2002 JEEP GRAND CHEROKEE head

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

(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)

(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)

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)

(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)

4C RETAINER/BULKHEAD
DISASSEMBLY
(1) Remove the 2C piston belleville spring snap-
ring from the 4C retainer /bulkhead (Fig. 53).
(2) Remove the 2C piston Belleville spring from
the retainer/bulkhead (Fig. 53).
(3) Remove the 2C piston from the retainer/bulk-
head. Use 20 psi of air pressure to remove the piston
if necessary.
(4) Remove the 4C clutch snap-ring from the
retainer/bulkhead (Fig. 53).
(5) Remove the 4C clutch pack from the retainer/
bulkhead (Fig. 53).
(6) Using Spring Compressor 8250 and a suitable
shop press, compress the 4C piston return spring and
remove the snap-ring (Fig. 53).(7) Remove the 4C piston return spring and piston
from the retainer/bulkhead (Fig. 53). Use 20 psi of
air pressure to remove the piston if necessary.ASSEMBLY
(1) Clean and inspect all components. Replace any
components which show evidence of excessive wear
or scoring.
(2) Install new seals on the 2C and 4C pistons
(Fig. 53).
(3) Lubricate all seals with MopartATF +4, type
9602 prior to installation.
(4) Install the 4C piston into the 4C retainer/bulk-
head (Fig. 53).
(5) Position the 4C piston return spring onto the
4C piston.
Fig. 53 4C Retainer/Bulkhead Components
1 - SEAL 8 - REACTION PLATE
2 - 2C PISTON 9 - SNAP-RING
3 - PLATE 10 - RETURN SPRING
4 - DISC 11 - SEAL
5 - 2C BELLEVILLE SPRING 12 - 4C PISTON
6 - SNAP-RING 13 - 4C RETAINER/BULKHEAD
7 - SNAP-RING (SELECT)
21 - 224 AUTOMATIC TRANSMISSION - 545RFEWJ