2002 JEEP GRAND CHEROKEE Gear

(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)

(28) Remove the front 2C clutch pack snap-ring
from the transmission case (Fig. 24).
(29) Remove the 2C clutch pack from the transmis-
sion case (Fig. 24).
(30) Remove the rear selective plate and number 6
bearing from the reaction annulus (Fig. 25).
(31) Remove the reaction annulus from the reac-
tion planetary carrier (Fig. 25).
(32) Remove the number 7 bearing (Fig. 25).
(33) Remove the reaction sun gear (Fig. 25).
(34) Remove the number 8 bearing from the reac-
tion planetary carrier (Fig. 25).
(35) Remove the reaction planetary carrier (Fig.
25). Note that this planetary gear set has three pin-
ion gears.
(36) Remove the number 9 bearing from the
reverse planetary gear set (Fig. 25).
Fig. 24 Remove 2C Clutch Pack
1 - SNAP-RING
2 - PLATE
3 - DISC
4 - REACTION PLATE
Fig. 25 Remove Reaction Annulus and Carrier
1 - BEARING NUMBER 8 5 - BEARING NUMBER 7
2 - BEARING NUMBER 9 6 - THRUST PLATE (SELECT)
3 - REACTION PLANETARY CARRIER 7 - BEARING NUMBER 6
4 - REACTION SUN GEAR 8 - REACTION ANNULUS
21 - 188 AUTOMATIC TRANSMISSION - 545RFEWJ
AUTOMATIC TRANSMISSION - 545RFE (Continued)

(37) Remove the snap-ring holding the park sprag
gear onto the output shaft (Fig. 26).
(38) Remove the park sprag gear from the output
shaft (Fig. 27).
(39) Remove the input/reverse planetary assembly
(Fig. 28).
(40) Remove the number 12 bearing from the
input/reverse planetary assembly (Fig. 28).(41) Remove the snap-ring holding the low/reverse
clutch retainer into the transmission case (Fig. 29).
(42) Remove the low/reverse clutch retainer from
the transmission case (Fig. 29).
(43) Remove the park pawl rod and e-clip (Fig. 30).
(44) Remove the park pawl rod guide snap-ring
(Fig. 30).
(45) Remove the park pawl rod guide (Fig. 30).
(46) Remove the park pawl pivot shaft, park pawl,
and spring (Fig. 30).
(47) Remove the manual selector shaft (Fig. 30).
Fig. 26 Remove Park Sprag Snap-Ring
1 - SNAP-RING
Fig. 27 Remove Park Sprag Gear
1 - PARK SPRAG GEAR
Fig. 28 Remove Input/Reverse Planetary Assembly
1 - INPUT/REVERSE PLANETARY ASSEMBLY
2 - BEARING NUMBER 9
3 - BEARING NUMBER 12
Fig. 29 Remove Low/Reverse Clutch Retainer
1 - LOW/REVERSE OVERRUNNING CLUTCH ASSEMBLY
2 - SNAP-RING
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 189
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)

Fig. 40 Install Reaction Annulus and Carrier
1 - BEARING NUMBER 8 5 - BEARING NUMBER 7
2 - BEARING NUMBER 9 6 - THRUST PLATE (SELECT)
3 - REACTION PLANETARY CARRIER 7 - BEARING NUMBER 6
4 - REACTION SUN GEAR 8 - REACTION ANNULUS
Fig. 41 Thrust Plate Alignment
1 - LOCATING LUG (3)
2 - THRUST PLATE
Fig. 42 Install 4C Clutch Retainer/Bulkhead
1 - SNAP-RING
2 - 4C CLUTCH RETAINER/BULKHEAD
21 - 194 AUTOMATIC TRANSMISSION - 545RFEWJ
AUTOMATIC TRANSMISSION - 545RFE (Continued)

(5) Carefully insert converter in oil pump. Then
rotate converter back and forth until fully seated in
pump gears.
(6) Check converter seating with steel scale and
straightedge (Fig. 52). Surface of converter lugs
should be at least 13 mm (1/2 in.) to rear of straight-
edge when converter is fully seated.
(7) Temporarily secure converter with C-clamp.
(8) Position transmission on jack and secure it
with chains.
(9) Check condition of converter driveplate.
Replace the plate if cracked, distorted or damaged.
Also be sure transmission dowel pins are seated
in engine block and protrude far enough to
hold transmission in alignment.
(10) Apply a light coating of MopartHigh Temp
Grease to the torque converter hub pocket in the rear
pocket of the engine's crankshaft.
(11) Raise transmission and align the torque con-
verter with the drive plate and the transmission con-
verter housing with the engine block.
(12) Move transmission forward. Then raise, lower,
or tilt transmission to align the converter housing
with the engine block dowels.
(13) Carefully work transmission forward and over
engine block dowels until converter hub is seated in
crankshaft. Verify that no wires, or the transmission
vent hose, have become trapped between the engine
block and the transmission.
(14) Install two bolts to attach the transmission to
the engine.(15) Install remaining torque converter housing to
engine bolts. Tighten to 68 N´m (50 ft.lbs.).
(16) Install rear transmission crossmember.
Tighten crossmember to frame bolts to 68 N´m (50
ft.lbs.).
(17) Install rear support to transmission. Tighten
bolts to 47 N´m (35 ft.lbs.).
(18) Lower transmission onto crossmember and
install bolts attaching transmission mount to cross-
member. Tighten clevis bracket to crossmember bolts
to 47 N´m (35 ft.lbs.). Tighten the clevis bracket to
rear support bolt to 68 N´m (50 ft.lbs.).
(19) Remove engine support fixture.
(20) Install new plastic retainer grommet on any
shift cable that was disconnected. Grommets should
not be reused. Use pry tool to remove rod from grom-
met and cut away old grommet. Use pliers to snap
new grommet into cable and to snap grommet onto
lever.
(21) Connect gearshift cable to transmission.
(22) Connect wires to solenoid and pressure switch
assembly connector, input and output speed sensors,
and line pressure sensor. Be sure transmission har-
nesses are properly routed.
CAUTION: It is essential that correct length bolts be
used to attach the converter to the driveplate. Bolts
that are too long will damage the clutch surface
inside the converter.
(23) Install all torque converter-to-driveplate bolts
by hand.
(24) Verify that the torque converter is pulled
flush to the driveplate. Tighten bolts to 31 N´m (270
in. lbs.).
(25) Install starter motor and cooler line bracket.
(26) Connect cooler lines to transmission.
(27) Install transmission fill tube.
(28) Install exhaust components.
(29) Install transfer case. Tighten transfer case
nuts to 35 N´m (26 ft.lbs.).
(30) Install the transfer case shift cable to the
cable support bracket and the transfer case shift
lever.
(31) Install the transmission collar onto the trans-
mission and the engine. Tighten the bolts to 54 N´m
(40 ft.lbs.).
(32) Align and connect propeller shaft(s).
(33) Adjust gearshift cable if necessary.
(34) Lower vehicle.
(35) Fill transmission with MopartATF +4, type
9602, Automatic Transmission fluid.
Fig. 52 Checking Torque Converter Seating - Typical
1 - SCALE
2 - STRAIGHTEDGE
21 - 198 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)