2002 JEEP GRAND CHEROKEE Valve cover

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)

(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)

SPECIFICATIONS
TRANSMISSION
GENERAL
Component Metric Inch
Output Shaft End Play 0.22-0.55
mm0.009-0.021
in.
Input Shaft End Play 0.46-0.89
mm0.018-0.035
in.
2C Clutch Pack
Clearance0.455-1.335
mm0.018-0.053
in.
4C Clutch Pack
Clearance0.770-1.390
mm0.030-0.055
in.
L/R Clutch Pack
Clearance1.00-1.74
mm0.039-0.069
in.
OD Clutch Pack
Clearance1.103-1.856
mm0.043-0.073
in.
Component Metric Inch
UD Clutch Pack
Clearance0.84-1.54
mm0.033-0.061
in.
Reverse Clutch Pack
Clearance0.81-1.24
mm0.032-0.049
in.
Recommended fluid MoparTATF +4, type 9602
GEAR RATIOS
1ST 3.00:1
2ND 1.67:1
2ND Prime 1.50:1
3RD 1.0:1
4TH 0.75:1
5TH 0.67:1
REVERSE 3.00:1
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Fitting, cooler line at trans 17.5 - 155
Bolt, torque convertor 31 23 -
Bolt/nut, crossmember 68 50 -
Bolt, driveplate to crankshaft 75 55 -
Bolt, oil pan 11.8 - 105
Screw, primary fluid filter 4.5 - 40
Bolt, oil pump 28.2 - 250
Bolt, oil pump body to cover 4.5 - 40
Screw, plate to oil pump body 4.5 - 40
Bolt, valve body to case 11.8 - 105
Plug, pressure test port 5.1 - 45
Bolt, reaction shaft support 11.8 - 105
Screw, valve body to transfer plate 5.6 - 50
Screw, solenoid module to transfer plate 5.7 - 50
Screw, accumulator cover 4.5 - 40
Screw, detent spring 4.5 - 40
Bolt, input speed sensor 11.8 - 105
Bolt, output speed sensor 11.8 - 105
Bolt, line pressure sensor 11.8 - 105
Bolt, extension housing 54 40 -
Valve, cooler return filter bypass 4.5 - 40
Screw, manual valve cam retaining 4.5 - 40
Bolt, manual lever 28.2 - 250
21 - 220 AUTOMATIC TRANSMISSION - 545RFEWJ
AUTOMATIC TRANSMISSION - 545RFE (Continued)

OIL PUMP
DESCRIPTION
The oil pump (Fig. 87) is located at the front of the
transmission inside the bell housing and behind the
transmission front cover. The oil pump consists of
two independent pumps (Fig. 88), a number of valves
(Fig. 89), a front seal (Fig. 90), and a bolt on reaction
shaft. The converter clutch switch and regulator
valves, pressure regulator valve, and converter pres-
sure limit valve are all located in the oil pump valve
body.
OPERATION
As the torque converter rotates, the converter hub
rotates the oil pump drive gear. As the drive gear
rotates both driven gears, a vacuum is created when
the gear teeth come out of mesh. This suction draws
fluid through the pump inlet from the oil pan. As the
gear teeth come back into mesh, pressurized fluid is
forced into the pump outlet and to the oil pump
valves.
At low speeds, both sides of the pump supply fluid
to the transmission. As the speed of the torque con-
verter increases, the flow from both sides increases
until the flow from the primary side alone is suffi-
cient to meet system demands. At this point, the
check valve located between the two pumps closes.
The secondary side is shut down and the primary
side supplies all the fluid to the transmission.
CONVERTER CLUTCH SWITCH VALVE
The converter clutch switch valve is used to control
the hydraulic pressure supplied to the front (OFF)
side of the torque converter clutch.
CONVERTER CLUTCH REGULATOR VALVE
The converter clutch regulator valve is used to con-
trol the hydraulic pressure supplied to the back (ON)
side of the torque converter clutch.
TORQUE CONVERTER LIMIT VALVE
The torque converter limit valve serves to limit the
available line pressure to the torque converter clutch
to approximately 120 psi.
Fig. 87 Oil Pump
1 - OIL PUMP TO CASE BOLT (6)
2 - OIL PUMP
Fig. 88 Oil Pump Gears
1 - PUMP HOUSING
2 - DRIVE GEAR
3 - DRIVEN GEARS
Fig. 89 Oil Pump Valves
1 - TORQUE CONVERTER CLUTCH ACCUMULATOR VALVE
2 - TORQUE CONVERTER CLUTCH CONTROL VALVE
3 - TORQUE CONVERTER CLUTCH SWITCH VALVE
4 - PUMP VALVE BODY
5 - PRESSURE REGULATOR VALVE
6 - TORQUE CONVERTER CLUTCH LIMIT VALVE
21 - 248 AUTOMATIC TRANSMISSION - 545RFEWJ

(9) Remove the oil pump valve retainers and asso-
ciated valve and spring one at a time (Fig. 93) (Fig.
94). Mark the combination of components as a group
and tag them as to the location from which they were
removed.
CLEANING
Clean pump and support components with solvent
and dry them with compressed air.
INSPECTION
Check condition of the seal rings and thrust
washer on the reaction shaft support. The seal rings
do not need to be replaced unless cracked, broken, or
severely worn.
Inspect the pump and support components. Replace
the pump or support if the seal ring grooves or
machined surfaces are worn, scored, pitted, or dam-
aged. Replace the pump gears if pitted, worn
chipped, or damaged.Inspect the pump reaction shaft support bushings.
Replace either bushing only if heavily worn, scored or
damaged. It is not necessary to replace the bushings
unless they are actually damaged.
Inspect the valves and plugs for scratches, burrs,
nicks, or scores. Minor surface scratches on steel
valves and plugs can be removed with crocus cloth
butdo not round off the edges of the valve or
plug lands.Maintaining sharpness of these edges is
vitally important. The edges prevent foreign matter
from lodging between the valves and plugs and the
bore.
Inspect all the valve and plug bores in the oil
pump cover. Use a penlight to view the bore interi-
ors. Replace the oil pump if any bores are distorted
or scored. Inspect all of the valve springs. The
springs must be free of distortion, warpage or broken
coils.
Trial fit each valve and plug in its bore to check
freedom of operation. When clean and dry, the valves
and plugs should drop freely into the bores.
Fig. 93 Oil Pump Valve Body
1 - T/C REGULATOR VALVE
2 - T/C LIMIT VALVE
3 - REGULATOR VALVE
4 - OIL PUMP VALVE BODY
Fig. 94 T/C Switch Valve
1 - RETAINER
2 - T/C SWITCH VALVE
3 - OIL PUMP VALVE BODY
21 - 252 AUTOMATIC TRANSMISSION - 545RFEWJ
OIL PUMP (Continued)

ASSEMBLY
(1) Clean and inspect all components. Make sure
that all passages are thoroughly cleaned and are free
from dirt or debris. Make sure that all valves move
freely in their proper bore. Make sure that all gear
pockets and bushings are free from excessive wear
and scoring. Replace the oil pump if any excessive
wear or scoring is found.
(2) Coat the gears with MopartATF +4, type 9602,
and install into their original locations.
(3) Lubricate the oil pump valves with Mopart
ATF +4, type 9602, and install the valve, spring and
retainer into the appropriate oil pump valve body
bore (Fig. 93) (Fig. 94).
(4) Place the separator plate onto the oil pump
body (Fig. 92).
(5) Install the screws to hold the separator plate
onto the oil pump body (Fig. 92). Tighten the screws
to 4.5 N´m (40 in.lbs.).
(6) Position the oil pump cover onto the locating
dowels (Fig. 91).
(7) Seat the two oil pump halves together and
install all bolts finger tight.
(8) Torque all bolts down slowly starting in the
center and working outward. The correct torque is
4.5 N´m (40 in.lbs.).
(9) Verify that the oil pump gears rotate freely and
smoothly.
(10) Position the reaction shaft support into the oil
pump (Fig. 91).
(11) Install and torque the bolts to hold the reac-
tion shaft support to the oil pump (Fig. 91). The cor-
rect torque is 12 N´m (105 in.lbs.).
OIL PUMP FRONT SEAL
REMOVAL
(1) Remove transmission from the vehicle.
(2) Remove the torque converter from the trans-
mission.
(3) Using a screw mounted in a slide hammer,
remove the oil pump front seal.
INSTALLATION
(1) Clean seal bore of the oil pump of any residue
or particles from the original seal.
(2) Install new oil seal in the oil pump housing
using Seal Installer C-3860-A (Fig. 95).
Fig. 95 Install Oil Pump Front Seal
1 - TOOL C-3860-A
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 253
OIL PUMP (Continued)

(7) Remove the screws holding the accumulator
cover onto the valve body (Fig. 128).
(8) Remove the accumulator springs and pistons
from the valve body. Note which accumulator piston
and spring belong in each location.
(9) Place the valve body on the bench with the
transfer plate upward.
NOTE: The valve body contains seven check balls.
The transfer plate must be placed upward to pre-
vent losing the check balls when the transfer plate
is removed from the valve body.
(10) Remove the screws holding the valve body to
the valve body transfer plate.
(11) Remove the transfer plate from the valve
body. Note the location of all check balls (Fig. 129).
(12) Remove the check balls from the valve body.
(13) Remove the retainers securing the solenoid
switch valve, manual valve, and the low/reverse
switch valve into the valve body and remove the
associated valve and spring. Tag each valve andspring combination with location information to aid
in assembly. (Fig. 130)
Fig. 128 Valve Body Components
1 - LOW/REVERSE ACCUMULATOR 6 - OVERDRIVE ACCUMULATOR
2 - LOW/REVERSE SWITCH VALVE 7 - UNDERDRIVE ACCUMULATOR
3 - UPPER VALVE BODY 8 - 4C ACCUMULATOR
4 - MANUAL VALVE 9 - 2C ACCUMULATOR
5 - SOLENOID SWITCH VALVE
Fig. 129 Check Ball Locations
21 - 276 AUTOMATIC TRANSMISSION - 545RFEWJ
VALVE BODY (Continued)