2002 JEEP GRAND CHEROKEE transmission oil

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)

(48) Remove the manual selector shaft seal.
(49) Remove the dipstick tube seal.
CLEANING
The use of crocus cloth is permissible where neces-
sary, providing it is used carefully. When used on
shafts, or valves, use extreme care to avoid rounding
off sharp edges. Sharp edges are vital as they pre-
vent foreign matter from getting between the valve
and valve bore.
Do not reuse oil seals, gaskets, seal rings, or
O-rings during overhaul. Replace these parts as a
matter of course. Also do not reuse snap rings or
E-clips that are bent or distorted. Replace these parts
as well.
Lubricate transmission parts with MopartATF +4,
Type 9602, transmission fluid during overhaul and
assembly. Use petroleum jelly, MopartDoor Ease, or
Ru-Glyde to prelubricate seals, O-rings, and thrust
washers. Petroleum jelly can also be used to hold
parts in place during reassembly.Clean the case in a solvent tank. Flush the case
bores and fluid passages thoroughly with solvent.
Dry the case and all fluid passages with compressed
air. Be sure all solvent is removed from the case and
that all fluid passages are clear.
NOTE: Do not use shop towels or rags to dry the
case (or any other transmission component) unless
they are made from lint-free materials. Lint will stick
to case surfaces and transmission components and
circulate throughout the transmission after assem-
bly. A sufficient quantity of lint can block fluid pas-
sages and interfere with valve body operation.
INSPECTION
Inspect the case for cracks, porous spots, worn
bores, or damaged threads. Damaged threads can be
repaired with Helicoil thread inserts. However, the
case will have to be replaced if it exhibits any type of
damage or wear.
ASSEMBLY
(1) Clean and inspect all components. Replace any
components which show evidence of excessive wear
or scoring.
(2) Install the cooler filter bypass valve.
(3) Torque the bypass valve to specification. The
valve uses a tapered pipe thread and excessive
torque can damage the transmission case. Tighten
the cooler filter bypass valve to 4.5 N´m (40 in.lbs.).
(4) Install a new selector shaft seal using Seal
Installer 8253 (Fig. 31).
Fig. 30 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
Fig. 31 Install Selector Shaft
1 - SEAL
2 - TOOL 8253
21 - 190 AUTOMATIC TRANSMISSION - 545RFEWJ
AUTOMATIC TRANSMISSION - 545RFE (Continued)

(5) Install the manual selector shaft and retaining
screw. Tighten the manual selector shaft retaining
screw to 28 N´m (250 in.lbs.).
(6) Install the park pawl, spring, and shaft (Fig.
32).
(7) Install the park rod and e-clip (Fig. 32).
(8) Install the park rod guide and snap-ring (Fig.
32).
(9) Install a new dipstick tube seal using Seal
Installer 8254 (Fig. 33).
NOTE: Before final assembly of transmission cen-
terline, the 2C/4C clutch components should be
installed into position and measured as follows:
(10) Install the 2C reaction plate into the trans-
mission case (Fig. 34). The reaction plate is direc-
tional. The plate must be installed with the flat side
toward the front of the transmission.
(11) Install the 2C clutch pack into the transmis-
sion case (Fig. 34).(12) Install the flat 2C clutch snap-ring into the
transmission case (Fig. 34).
(13) Install the 4C retainer/bulkhead into the
transmission case. Make sure that the oil feed holes
are pointing toward the valve body area.
(14) Install the 4C retainer/bulkhead tapered
snap-ring into the transmission case. Make sure that
the open ends of the snap-ring are located in the case
opening toward the valve body area.
Fig. 32 Manual Shaft/Park Lock Components
1 - GUIDE
2 - SNAP-RING
3 - SHAFT
4 - SPRING
5 - PARK PAWL
6 - MANUAL SHAFT/LEVER
7 - PARK ROD
Fig. 33 Install Dipstick Tube Seal Using Tool 8254
1 - TOOL 8254
2 - SEAL
Fig. 34 Install 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 191
AUTOMATIC TRANSMISSION - 545RFE (Continued)

(15) Using a feeler gauge through the opening in
the rear of the transmission case, measure the 2C
clutch pack clearance between the 2C reaction plate
and the transmission case at four different points.
The average of these measurements is the 2C clutch
pack clearance. The correct clutch clearance is 0.455-
1.335 mm (0.018-0.053 in.). The reaction plate is not
selective. If the clutch pack clearance is not within
specification, the reaction plate, all the friction discs,
and steels must be replaced.
(16) Remove the 4C retainer/bulkhead and all of
the 2C clutch components from the transmission
case.
(17) Install the low/reverse clutch assembly (Fig.
35). Make sure that the oil feed hole points toward
the valve body area and that the bleed orifice is
aligned with the notch in the rear of the transmis-
sion case.
(18) Install the snap-ring to hold the low/reverse
clutch retainer into the transmission case (Fig. 35).
The snap-ring is tapered and must be installed with
the tapered side forward. Once installed, verify that
the snap-ring is fully seated in the snap-ring groove.
(19) Air check the low/reverse clutch and verify
correct overrunning clutch operation.
(20) Install the number 12 bearing over the output
shaft and against the rear planetary gear set. The
flat side of the bearing goes toward the planetary
gearset and the raised tabs on the inner race should
face the rear of the transmission.(21) Install the reverse/input planetary assembly
through the low/reverse clutch assembly (Fig. 36).
(22) Install the park sprag onto the output shaft
(Fig. 37).
(23) Install the snap-ring to hold the park sprag
onto the output shaft (Fig. 38).
Fig. 35 Install Low/Reverse Clutch Retainer
1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
2 - SNAP-RING
Fig. 36 Install Input/Reverse Planetary Assembly
1 - INPUT/REVERSE PLANETARY ASSEMBLY
2 - BEARING NUMBER 9
3 - BEARING NUMBER 12
Fig. 37 Install Park Sprag Gear
1 - PARK SPRAG GEAR
21 - 192 AUTOMATIC TRANSMISSION - 545RFEWJ
AUTOMATIC TRANSMISSION - 545RFE (Continued)

(24) Install the 2C reaction plate into the trans-
mission case (Fig. 39). The reaction plate is direc-
tional. The plate must be installed with the flat side
toward the front of the transmission.
(25) Install the 2C clutch pack into the transmis-
sion case (Fig. 39).(26) Install the number 8 bearing inside the reac-
tion carrier with the outer race against the reaction
planetary carrier.
(27) Install the reaction planetary gear set and the
number 9 bearing, with the inner race against the
reaction planetary carrier, into the transmission case
(Fig. 40).
(28) Install the flat 2C clutch snap-ring into the
transmission case (Fig. 39).
(29) Install the reaction sun gear into the reaction
planetary gear set.Make surethe small shoulder is
facing the front of the transmission (Fig. 40).
(30) Install the number 7 bearing onto the reaction
sun gear with the inner race against the sun gear
(Fig. 40).
(31) Install the output shaft selective thrust plate
onto the reaction annulus with the oil grooves facing
the annulus gear and the tabs and notches aligned as
shown in (Fig. 41).
(32) Install the number 6 bearing against the out-
put shaft selective thrust plate with the flat side
against the thrust plate (Fig. 40) and the raised tabs
on the inner race facing the front of the transmis-
sion.
(33) Install the reaction annulus into the reaction
planetary gear set (Fig. 40).
(34) Install the 4C retainer/bulkhead into the
transmission case. Make sure that the oil feed holes
are pointing toward the valve body area. Rotate the
reaction annulus during the installation of the 4C
retainer/bulkhead to ease installation.
(35) Install the 4C retainer/bulkhead tapered
snap-ring into the transmission case (Fig. 42) with
the taper toward the front of the case. Make sure
that the open ends of the snap-ring are located in the
case opening toward the valve body area.
(36) Air check the 2C and 4C clutch operation.
Fig. 38 Install Park Sprag Snap-Ring
1 - SNAP-RING
Fig. 39 Install 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 193
AUTOMATIC TRANSMISSION - 545RFE (Continued)

(37) 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. 43). The correct output shaft end-play is
0.22-0.55 mm (0.009-0.021 in.). Adjust as necessary.
Install the chosen output shaft selective thrust plate
and re-measure end-play to verify selection.
(38) Apply a bead of RTV silicone and install the
extension/adapter housing onto the transmission
case.
(39) Install and torque the bolts to hold the exten-
sion/adapter housing onto the transmission case. The
correct torque is 54 N´m (40 ft.lbs.).
(40) Install the number 5 bearing and selective
thrust plate onto the 4C retainer/bulkhead (Fig. 44).
Be sure that the outer race of the bearing is against
the thrust plate.
(41) Install the input clutch assembly into the
transmission case (Fig. 44). Make sure that the input
clutch assembly is fully installed by performing a
visual inspection through the input speed sensor
hole. If the tone wheel teeth on the input clutch
assembly are centered in the hole, the assembly is
fully installed.
(42) Install the number 1 bearing with the outer
race up in the pocket of the input clutch assembly
(Fig. 44).(43) Install the oil pump into the transmission
case (Fig. 45).
(44) Install the bolts to hold the oil pump into the
transmission case. Tighten the oil pump bolts to 28
N´m (250 in.lbs.).
Fig. 43 Measure Output Shaft End Play
1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339
Fig. 44 Install Input Clutch Assembly
1 - BEARING NUMBER 5
2 - THRUST PLATE (SELECT)
3 - INPUT CLUTCH ASSEMBLY
4 - BEARING NUMBER 1
Fig. 45 Install Oil Pump
1 - OIL PUMP TO CASE BOLT (6)
2 - OIL PUMP
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 195
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)