2002 JEEP GRAND CHEROKEE Indicator

(c) Zero the dial indicator.
(d) Lift the pressure plate until it contacts the
snap-ring and record the dial indicator reading.Clearance should be 0.559 - 0.914 mm (0.022 -
0.036 in.). If clearance is incorrect, steel plates, discs,
selective snap ring and pressure plates may have to
be changed.
Fig. 227 Rear Clutch Retainer And Input Shaft Seal
Ring Installation
1 - REAR CLUTCH RETAINER HUB SEAL RING
2 - INPUT SHAFT SEAL RINGS
Fig. 228 Input Shaft Seal Ring Identification
1 - PLASTIC REAR SEAL RING
2 - TEFLON FRONT SEAL RING (SQUEEZE RING TOGETHER
SLIGHTLY BEFORE INSTALLATION FOR BETTER FIT)
Fig. 229 Pressing Input Shaft Into Rear Clutch
Retainer
1 - INPUT SHAFT
2 - REAR CLUTCH RETAINER
3 - PRESS RAM
Fig. 230 Piston Spring/Wave Spring Position
1 - REAR CLUTCH RETAINER
2 - PISTON SPRING
3 - WAVE SPRING
4 - CLUTCH PISTON
WJAUTOMATIC TRANSMISSION - 42RE 21 - 121
REAR CLUTCH (Continued)

The selective snap-ring thicknesses are:
²0.107-0.109 in.
²0.098-0.100 in.
²0.095-0.097 in.
²0.083-0.085 in.
²0.076-0.078 in.
²0.071-0.073 in.
²0.060-0.062 in.
(16) Coat rear clutch thrust washer with petro-
leum jelly and install washer over input shaft and
into clutch retainer (Fig. 232). Use enough petroleum
jelly to hold washer in place.REAR SERVO
DESCRIPTION
The rear (low/reverse) servo consists of a single
stage or diameter piston and a spring loaded plug.
The spring is used to cushion the application of the
rear (low/reverse) band.
OPERATION
While in the de-energized state (no pressure
applied), the piston is held up in its bore by the pis-
ton spring. The plug is held down in its bore, in the
piston, by the plug spring. When pressure is applied
to the top of the piston, the plug is forced down in its
bore, taking up any clearance. As the piston moves, it
causes the plug spring to compress, and the piston
moves down over the plug. The piston continues to
move down until it hits the shoulder of the plug and
fully applies the band. The period of time from the
initial application, until the piston is against the
shoulder of the plug, represents a reduced shocking
of the band that cushions the shift.
DISASSEMBLY
(1) Remove small snap-ring and remove plug and
spring from servo piston (Fig. 233).
(2) Remove and discard servo piston seal ring.
CLEANING
Remove and discard the servo piston seal ring (Fig.
234). Then clean the servo components with solvent
and dry with compressed air. Replace either spring if
collapsed, distorted or broken. Replace the plug and
piston if cracked, bent, or worn. Discard the servo
snap-rings and use new ones at assembly.
Fig. 231 Checking Rear Clutch Pack Clearance
1 - DIAL INDICATOR
2 - PRESSURE PLATE
3 - SNAP-RING
4-STAND
5 - REAR CLUTCH
6 - GAUGE BAR
Fig. 232 Installing Rear Clutch Thrust Washer
1 - REAR CLUTCH RETAINER
2 - REAR CLUTCH THRUST WASHER
Fig. 233 Rear Servo Components
1 - SNAP-RING
2 - PISTON SEAL
3 - PISTON PLUG
4 - SPRING RETAINER
5 - SNAP-RING
6 - PISTON SPRING
7 - CUSHION SPRING
8 - PISTON
21 - 122 AUTOMATIC TRANSMISSION - 42REWJ
REAR CLUTCH (Continued)

(26) To remove torque converter, carefully slide
torque converter out of the transmission.
DISASSEMBLY
(1) Drain fluid from transmission.
(2) Clean exterior of transmission with suitable
solvent or pressure washer.
(3) Remove the torque converter from the trans-
mission.
(4) Remove the manual shift lever from the trans-
mission.
(5) Remove the input, output, and line pressure
sensors from the transmission case (Fig. 14).(6) Inspect the ends of the sensors for debris,
which may indicate the nature of the transmission
failure.
(7) Install Support Stand 8257 onto the transmis-
sion case (Fig. 15).
(8) Using Adapter 8266-1 from End-Play Tool Set
8266 and Dial Indicator C-3339, measure and record
the input shaft end-play (Fig. 16).
Fig. 13 Remove NV242 Transfer Case
1 - NV242 TRANSFER CASE
Fig. 14 Remove Input, Output, and Line Pressure
Sensors
1 - OUTPUT SPEED SENSOR
2 - LINE PRESSURE SENSOR
3 - INPUT SPEED SENSOR
Fig. 15 Install Support Stand - Tool 8257
1 - TOOL 8257
Fig. 16 Measure Input Shaft End Play
1 - TOOL 8266
2 - TOOL C-3339
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 185
AUTOMATIC TRANSMISSION - 545RFE (Continued)

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)

(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)

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)

STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK
Low fluid level can cause a variety of conditions
because it allows the pump to take in air along with
the fluid. As in any hydraulic system, air bubbles
make the fluid spongy, therefore, pressures will be
low and build up slowly.
Improper filling can also raise the fluid level too
high. When the transmssion has too much fluid, the
geartrain churns up foam and cause the same condi-
tions which occur with a low fluid level.
In either case, air bubbles can cause overheating
and/or fluid oxidation, and varnishing. This can inter-
fere with normal valve, clutch, and accumulator opera-
tion. Foaming can also result in fluid escaping from the
transmission vent where it may be mistaken for a leak.
After the fluid has been checked, seat the dipstick
fully to seal out water and dirt.
The transmission has a dipstick to check oil level.
It is located on the right side of the engine. Be sure
to wipe all dirt from dipstick handle before removing.
The torque converter fills in both the P (PARK)
and N (NEUTRAL) positions. Place the selector lever
in P (PARK) to be sure that the fluid level check is
accurate.The engine should be running at idle
speed for at least one minute, with the vehicle
on level ground.At normal operating temperature(approximately 82 C. or 180 F.), the fluid level is cor-
rect if it is in the HOT region (cross-hatched area) on
the oil level indicator. The fluid level will be approx-
imately at the upper COLD hole of the dipstick at
70É F fluid temperature.
NOTE: Engine and Transmission should be at nor-
mal operating temperature before performing this
procedure.
(1) Start engine and apply parking brake.
(2) Shift the transmission into DRIVE for approxi-
mately 2 seconds.
(3) Shift the transmission into REVERSE for
approximately 2 seconds.
(4) Shift the transmission into PARK.
(5)
Hook up DRBtscan tool and select transmission.
(6) Select sensors.
(7) Read the transmission temperature value.
(8) Compare the fluid temperature value with the
chart. (Fig. 59)
(9) Adjust transmission fluid level shown on the
dipstick according to the chart.
NOTE: After adding any fluid to the transmission,
wait a minimum of 2 minutes for the oil to fully
drain from the fill tube into the transmission before
rechecking the fluid level.
(10) Check transmission for leaks.
Fig. 59 Transmission Fluid Temperature Chart
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 229
FLUID AND FILTER (Continued)