2002 JEEP GRAND CHEROKEE Air filter assembly

CONDITION POSSIBLE CAUSES CORRECTION
SHIFTS DELAYED OR
ERRATIC (SHIFTS
ALSO HARSH AT
TIMES)1. Fluid Level Low/High. 1. Correct fluid level and check for leaks if low.
2. Fluid Filter Clogged. 2. Replace filter. If filter and fluid contained clutch
material or metal particles, an overhaul may be
necessary. Perform lube flow test.
3. Throttle Linkage Mis-adjusted. 3. Adjust linkage as described in service section.
4. Throttle Linkage Binding. 4. Check cable for binding. Check for return to
closed throttle at transmission.
5. Gearshift Linkage/Cable
Mis-adjusted.5. Adjust linkage/cable as described in service
section.
6. Clutch or Servo Failure. 6. Remove valve body and air test clutch, and
band servo operation. Disassemble and repair
transmission as needed.
7. Governor Circuit Electrical Fault. 7. Test using DRBTscan tool and repair as
required.
8. Front Band Mis-adjusted. 8. Adjust band.
9. Pump Suction Passage Leak. 9. Check for excessive foam on dipstick after
normal driving. Check for loose pump bolts,
defective gasket. Replace pump assembly if
needed.
NO REVERSE (D
RANGES OK)1. Gearshift Linkage/Cable
Mis-adjusted/Damaged.1. Repair or replace linkage parts as needed.
2. Park Sprag Sticking. 2. Replace overdrive annulus gear.
3. Rear Band Mis-adjusted/Worn. 3. Adjust band; replace.
4. Valve Body Malfunction. 4. Remove and service valve body. Replace valve
body if any valves or valve bores are worn or
damaged.
5. Rear Servo Malfunction. 5. Remove and disassemble transmission.
Replace worn/damaged servo parts as necessary.
6. Direct Clutch in Overdrive Worn. 6. Disassemble overdrive. Replace worn or
damaged parts.
7. Front Clutch Burnt. 7. Remove and disassemble transmission.
Replace worn, damaged clutch parts as required.
HAS FIRST/REVERSE
ONLY (NO 1-2 OR 2-3
UPSHIFT)1. Governor Circuit Electrical Fault. 1. Test using DRBTscan tool and repair as
required.
2. Valve Body Malfunction. 2. Repair stuck 1-2 shift valve or governor plug.
3. Front Servo/Kickdown Band
Damaged/Burned.3. Repair/replace.
MOVES IN 2ND OR
3RD GEAR,
ABRUPTLY
DOWNSHIFTS TO
LOW1. Valve Body Malfunction. 1. Remove, clean and inspect. Look for stuck 1-2
valve or governor plug.
WJAUTOMATIC TRANSMISSION - 42RE 21 - 19
AUTOMATIC TRANSMISSION - 42RE (Continued)

CONDITION POSSIBLE CAUSES CORRECTION
BUZZING NOISE 1. Fluid Level Low 1. Add fluid and check for leaks.
2. Shift Cable Mis-assembled. 2. Route cable away from engine and bell
housing.
3. Valve Body Mis-assembled. 3. Remove, disassemble, inspect valve body.
Reassemble correctly if necessary. Replace
assembly if valves or springs are damaged.
Check for loose bolts or screws.
4. Pump Passages Leaking. 4. Check pump for porous casting, scores on
mating surfaces and excess rotor clearance.
Repair as required. Loose pump bolts.
5. Cooling System Cooler Plugged. 5. Flow check cooler circuit. Repair as needed.
6. Overrunning Clutch Damaged. 6. Replace clutch.
SLIPS IN REVERSE
ONLY1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Gearshift Linkage Mis-adjusted. 2. Adjust linkage.
3. Rear Band Mis-adjusted. 3. Adjust band.
4. Rear Band Worn. 4. Replace as required.
5. Overdrive Direct Clutch Worn. 5. Disassemble overdrive. Repair as needed.
6. Hydraulic Pressure Too Low. 6. Perform hydraulic pressure tests to determine
cause.
7. Rear Servo Leaking. 7. Air pressure check clutch-servo operation and
repair as required.
8. Band Linkage Binding. 8. Inspect and repair as required.
SLIPS IN FORWARD
DRIVE RANGES1. Fluid Level Low. 1. Add fluid and check for leaks.
2. Fluid Foaming. 2. Check for high oil level, bad pump gasket or
seals, dirt between pump halves and loose pump
bolts. Replace pump if necessary.
3. Throttle Linkage Mis-adjusted. 3. Adjust linkage.
4. Gearshift Linkage Mis-adjusted. 4. Adjust linkage.
5. Rear Clutch Worn. 5. Inspect and replace as needed.
6. Low Hydraulic Pressure Due to
Worn Pump, Incorrect Control
Pressure Adjustments, Valve Body
Warpage or Malfunction, Sticking,
Leaking Seal Rings, Clutch Seals
Leaking, Servo Leaks, Clogged
Filter or Cooler Lines.6. Perform hydraulic and air pressure tests to
determine cause.
7. Rear Clutch Malfunction,
Leaking Seals or Worn Plates.7. Air pressure check clutch-servo operation and
repair as required.
8. Overrunning Clutch Worn, Not
Holding (Slips in 1 Only).8. Replace Clutch.
SLIPS IN LOW GEAR
9D9ONLY, BUT NOT
IN MANUAL 1
POSITIONOverrunning Clutch Faulty. Replace overrunning clutch.
WJAUTOMATIC TRANSMISSION - 42RE 21 - 21
AUTOMATIC TRANSMISSION - 42RE (Continued)

GEAR CASE AND PARK LOCK
(1) Remove locating ring from gear case.
(2) Remove park pawl shaft retaining bolt and
remove shaft, pawl and spring.
(3) Remove reaction plug snap-ring and remove
reaction plug.
(4) Remove output shaft seal.
CLEANING
Clean the geartrain and case components with sol-
vent. Dry all parts except the bearings with com-
pressed air. Allow bearings to air dry.
Do not use shop towels for wiping parts dry unless
the towels are made from a lint-free material. A suf-
ficient quantity of lint (from shop towels, cloths, rags,
etc.) could plug the transmission filter and fluid pas-
sages.
Discard the old case gasket and seals. Do not
attempt to salvage these parts. They are not reus-
able. Replace any of the overdrive unit snap-rings if
distorted or damaged.
Minor nicks or scratches on components can be
smoothed with crocus cloth. However, do not attempt
to reduce severe scoring on any components with
abrasive materials. Replace severely scored compo-
nents; do not try to salvage them.
INSPECTION
Check condition of the park lock components and
the overdrive case.
Check the bushings in the overdrive case. Replace
the bushings if severely scored or worn. Also replace
the case seal if loose, distorted, or damaged.
Examine the overdrive and direct clutch discs and
plates. Replace the discs if the facing is worn,
severely scored, or burned and flaking off. Replace
the clutch plates if worn, heavily scored, or cracked.
Check the lugs on the clutch plates for wear. The
plates should slide freely in the drum. Replace the
plates or drum if binding occurs.
Check condition of the annulus gear, direct clutch
hub, clutch drum and clutch spring. Replace the gear,
hub and drum if worn or damaged. Replace the
spring if collapsed, distorted, or cracked.
Be sure the splines and lugs on the gear, drum and
hub are in good condition. The clutch plates and
discs should slide freely in these components.
Inspect the thrust bearings and spring plate.
Replace the plate if worn or scored. Replace the bear-
ings if rough, noisy, brinnelled, or worn.
Inspect the planetary gear assembly and the sun
gear and bushings. If either the sun gear or the
bushings are damaged, replace the gear and bush-
ings as an assembly. The gear and bushings are not
serviced separately.The planetary carrier and pinions must be in good
condition. Also be sure the pinion pins are secure and
in good condition. Replace the carrier if worn or dam-
aged.
Inspect the overrunning clutch and race. The race
surface should be smooth and free of scores. Replace
the overrunning clutch assembly or the race if either
assembly is worn or damaged in any way.
Replace the shaft pilot bushing and inner bushing
if damaged. Replace either shaft bearing if rough or
noisy. Replace the bearing snap-rings if distorted or
cracked.
Check the machined surfaces on the output shaft.
These surfaces should clean and smooth. Very minor
nicks or scratches can be smoothed with crocus cloth.
Replace the shaft if worn, scored or damaged in any
way.
Inspect the output shaft bushings. The small bush-
ing is the intermediate shaft pilot bushing. The large
bushing is the overrunning clutch hub bushing.
Replace either bushing if scored, pitted, cracked, or
worn.
ASSEMBLY
GEARTRAIN AND DIRECT CLUTCH
(1) Soak direct clutch and overdrive clutch discs in
MopartATF +4, type 9602, transmission fluid. Allow
discs to soak for 10-20 minutes.
(2) Install new pilot bushing and clutch hub bush-
ing in output shaft if necessary (Fig. 155). Lubricate
bushings with petroleum jelly, or transmission fluid.
(3) Install annulus gear on output shaft, if
removed. Then install annulus gear retaining snap-
ring (Fig. 156).
Fig. 155 Output Shaft Pilot Bushing
1 - OUTPUT SHAFT HUB
2 - OVERRUNNING CLUTCH HUB BUSHING
3 - INTERMEDIATE SHAFT PILOT BUSHING
WJAUTOMATIC TRANSMISSION - 42RE 21 - 95
OVERDRIVE UNIT (Continued)

VALVE BODY LOWER HOUSING
(1) Remove timing valve cover.
(2) Remove 3-4 timing valve and spring.
(3) Remove 3-4 quick fill valve, spring and plug.
(4) Remove 3-4 shift valve and spring.
(5) Remove converter clutch valve, spring and plug
(Fig. 309).
(6) Remove converter clutch timing valve, retainer
and valve spring.
3-4 ACCUMULATOR HOUSING
(1) Remove end plate from housing.
(2) Remove piston spring.
(3) Remove piston. Remove and discard piston
seals (Fig. 310).
CLEANING
Clean the valve housings, valves, plugs, springs,
and separator plates with a standard parts cleaning
solution only. Do not use gasoline, kerosene, or any
type of caustic solution.
Do not immerse any of the electrical components in
cleaning solution. Clean the governor solenoid and
sensor and the dual solenoid and harness assembly
by wiping them off with dry shop towels only.
Dry all except the electrical parts with compressed
air. Make sure all passages are clean and free from
obstructions.Do not use rags or shop towels to
dry or wipe off valve body components. Lint
from these materials can stick to valve body
parts, interfere with valve operation, and clog
filters and fluid passages.
Fig. 309 Lower Housing Shift Valves and Springs
1 - 3-4 ACCUMULATOR HOUSING 11 - TIMING VALVE COVER
2 - 3-4 SHIFT VALVE AND SPRING 12 - PLUG
3 - PLUG 13 - 3-4 TIMING VALVE AND SPRING
4 - SPRING RETAINER 14 - LOWER HOUSING
5 - CONVERTER CLUTCH VALVE AND SPRING 15 - ACCUMULATOR END PLATE
6 - CONVERTER CLUTCH TIMING VALVE AND SPRING 16 - 3-4 ACCUMULATOR PISTON AND SPRING
7 - OVERDRIVE SEPARATOR PLATE 17 - E-CLIP
8 - CASE CONNECTOR 18 - 3-4 QUICK FILL SPRING AND VALVE
9 - CONVERTER CLUTCH SOLENOID 19 - SOLENOID GASKET
10 - OVERDRIVE SOLENOID 20 - HARNESS
WJAUTOMATIC TRANSMISSION - 42RE 21 - 165
VALVE BODY (Continued)

GOVERNOR BODY, SENSOR AND SOLENOID
(1) Turn valve body assembly over so accumulator
side of transfer plate is facing down.
(2) Install new O-rings on governor pressure sole-
noid and sensor.
(3) Lubricate solenoid and sensor O-rings with
clean transmission fluid.
(4) Install governor pressure sensor in governor
body.
(5) Install governor pressure solenoid in governor
body. Push solenoid in until it snaps into place in
body.
(6) Position governor body gasket on transfer
plate.
(7) Install retainer plate on governor body and
around solenoid. Be sure solenoid connector is posi-
tioned in retainer cutout.
(8) Align screw holes in governor body and trans-
fer plate. Then install and tighten governor body
screws to 4 N´m (35 in. lbs.) torque.
(9) Connect harness wires to governor pressure
solenoid and governor pressure sensor.
(10) Install fluid filter and pan.
(11) Lower vehicle.
(12) Fill transmission with recommended fluid and
road test vehicle to verify repair.
INSTALLATION
(1) Check condition of O-ring seals on valve body
harness connector (Fig. 330). Replace seals on con-
nector body if cut or worn.
(2) Check condition of manual lever shaft seal in
transmission case. Replace seal if lip is cut or worn.
Install new seal with 15/16 deep well socket (Fig.
331).
(3) Check condition of seals on accumulator piston
(Fig. 332). Install new piston seals, if necessary.
(4) Place valve body manual lever in low (1 posi-
tion) so ball on park lock rod will be easier to install
in sprag.
(5) Lubricate shaft of manual lever with petroleum
jelly. This will ease inserting shaft through seal in
case.
(6) Lubricate seal rings on valve body harness con-
nector with petroleum jelly.
(7) Position valve body in case and work end of
park lock rod into and through pawl sprag. Turn pro-
peller shaft to align sprag and park lock teeth if nec-
essary. The rod will click as it enters pawl. Move rod
to check engagement.
CAUTION: It is possible for the park rod to displace
into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into this cavity.(8) Install accumulator springs and piston into
case. Then swing valve body over piston and outer
spring to hold it in place.
(9) Align accumulator piston and outer spring,
manual lever shaft and electrical connector in case.
(10) Then seat valve body in case and install one
or two bolts to hold valve body in place.
(11) Tighten valve body bolts alternately and
evenly to 11 N´m (100 in. lbs.) torque.
(12) Install new fluid filter on valve body. Tighten
filter screws to 4 N´m (35 in. lbs.) torque.
(13) Install throttle and gearshift levers on valve
body manual lever shaft.
(14) Check and adjust front and rear bands if nec-
essary.
(15) Connect solenoid case connector wires.
(16) Install oil pan and new gasket. Tighten pan
bolts to 13.6 N´m (125 in. lbs.) torque.
(17) Lower vehicle and fill transmission with
MopartATF +4, type 9602, fluid.
(18) Check and adjust gearshift and throttle valve
cables, if necessary.
ADJUSTMENTS - VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the
valve body;
²Line Pressure
²Throttle Pressure
Line and throttle pressures are interdependent
because each affects shift quality and timing. As a
result, both adjustments must be performed properly
and in the correct sequence. Adjust line pressure first
and throttle pressure last.
Fig. 330 Valve Body Harness Connector O-Ring Seal
1 - CONNECTOR O-RINGS
2 - VALVE BODY HARNESS CONNECTOR
3 - HARNESS
WJAUTOMATIC TRANSMISSION - 42RE 21 - 175
VALVE BODY (Continued)

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

TRANSMISSION IDENTIFICATION
Transmission identification numbers are stamped
on the left side of the case just above the oil pan
sealing surface (Fig. 1). Refer to this information
when ordering replacement parts. A label is attached
to the transmission case above the stamped numbers.
The label gives additional information which may
also be necessary for identification purposes.
GEAR RATIOS The 545RFE gear ratios are:
1st .................................3.00:1
2nd.................................1.67:1
2nd Prime............................1.50:1
3rd .................................1.00:1
4th .................................0.75:1
5th .................................0.67:1
Reverse..............................3.00:1
OPERATION
The 545RFE offers full electronic control of all auto-
matic up and downshifts, and features real-time adap-
tive closed-loop shift and pressure control. Electronic
shift and torque converter clutch controls help protect
the transmission from damage due to high tempera-
tures, which can occur under severe operating condi-
tions. By altering shift schedules, line pressure, and
converter clutch control, these controls reduce heat gen-
eration and increase transmission cooling.
To help reduce efficiency-robbing parasitic losses,
the transmission includes a dual-stage transmission
fluid pump with electronic output pressure control.
Under most driving conditions, pump output pres-
sure greatly exceeds that which is needed to keep the
clutches applied. The 545RFE pump-pressure controlsystem monitors input torque and adjusts the pump
pressure accordingly. The primary stage of the pump
works continuously; the second stage is bypassed
when demand is low. The control system also moni-
tors input and output speed and, if incipient clutch
slip is observed, the pressure control solenoid duty
cycle is varied, increasing pressure in proportion to
demand.
A high-travel torque converter damper assembly
allows earlier torque converter clutch engagement to
reduce slippage. Needle-type thrust bearings reduce
internal friction. The 545RFE is packaged in a one-
piece die-cast aluminum case. To reduce NVH, the
case has high lateral, vertical and torsional stiffness.
It is also designed to maximize the benefit of the
structural dust cover that connects the bottom of the
bell housing to the engine bedplate, enhancing over-
all power train stiffness. Dual filters protect the
pump and other components. A pump return filter is
added to the customary main sump filter. Indepen-
dent lubrication and cooler circuits assure ample
pressure for normal transmission operation even if
the cooler is obstructed or the fluid cannot flow due
to extremely low temperatures.
The hydraulic control system design (without elec-
tronic assist) provides the transmission with PARK,
REVERSE, NEUTRAL, SECOND, and THIRD gears,
based solely on driver shift lever selection. This
design allows the vehicle to be driven (in ªlimp-inº
mode) in the event of a electronic control system fail-
ure, or a situation that the Transmission Control
Module (TCM) recognizes as potentially damaging to
the transmission.
The TCM also performs certain self-diagnostic
functions and provides comprehensive information
(sensor data, DTC's, etc.) which is helpful in proper
diagnosis and repair. This information can be viewed
with the DRB scan tool.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION
CAUTION: Before attempting any repair on a
545RFE automatic transmission, check for Diagnos-
tic Trouble Codes with the DRBTscan tool.
Transmission malfunctions may be caused by these
general conditions:
²Poor engine performance
²Improper adjustments
²Hydraulic malfunctions
²Mechanical malfunctions
²Electronic malfunctions
Fig. 1 Transmission Part And Serial Number
Location
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 179
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)