the adapter. This will allow a comparison of the
DRBtreadings and the gauge reading to determe the
accuracy of the line pressure sensor. The DRBtline
pressure reading should match the gauge reading
within  10 psi.
In order to access any other pressure tap locations,
the transmission oil pan must be removed, the pres-
sure port plugs removed and Valve Body Pressure
Tap Adapter 8258-A (Fig. 5) installed. The extensions
supplied with Adapter 8258-A will allow the installa-
tion of pressure gauges to the valve body. Refer to
(Fig. 3) for correct pressure tap location identifica-
tion.
TEST PROCEDURE
All pressure readings should be taken with the
transmission fluid level full, transmission oil at the
normal operating temperature, and the engine at
1500 rpm. Check the transmission for proper opera-
tion in each gear position that is in question or if a
specific element is in question, check the pressure
readings in at least two gear positions that employ
that element. Refer to the Hydraulic Schematics at
the rear of this section to determine the correct pres-
sures for each element in a given gear position.
Fig. 2 Torque Converter Pressure Locations
1 - TCC RELEASE
2 - TO COOLER
3 - TCC APPLY
4 - FROM COOLER
5 - LINE PRESSURE SENSOR
Fig. 3 Pressure Tap Locations
Fig. 4 Line Pressure Adapter 8259
1 - LINE PRESSURE SENSOR PORT
2 - LINE PRESSURE SENSOR
3 - TOOL 8259
4 - PRESSURE TAP
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 181
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)

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)

(45) Using Adapter 8266-1 from End-Play Tool Set
8266 and Dial Indicator C-3339, measure and record
the input shaft end-play (Fig. 46). The correct end-
play is 0.46-0.89 mm (0.018-0.035 in.). Adjust as nec-
essary. Install the chosen thrust plate on the number
5 bearing and re-measure end-play to verify selec-
tion.
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.
(46) Install the transmission front cover into the
transmission case (Fig. 47).
(47) Install the outer snap-ring to hold the trans-
mission front cover into the transmission case (Fig.
47).
(48) Partially install the inner transmission front
cover snap-ring onto the oil pump (Fig. 47).(49) Using Installer 8255, install the inner trans-
mission front cover snap-ring the remainder of the
way onto the oil pump (Fig. 48).
(50) Install the valve body (Fig. 49). Verify that
the pin on the manual lever has properly engaged
the TRS selector plate. Tighten the valve body to
transmission case bolts to 12 N´m (105 in.lbs.).
Fig. 46 Measure Input Shaft End Play
1 - TOOL 8266
2 - TOOL C-3339
Fig. 47 Install the Transmission Front Cover
1 - INNER SNAP-RING
2 - TRANSMISSION COVER
3 - OUTER SNAP-RING
Fig. 48 Seat Snap-Ring Using Tool 8255
1 - TOOL 8255
2 - SNAP-RING
21 - 196 AUTOMATIC TRANSMISSION - 545RFEWJ
AUTOMATIC TRANSMISSION - 545RFE (Continued)

(51) 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.
(52) Install the primary oil filter and the oil cooler
return filter (Fig. 50). Tighten the screw to hold the
primary oil filter to the valve body to 4.5 N´m (40
in.lbs.). Using Oil Filter Wrench 8321, tighten the
cooler return oil filter to the transmission case to 14
N´m (125 in.lbs.).
(53) Apply RTV silicone to the oil pan and install
the transmission oil pan. Tighten the bolts to 12 N´m
(105 in.lbs.).
(54) Install the input, output, and line pressure
sensors (Fig. 51). Tighten the bolts to 12 N´m (105
in.lbs.).
(55) Install the manual shift lever from the trans-
mission. Torque the retaining cross-bolt to 16 N´m
(140 in.lbs.).
INSTALLATION
(1) Check torque converter hub and hub drive flats
for sharp edges burrs, scratches, or nicks. Polish the
hub and flats with 320/400 grit paper and crocus
cloth if necessary. Verify that the converter hub
o-ring is properly installed and is free of any debris.
The hub must be smooth to avoid damaging pump
seal at installation.(2) If a replacement transmission is being
installed, transfer any components necessary, such as
the manual shift lever and shift cable bracket, from
the original transmission onto the replacement trans-
mission.
(3) Lubricate oil pump seal lip with transmission
fluid.
(4) Align converter and oil pump.
Fig. 49 Install Valve Body Assembly
1 - VALVE BODY TO CASE BOLT (6)
Fig. 50 Install Primary Oil and Cooler Filters
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
Fig. 51 Install Input, Output, and Line Pressure
Sensors
1 - OUTPUT SPEED SENSOR
2 - LINE PRESSURE SENSOR
3 - INPUT SPEED SENSOR
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 197
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)