2002 JEEP GRAND CHEROKEE reverse

(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)

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)

(8) Engine starts must be possible with shifter
lever in PARK or NEUTRAL gate positions only.
Engine starts must not be possible in any other gate
positions other than PARK or NEUTRAL.
(9) With shifter lever handle push-button not
depressed and lever detent in:
²PARK position- apply forward force on center of
handle and remove pressure. Engine start must be
possible.
²PARK position- apply rearward force on center
of handle and remove pressure. Engine start must be
possible.
²NEUTRAL position- engine start must be possi-
ble.
²NEUTRAL position, engine running and brakes
applied- Apply forward force on center of shift han-
dle. Transmission should not be able to shift into
REVERSE detent.
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL
A low fluid level allows the pump to take in air
along with the fluid. Air in the fluid will cause fluid
pressures to be low and develop slower than normal.
If the transmission is overfilled, the gears churn the
fluid into foam. This aerates the fluid and causing
the same conditions occurring with a low level. In
either case, air bubbles cause fluid overheating, oxi-
dation and varnish buildup which interferes with
valve and clutch operation. Foaming also causes fluid
expansion which can result in fluid overflow from the
transmission vent or fill tube. Fluid overflow can eas-
ily be mistaken for a leak if inspection is not careful.
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID
Burnt, discolored fluid is a result of overheating
which has three primary causes.
(1) Internal clutch slippage, usually caused by low
line pressure, inadequate clutch apply pressure, or
clutch seal failure.
(2) A result of restricted fluid flow through the
main and/or auxiliary cooler. This condition is usu-
ally the result of a faulty or improperly installed
drainback valve, a damaged main cooler, or severe
restrictions in the coolers and lines caused by debris
or kinked lines.(3) Heavy duty operation with a vehicle not prop-
erly equipped for this type of operation. Trailer tow-
ing or similar high load operation will overheat the
transmission fluid if the vehicle is improperly
equipped. Such vehicles should have an auxiliary
transmission fluid cooler, a heavy duty cooling sys-
tem, and the engine/axle ratio combination needed to
handle heavy loads.
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION
Transmission fluid contamination is generally a
result of:
²adding incorrect fluid
²failure to clean dipstick and fill tube when
checking level
²engine coolant entering the fluid
²internal failure that generates debris
²overheat that generates sludge (fluid break-
down)
²failure to reverse flush cooler and lines after
repair
²failure to replace contaminated converter after
repair
The use of non-recommended fluids can result in
transmission failure. The usual results are erratic
shifts, slippage, abnormal wear and eventual failure
due to fluid breakdown and sludge formation. Avoid
this condition by using recommended fluids only.
The dipstick cap and fill tube should be wiped
clean before checking fluid level. Dirt, grease and
other foreign material on the cap and tube could fall
into the tube if not removed beforehand. Take the
time to wipe the cap and tube clean before withdraw-
ing the dipstick.
Engine coolant in the transmission fluid is gener-
ally caused by a cooler malfunction. The only remedy
is to replace the radiator as the cooler in the radiator
is not a serviceable part. If coolant has circulated
through the transmission, an overhaul is necessary.
The transmission cooler and lines should be
reverse flushed whenever a malfunction generates
sludge and/or debris. The torque converter should
also be replaced at the same time.
Failure to flush the cooler and lines will result in
recontamination. Flushing applies to auxiliary cool-
ers as well. The torque converter should also be
replaced whenever a failure generates sludge and
debris. This is necessary because normal converter
flushing procedures will not remove all contami-
nants.
21 - 228 AUTOMATIC TRANSMISSION - 545RFEWJ
BRAKE TRANSMISSION SHIFT INTERLOCK MECHANISM (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)

GEARSHIFT CABLE
DIAGNOSIS AND TESTING - GEARSHIFT
CABLE
(1) The floor shifter lever and gate positions
should be in alignment with all transmission PARK,
NEUTRAL, and gear detent positions.
(2) Engine starts must be possible with floor shift
lever in PARK or NEUTRAL gate positions only.
Engine starts must not be possible in any other gear
position.
(3) With floor shift lever handle push-button not
depressed and lever in:
(a) PARK position - Apply forward force on cen-
ter of handle and remove pressure. Engine starts
must be possible.
(b) PARK position - Apply rearward force on cen-
ter of handle and remove pressure. Engine starts
must be possible.
(c) NEUTRAL position - Normal position. Engine
starts must be possible.
(d) NEUTRAL position - Engine running and
brakes applied, apply forward force on center of
shift handle. Transmission shall not be able to shift
from NEUTRAL to REVERSE.
REMOVAL
(1) Shift transmission into PARK.
(2) Raise vehicle.
(3) Remove the shift cable eyelet from the trans-
mission manual shift lever (Fig. 61).
(4) Remove shift cable from the cable support
bracket.
(5) Lower vehicle.(6) Remove necessary console parts for access to
shift lever assembly and shift cable. (Refer to 23 -
BODY/INTERIOR/FLOOR CONSOLE - REMOVAL)
(7) Disconnect cable at shift lever and shifter
assembly bracket (Fig. 62).
(8) Remove the nuts holding the shift cable seal
plate to the floor pan (Fig. 63).
(9) Pull cable through floor panel opening.
(10) Remove shift cable from vehicle.
INSTALLATION
(1) Route cable through hole in floor pan.
(2) Install seal plate to studs in floor pan.
Fig. 61 Remove Shift Cable From Transmission
1 - SHIFT CABLE
2 - MANUAL LEVER
3 - MANUAL LEVER
Fig. 62 Transmission Shift Cable at Shifter
1 - SHIFT LEVER PIN
2 - ADJUSTMENT SCREW
3 - SHIFT CABLE
4 - SHIFTER ASSEMBLY BRACKET
Fig. 63 Shift Cables at Floor Pan
1 - SEAL PLATES
2 - TRANSMISSION SHIFT CABLE
3 - TRANSFER CASE SHIFT CABLE
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 231

HOLDING CLUTCHES
DESCRIPTION
Three hydraulically applied multi-disc clutches are
used to hold some planetary geartrain components
stationary while the input clutches drive others. The
2C, 4C, and Low/Reverse clutches are considered
holding clutches. The 2C and 4C clutches are located
in the 4C retainer/bulkhead (Fig. 66), while the Low/
Reverse clutch is located at the rear of the transmis-
sion case (Fig. 67).
Fig. 66 2C and 4C Clutches
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)
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 233