Flush JEEP GRAND CHEROKEE 2003 WJ / 2.G Repair Manual

SPECIAL TOOLS
RFE TRANSMISSION
Gauge, Oil Pressure - C-3292
Gauge, Oil Pressure - C-3293SP
Dial Indicator - C-3339
Installer, Seal - C-3860-A
Flusher, Oil Cooler - 6906-C
Compressor, Spring - 8249
Compressor, Spring - 8250
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 221
AUTOMATIC TRANSMISSION - 545RFE (Continued)

(6) Using Spring Compressor 8250 and a suitable
shop press, compress the 4C piston return spring and
install the snap-ring (Fig. 54).
(7) Assemble and install the 4C clutch pack into
the retainer/bulkhead (Fig. 53) with the steel separa-
tor plate against the piston.
(8) Install the 4C reaction plate and snap-ring into
the retainer/bulkhead (Fig. 53). The 4C reaction plate
is non-directional.
(9) Measure the 4C clutch clearance. The correct
clutch clearance is 0.77-1.39 mm (0.030-0.055 in.).
The snap-ring is selectable. Install the chosen snap-
ring and re-measure to verify the selection.
(10) Install the 2C piston into the retainer/bulk-
head (Fig. 53).
(11) Position the 2C Belleville spring onto the 2C
piston.
(12) Position the 2C Belleville spring snap-ring
onto the 2C Belleville spring (Fig. 53).
(13) Using Spring Compressor 8249 and a suitable
shop press (Fig. 55), compress the belleville spring
until the snap-ring is engaged with the snap-ring
groove in the retainer/bulkhead.
ADAPTER HOUSING SEAL
REMOVAL
(1) Remove the transfer case from the transmis-
sion.
(2) Using a screw mounted on a slide hammer,
remove the adapter housing seal.
INSTALLATION
(1) Clean the adapter seal bore in the adapter
housing of any residue or particles remaining from
the original seal.
(2) Install new oil seal in the adapter housing
using Seal Installer C-3860-A (Fig. 56). A properly
installed seal is flush to the face of the seal bore.
(3) Install the transfer case onto the transmission.
Fig. 54 Compress 4C Piston Return Spring Using
Tool 8250
1 - PRESS
2 - TOOL 8250
Fig. 55 Compress 2C Belleville Spring Using Tool
8249
1 - PRESS
2 - TOOL 8249
Fig. 56 Adapter Housing Seal Installation
1 - TOOL C-3860-A
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 225
4C RETAINER/BULKHEAD (Continued)

(8) Engine starts must be possible with shifter
lever in PARK or NEUTRAL gate positions only.
Engine starts must not be possible in any other gate
positions other than PARK or NEUTRAL.
(9) With shifter lever handle push-button not
depressed and lever detent in:
²PARK position- apply forward force on center of
handle and remove pressure. Engine start must be
possible.
²PARK position- apply rearward force on center
of handle and remove pressure. Engine start must be
possible.
²NEUTRAL position- engine start must be possi-
ble.
²NEUTRAL position, engine running and brakes
applied- Apply forward force on center of shift han-
dle. Transmission should not be able to shift into
REVERSE detent.
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL
A low fluid level allows the pump to take in air
along with the fluid. Air in the fluid will cause fluid
pressures to be low and develop slower than normal.
If the transmission is overfilled, the gears churn the
fluid into foam. This aerates the fluid and causing
the same conditions occurring with a low level. In
either case, air bubbles cause fluid overheating, oxi-
dation and varnish buildup which interferes with
valve and clutch operation. Foaming also causes fluid
expansion which can result in fluid overflow from the
transmission vent or fill tube. Fluid overflow can eas-
ily be mistaken for a leak if inspection is not careful.
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID
Burnt, discolored fluid is a result of overheating
which has three primary causes.
(1) Internal clutch slippage, usually caused by low
line pressure, inadequate clutch apply pressure, or
clutch seal failure.
(2) 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.(3) 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 cool-
ers as well. The torque converter should also be
replaced whenever a failure generates sludge and
debris. This is necessary because normal converter
flushing procedures will not remove all contami-
nants.
21 - 228 AUTOMATIC TRANSMISSION - 545RFEWJ
BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM (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)

A solenoid can also be described by the method by
which it is controlled. Some of the possibilities
include variable force, pulse-width modulated, con-
stant ON, or duty cycle. The variable force and pulse-
width modulated versions utilize similar methods to
control the current flow through the solenoid to posi-
tion the solenoid plunger at a desired position some-
where between full ON and full OFF. The constant
ON and duty cycled versions control the voltage
across the solenoid to allow either full flow or no flow
through the solenoid's valve.
OPERATION
When an electrical current is applied to the sole-
noid coil, a magnetic field is created which produces
an attraction to the plunger, causing the plunger to
move and work against the spring pressure and the
load applied by the fluid the valve is controlling. The
plunger is normally directly attached to the valve
which it is to operate. When the current is removed
from the coil, the attraction is removed and the
plunger will return to its original position due to
spring pressure.
The plunger is made of a conductive material and
accomplishes this movement by providing a path for
the magnetic field to flow. By keeping the air gap
between the plunger and the coil to the minimum
necessary to allow free movement of the plunger, the
magnetic field is maximized.
TORQUE CONVERTER
DESCRIPTION
The torque converter (Fig. 109) is a hydraulic
device that couples the engine crankshaft to the
transmission. The torque converter consists of an
outer shell with an internal turbine, a stator, an
overrunning clutch, an impeller and an electronically
applied converter clutch. The converter clutch pro-vides reduced engine speed and greater fuel economy
when engaged. Clutch engagement also provides
reduced transmission fluid temperatures. The con-
verter clutch engages in third gear. The torque con-
verter hub drives the transmission oil (fluid) pump
and contains an o-ring seal to better control oil flow.
The torque converter is a sealed, welded unit that
is not repairable and is serviced as an assembly.
CAUTION: The torque converter must be replaced if
a transmission failure resulted in large amounts of
metal or fiber contamination in the fluid. If the fluid
is contaminated, flush the fluid cooler and lines.
Fig. 109 Torque Converter Assembly
1 - TURBINE ASSEMBLY
2-STATOR
3 - CONVERTER HUB
4 - O-RING
5 - IMPELLER ASSEMBLY
6 - CONVERTER CLUTCH PISTON
7 - TURBINE HUB
21 - 264 AUTOMATIC TRANSMISSION - 545RFEWJ
SOLENOIDS (Continued)

(8) Position the accumulator cover onto the valve
body.
(9) Install the screws to hold the accumulator
cover onto the valve body. Tighten the screws to 4.5
N´m (40 in. lbs.).
(10) Install the TRS selector plate onto the valve
body and the manual valve.
(11) Install the solenoid and pressure switch
assembly onto the valve body.
(12) Install the screws to hold the solenoid and
pressure switch assembly onto the valve body.
Tighten the screws to 5.7 N´m (50 in. lbs.). Tighten
the screws adjacent to the arrows cast into the bot-
tom of the transfer plate first.
(13) Position the detent spring onto the valve body.
(14) Install the screw to hold the detent spring
onto the valve body. Tighten the screw to 4.5 N´m (40
in. lbs.).
(15) Install new clutch passage seals onto the
valve body, if necessary
INSTALLATION
(1) Check condition of seals on valve body and the
solenoid and pressure switch assembly. Replace seals
if cut or worn.
(2) Place TRS selector plate in the PARK position.
(3) Place the transmission in the PARK position.
(4) Lubricate seal on the solenoid and pressure
switch assembly connector with petroleum jelly.(5) Position valve body in transmission and align
the manual lever on the valve body to the pin on the
transmission manual shift lever.
(6) Seat valve body in case and install one or two
bolts to hold valve body in place.
(7) Tighten valve body bolts alternately and evenly
to 12 N´m (105 in. lbs.) torque.
(8) 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.
(9) Place replacement filter in position on valve
body and into the oil pump.
(10) Install screw to hold filter to valve body.
Tighten screw to 4.5 N´m (40 in. lbs.) torque.
(11) Connect the solenoid and pressure switch
assembly connector.
(12) Install oil pan. Tighten pan bolts to 12 N´m
(105 in. lbs.) torque.
(13) Lower vehicle and fill transmission with
MopartATF +4, type 9602, fluid.
(14) Check and adjust gearshift cable, if necessary.
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 279
VALVE BODY (Continued)

(2) Remove retainer (Fig. 28).
(3) Remove front tabbed thrust washer (Fig. 29).
(4) Remove input gear (Fig. 30).
(5) Remove rear tabbed thrust washer from low
range gear (Fig. 31).
CLEANING
Clean the transfer case components with parts
cleaning solvent. Flush the oil passages in the cases
and drivetrain components with solvent. This will
help remove dirt and particles from these passages.
Dry the transfer case components with compressed
air or allow them to air dry on clean shop towels.
Apply compressed air through all oil passages in
the cases and gear components to clear them of any
residue.
INSPECTION
MAINSHAFT
Examine the mainshaft components carefully for
evidence of wear or damage.
Replace the thrust washers if worn or damaged.
Replace the mainshaft and sprocket gears if the
teeth or gear bores are worn or damaged.
Replace the mainshaft bearings if worn, flat spot-
ted, brinelled, or damaged in any way.
Replace the mainshaft if it is bent, exhibits wear or
damage to the bearing surfaces, splines or gear teeth.
Fig. 28 Input Gear Retainer
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
Fig. 29 Front Tabbed Thrust Washer
1 - FRONT TABBED THRUST WASHER
Fig. 30 Input Gear Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
Fig. 31 Rear Tabbed Thrust Washer Removal
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER
21 - 324 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)

(6) Install new front output seal in front case with
Installer Tool 6952-A as follows:
(a) Place new seal on tool.Garter spring on
seal goes toward interior of case.
(b) Start seal in bore with light taps from ham-
mer (Fig. 36). Once seal is started, continue tap-
ping seal into bore until installer tool bottoms
against case.
(7) Remove the output shaft rear bearing with the
screw and jaws from Remover L-4454 and Cup 8148
(Fig. 37).(8) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 38).The bearing bore is
chamfered at the top. Install the bearing so it is
flush with the lower edge of this chamfer (Fig.
39).
Fig. 37 Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
Fig. 36 Front Output Seal Installation
1 - INSTALLER 6952-A
2 - TRANSFER CASE
Fig. 38 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 39 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
WJTRANSFER CASE - NV247 21 - 327
TRANSFER CASE - NV247 (Continued)

(1) Install the tire pressure sensor/transmitter on
the wheel (Fig. 23).
(2) Tighten the tire pressure sensor/transmitter
mounting nut to a torque of 11 N´m (97 in. lbs.) (Fig.
24). When tightening the sensor/transmitter nut,
hold the transmitter so it does not rotate. If the sen-
sor/transmitter rotates so the top edge is not level
with the wheel (Fig. 25), damage to the transmitter
will occur when mounting the tire. If the top edge of
the transmitter is not level with the wheel, it can be
rotated into position by lightly tapping it with your
hand.
CAUTION: When mounting the upper bead of the
extended mobility tire, the proper procedure must
be used. Not using the proper procedure will result
in damage to the wheel and tire.
(3) Mount the upper bead of the tire on the wheel.
(4) Install the original or an OEM replacement
valve stem cap on the valve stem.
(5) Using a soap solution, check that no air leak is
present where the valve stem mounts to the wheel.
(6) Balance the tire/wheel assembly using the cor-
rect procedure for using wheel flange mount and
stick-on wheel weights. For balancing information
and wheel weight positioning, (Refer to 22 - TIRES/
WHEELS - STANDARD PROCEDURE).
(7) Install the tire/wheel on the vehicle (Refer to
22 - TIRES/WHEELS - STANDARD PROCEDURE).
(8) Program the identification code for the new tire
pressure sensor/transmitter into the TPM module.(9) Verify that the TPM module has been pro-
grammed with the identification code from the new
tire pressure sensor/transmitter Refer to the appropi-
ate electrical section. If the identification code and
tire pressure thresholds from the new tire pressure
transmitter are present in the receivers memory the
new tire pressure transmitter has been correctly pro-
grammed to the receiver.
Fig. 23 TIRE PRESSURE SENSOR/TRANSMITTER -
TYPICAL
1 - WHEEL
2 - TIRE PRESSURE TRANSMITTER
Fig. 24 TIGHTENING SENSOR/TRANSDUCER -
TYPICAL
1 - TORQUE WRENCH
2 - WHEN TORQUING TRANSMITTER MOUNTING NUT DO NOT
LET THIS END OF TRANSMITTER ROTATE AWAY FROM THE
WHEEL
3 - WHEEL
4 - TIRE PRESSURE TRANSMITTER
Fig. 25 CORRECTLY POSITIONED SENSOR/TRAN -
TYPICAL
1 - THE TOP EDGES OF THE TIRE PRESSURE SENSOR/
TRANSMITTER MUST BE FLUSH WITH THE WHEEL HERE
2 - WHEEL
3 - TIRE PRESSURE SENSOR/TRANSMITTER
22 - 14 TIRES/WHEELSWJ
SENSOR (Continued)

GLOVE BOX LATCH STRIKER
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) If the inboard glove box latch striker is being
serviced, remove the lower right center bezel from
the instrument panel. (Refer to 23 - BODY/INSTRU-
MENT PANEL/IP LOWER RIGHT CENTER BEZEL
- REMOVAL). If the outboard glove box latch striker
is being serviced, remove the end cap from the
instrument panel. (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL END CAP -
REMOVAL).
(3) Remove the one screw that secures the upper
mounting flange of the glove box latch striker to the
instrument panel structural duct at either side of the
glove box opening (Fig. 20).
(4) Pull the upper mounting flange of the glove box
latch striker downward to disengage the hook forma-
tion on the lower end of the striker from the mount-
ing hole in the instrument panel structural duct.
(5) Remove the glove box latch striker from the
instrument panel.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Position the glove box latch striker to the
instrument panel.
(2) Engage the hook formation on the lower end of
the glove box latch striker in the mounting hole in
the instrument panel structural duct.
(3) Roll the upper mounting flange of the glove box
latch striker upward until it is flush with the instru-
ment panel structural duct on either side of the glove
box opening.
(4) Install and tighten the screw that secures the
upper mounting flange of the glove box latch striker
to the instrument panel structural duct (Fig. 20).
Tighten the screw to 2.2 N´m (20 in. lbs.).
(5) If the inboard glove box latch striker was ser-
viced, reinstall the lower right center bezel onto the
instrument panel. (Refer to 23 - BODY/INSTRU-
MENT PANEL/IP LOWER RIGHT CENTER BEZEL
- INSTALLATION). If the outboard glove box latch
striker was serviced, reinstall the end cap onto the
instrument panel. (Refer to 23 - BODY/INSTRU-
MENT PANEL/INSTRUMENT PANEL END CAP -
INSTALLATION).
(6) Reconnect the battery negative cable.
Fig. 20 Glove Box Latch Striker Remove/Install
1 - SCREW
2 - GLOVE BOX LATCH STRIKER
3 - INSTRUMENT PANEL TOP PAD
WJINSTRUMENT PANEL SYSTEM 23 - 49