2002 JEEP GRAND CHEROKEE nv 247

AUTOMATIC TRANSMISSION - 545RFE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 545RFE
DESCRIPTION........................178
OPERATION..........................179
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION.....................179
DIAGNOSIS AND TESTING - PRELIMINARY . 180
DIAGNOSIS AND TESTING - ROAD
TESTING...........................180
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST....................181
DIAGNOSIS AND TESTING - AIR CHECKING
TRANSMISSION CLUTCH OPERATION....182
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK................182
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR.....................183
REMOVAL............................183
DISASSEMBLY........................185
CLEANING...........................190
INSPECTION.........................190
ASSEMBLY...........................190
INSTALLATION........................197
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS.............199
SPECIFICATIONS
TRANSMISSION.....................220
SPECIAL TOOLS
RFE TRANSMISSION.................221
4C RETAINER/BULKHEAD
DISASSEMBLY........................224
ASSEMBLY...........................224
ADAPTER HOUSING SEAL
REMOVAL............................225
INSTALLATION........................225
BRAKE TRANSMISSION SHIFT INTERLOCK
MECHANISM
DESCRIPTION........................226
OPERATION..........................226
DIAGNOSIS AND TESTING - BRAKE
TRANSMISSION SHIFT INTERLOCK......226
ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK...................227
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL.............228
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID.......................228DIAGNOSIS AND TESTING - FLUID
CONTAMINATION....................228
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK............................229
STANDARD PROCEDURE - FLUID AND
FILTER REPLACEMENT...............230
STANDARD PROCEDURE - TRANSMISSION
FILL...............................230
GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE.............................231
REMOVAL............................231
INSTALLATION........................231
ADJUSTMENTS - GEARSHIFT CABLE......232
HOLDING CLUTCHES
DESCRIPTION........................233
OPERATION..........................234
INPUT CLUTCH ASSEMBLY
DESCRIPTION........................235
OPERATION..........................235
DISASSEMBLY........................237
ASSEMBLY...........................238
INPUT SPEED SENSOR
DESCRIPTION........................244
OPERATION..........................244
REMOVAL............................244
INSTALLATION........................244
LINE PRESSURE (LP) SENSOR
DESCRIPTION........................245
OPERATION..........................245
REMOVAL............................245
INSTALLATION........................245
LOW/REVERSE CLUTCH
DISASSEMBLY........................246
CLEANING...........................247
INSPECTION.........................247
ASSEMBLY...........................247
OIL PUMP
DESCRIPTION........................248
OPERATION..........................248
STANDARD PROCEDURE - OIL PUMP
VOLUME CHECK.....................249
DISASSEMBLY........................250
CLEANING...........................252
INSPECTION.........................252
ASSEMBLY...........................253
OIL PUMP FRONT SEAL
REMOVAL............................253
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 177

(12) Disconnect gearshift cable from transmission
manual valve lever (Fig. 9).
(13) Disconnect transfer case shift cable from the
transfer case shift lever (Fig. 10).
(14) Remove the clip securing the transfer case
shift cable into the cable support bracket.
(15) Disconnect transmission fluid cooler lines at
transmission fittings and clips.
(16) Disconnect the transmission vent hose from
the transmission.
(17) Support rear of engine with safety stand or
jack.
(18) Raise transmission slightly with service jack
to relieve load on crossmember and supports.(19) Remove bolts securing rear support and cush-
ion to transmission and crossmember (Fig. 11).
(20) Remove bolts attaching crossmember to frame
and remove crossmember.
(21) Remove transfer case (Fig. 12) and (Fig. 13).
(22) Remove all remaining converter housing bolts.
(23) Carefully work transmission and torque con-
verter assembly rearward off engine block dowels.
(24) Hold torque converter in place during trans-
mission removal.
(25) Lower transmission and remove assembly
from under the vehicle.
Fig. 9 Transmission Shift Cable
1 - SHIFT CABLE
2 - MANUAL LEVER
3 - MANUAL LEVER
Fig. 10 Transfer Case Shift Cable
1 - TRANSFER CASE SHIFT LEVER
2 - TRANSFER CASE SHIFT CABLE
Fig. 11 Rear Transmission Crossmember
1 - CROSSMEMBER
2 - REAR TRANSMISSION MOUNT
Fig. 12 Remove NV247 Transfer Case
1 - NV247 TRANSFER CASE
21 - 184 AUTOMATIC TRANSMISSION - 545RFEWJ
AUTOMATIC TRANSMISSION - 545RFE (Continued)

holding the Belleville spring into the low/reverse
clutch retainer.
(10) Remove the low/reverse clutch Belleville
spring and piston from the low/reverse clutch
retainer. Use 20 psi of air pressure to remove the pis-
ton if necessary.
CLEANING
Clean the overrunning clutch assembly, clutch cam,
and low-reverse clutch retainer. Dry them with com-
pressed air after cleaning.
INSPECTION
Inspect condition of each clutch part after cleaning.
Replace the overrunning clutch roller and spring
assembly if any rollers or springs are worn or dam-
aged, or if the roller cage is distorted, or damaged.
Replace the cam if worn, cracked or damaged.
Replace the low-reverse clutch retainer if the
clutch race, roller surface or inside diameter is
scored, worn or damaged.
ASSEMBLY
(1) Check the bleed orifice to ensure that it is not
plugged or restricted.
(2) Install a new seal on the low/reverse piston.
Lubricate the seal with MopartATF +4, type 9602,
prior to installation.
(3) Install the low/reverse piston into the low/re-
verse clutch retainer.
(4) Position the low/reverse piston Belleville spring
on the low/reverse piston.
(5) Using Spring Compressor 8285 and a suitable
shop press (Fig. 86), compress the low/reverse piston
Belleville spring and install the split retaining ring
to hold the Belleville spring into the low/reverse
clutch retainer.
(6) Install the lower overrunning clutch snap-ring
(Fig. 85).
(7) Assemble the inner and outer races of the over-
running clutch (Fig. 85).
(8) Position the overrunning clutch spacer on the
overrunning clutch.
(9) Install the upper overrunning clutch snap-ring
(Fig. 85).
(10) Assemble and install the low/reverse clutch
pack into the low/reverse clutch retainer (Fig. 84).
(11) Install the low/reverse reaction plate into the
low/reverse clutch retainer (Fig. 84). The reaction
plate is directional and must be installed with the
flat side down.
(12) Install the low/reverse clutch pack snap-ring
(Fig. 84). The snap-ring is selectable and should be
chosen to give the correct clutch pack clearance.
(13) Measure the low/reverse clutch pack clearance
and adjust as necessary. The correct clutch clearance
is 1.00-1.74 mm (0.039-0.075 in.).
(14) Install the overrunning clutch into the low/re-
verse clutch retainer making sure that the index
splines are aligned with the retainer.
(15) Install the overrunning clutch inner snap-
ring.
Fig. 85 Overrunning Clutch
1 - SNAP-RING
2 - OUTER RACE
3 - OVERRUNNING CLUTCH
4 - SPACER
Fig. 86 Compress Low/Reverse Belleville Spring
Using Tool 8285
1 - PRESS
2 - TOOL 8285
3 - BELLEVILLE SPRING
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 247
LOW/REVERSE CLUTCH (Continued)

TRANSFER CASE - NV247
TABLE OF CONTENTS
page page
TRANSFER CASE - NV247
DESCRIPTION........................315
OPERATION..........................316
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV247.......................316
REMOVAL............................317
DISASSEMBLY........................317
CLEANING...........................324
INSPECTION.........................324
ASSEMBLY...........................326
INSTALLATION........................335
SPECIFICATIONS
TRANSFER CASE - NV247.............336
SPECIAL TOOLS
TRANSFER CASE - NV247.............337FLUID
STANDARD PROCEDURE - FLUID DRAIN/
REFILL............................338
FRONT OUTPUT SHAFT SEAL
REMOVAL............................338
INSTALLATION........................338
REAR RETAINER BUSHING AND SEAL
REMOVAL............................339
INSTALLATION........................339
SHIFT CABLE
REMOVAL............................340
INSTALLATION........................340
TRANSFER CASE - NV247
DESCRIPTION
The NV247 (Fig. 1) is an on-demand 4-wheel drive
transfer case with two operating ranges and a neu-
tral position. Operating ranges are 4-high and 4-low.
The 4-low range is used for extra pulling power in
off-road situations.
TRANSFER CASE IDENTIFICATION
A circular I.D. tag is attached to the rear case of
each NV247 transfer case (Fig. 2). The tag indicates
the following information:
²Model number
²Serial number
²Assembly number
²Gear ratio
²Location of manufacture
The transfer case serial number also represents
the date of build.
Fig. 1 NV247 Transfer Case
Fig. 2 Transfer Case I.D. Tag
1 - FILL PLUG
2 - I.D. TAG
3 - DRAIN PLUG
WJTRANSFER CASE - NV247 21 - 315

OPERATION
Under normal driving conditions, the system oper-
ates conventionally, and the majority of available
torque is applied to the rear wheels. However, when
front-to-rear wheel speed variations exist, the pro-
gressive differential transfers torque to the axle with
the better traction, thus minimizing wheel spin and
maximizing control.
The key to this design is a progressive coupling
(Fig. 3), which is supplied with pressurized oil by a
gerotor style pump. The pump rotor and case are
driven by the front and rear driveshafts respectively,
and deliver pressurized oil flow to the coupling in
proportion to their speed difference. The progressive
coupling contains a multi-disc clutch pack that is
alternately splined to the front and rear driveshafts,
and controls torque variation between the front and
rear driveshafts as dictated by the pump.
A set of orifices and valves control the speed-differ-
ential starting point and rate of torque transfer rise
in the clutch. This allows the system to disregard the
normal speed differences between axles that result
from variations in front-to-rear loading and typical
cornering.
Transfer case operating ranges are selected with a
floor mounted shift lever. The shift lever is connectedto the transfer case range lever by an adjustable
cable. Range positions are marked on the shifter
bezel plate.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV247
CONDITION POSSIBLE CAUSE CORRECTION
TRANSFER CASE DIFFICULT TO
SHIFT OR WILL NOT SHIFT INTO
DESIRED RANGE1. Vehicle speed too great to permit
shifting1. Reduce speed to 3-4 km/h (2-3
mph) before attempting to shift
2. Transfer case external shift cable
binding2. Lubricate, repair or replace cable,
or thighten loose components as
necessary
3. Insufficient or incorrect lubricant 3. Drain and refill to edge of fill hole
with correct lubricant
4. Internal components binding,
worn, or damaged4. Disassemble unit and replace
worn or damaged components as
necessary
TRANSFER CASE NOISY IN ALL
MODES1. Insufficient or incorrect lubricant 1. Drain and refill to edge of fill hole
with correct lubricant.If unit is still
noisy after drain and refill,
disassembly and inspection may
be required to locate source of
noise
Fig. 3 Progressive Coupling
21 - 316 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)

CONDITION POSSIBLE CAUSE CORRECTION
NOISY INÐOR JUMPS OUT OF
4WD LOW RANGE1. Transfer case not completely
engaged in 4WD LOW (possibly
from shift to 4L while rolling)1. Stop vehicle, shift transfer case
to neutral, then shift back to 4WD
LOW
2. Shift linkage loose, binding, or is
misadjusted2. Tighten, lubricate, or repair
linkage as necessary. Adjust linkage
if necessary
3. Range fork cracked, inserts
worn, or fork is binding on shift rail3. Disassemble unit and repair as
necessary
4. Annulus gear or lockplate worn
or damaged4. Disassemble unit and repair as
necessary
LUBRICANT LEAKING FROM
OUTPUT SHAFT SEALS OR FROM
VENT1. Transfer case over filled 1. Drain to correct level
2. Vent closed or restricted 2. Clear or replace vent if necessary
3. Output shaft seals damaged or
installed correctly3. Replace seals. Be sure seal lip
faces interior of case when installed.
Also be sure yoke seal surfaces are
not scored or nicked. Remove
scores and nicks with fine
sandpaper or replace yoke(s) if
necessary.
REMOVAL
(1) Shift transfer case into NEUTRAL.
(2) Raise vehicle.
(3) Remove transfer case drain plug and drain
transfer case lubricant.
(4) Mark front and rear propeller shaft yokes for
alignment reference.
(5) Support transmission with jack stand.
(6) Remove rear crossmember and skid plate, if
equipped (Fig. 4).
(7) Disconnect front propeller shaft from transfer
case at companion flange. Remove rear propeller
shaft from vehicle. (Refer to 3 - DIFFERENTIAL &
DRIVELINE/PROPELLER SHAFT/PROPELLER
SHAFT - REMOVAL)
CAUTION: Do not allow propshafts to hang at
attached end. Damage to joint can result.
(8) Disconnect transfer case cable from range
lever.
(9) Disconnect transfer case vent hose (Fig. 5).
(10) Support transfer case with transmission jack.
(11) Secure transfer case to jack with chains.
(12) Remove nuts attaching transfer case to trans-
mission.
(13) Pull transfer case and jack rearward to disen-
gage transfer case (Fig. 5).
(14) Remove transfer case from under vehicle.
DISASSEMBLY
Position transfer case on shallow drain pan.
Remove drain plug and drain lubricant remaining in
case.
Fig. 4 Crossmember Removal
1 - CROSSMEMBER
2 - REAR TRANSMISSION MOUNT
WJTRANSFER CASE - NV247 21 - 317
TRANSFER CASE - NV247 (Continued)

REAR RETAINER AND OIL PUMP
(1) Remove rear retainer bolts (Fig. 6).
(2) Remove rear bearing locating ring access plug
(Fig. 7).(3) Loosen rear retainer with pry tool to break
sealer bead. Pry only against retainer boss as shown
(Fig. 8).
(4) Remove rear retainer as follows:
(a) Spread rear bearing locating ring with snap
ring pliers (Fig. 9).
(b) Then slide retainer off mainshaft and rear
bearing (Fig. 10).
Fig. 5 Transfer Case Mounting
1 - NV247 TRANSFER CASE
Fig. 6 Rear Retainer Bolt Removal
1 - REAR RETAINER
Fig. 7 Remove Rubber Access Plug
1 - PLUG
Fig. 8 Loosening Rear Retainer
1 - RETAINER BOSS
2-PRYTOOL
3 - SEALER BEAD
4 - REAR RETAINER
21 - 318 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)

(5) Remove rear bearing snap-ring.
(6) Remove rear bearing. Note position of bearing
locating ring groove for assembly reference.
(7) Disengage oil pickup tube from oil pump and
remove oil pump assembly (Fig. 11).
(8) Remove pick-up tube o-ring from oil pump (Fig.
12), if necessary. Do not disassemble the oil pump, it
is not serviceable.
COMPANION FLANGE AND RANGE LEVER
(1) Remove front companion flange nut as follows:
(a) Move range lever to 4L position.
(b) Remove nut with socket and impact wrench.
(2) Remove companion flange. If flange is difficult
to remove by hand, remove it with bearing splitter, orwith standard two jaw puller. Be sure puller tool is
positioned on flange and not on slinger as slinger will
be damaged.
(3) Remove seal washer from front output shaft.
Discard washer as it should not be reused.
(4) Remove nut and washer that attach range
lever to sector shaft. Then move sector to neutral
position and remove range lever from shaft.
NOTE: Note position of range lever so it can be re-
installed correctly.
Fig. 9 Disengaging Rear Bearing Locating Ring
1 - REAR RETAINER
2 - PARALLEL JAW SNAP-RING PLIERS
Fig. 10 Rear Retainer Removal
1 - REAR CASE
2 - REAR RETAINER
Fig. 11 Rear Bearing and Oil Pump Removal
1 - OIL PUMP
2 - TUBE O-RING
3 - OIL PICKUP TUBE
Fig. 12 Pick-up Tube O-ring Location
1 - OIL PUMP
2 - O-RING
WJTRANSFER CASE - NV247 21 - 319
TRANSFER CASE - NV247 (Continued)