2003 JEEP GRAND CHEROKEE Workshop Manual

ECU interior lights fuse chart maintenance brake sensor air filter

Page 1513 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual SPECIAL TOOLS
POWER STEERING PUMP
FLUID COOLER
DESCRIPTION
4.7L models of this vehicle are equipped with a
cooler for the power steering system fluid. The power
steering fluid cooler is located at the

Page 1514 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual INSTALLATION
(1) Position and install the power steering cooler
to the vehicle.
(2) Install the three mounting bracket bolts (Fig.
6).
(3) Reconnect the upper hose at cooler (Fig. 6).
(4) Reconnect th

INSTALLATION
(1) Position and install the power steering cooler
to the vehicle.
(2) Install the three mounting bracket bolts (Fig.
6).
(3) Reconnect the upper hose at cooler (Fig. 6).
(4) Reconnect the lower hose at cooler (Fig. 6).
(5) Connect negative battery cable to battery.
(6) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
(7) Start engine and check for leaks.
(8) Install the grille opening reinforcement panel
(9) Install the front fascia grille,(Refer to 13 -
FRAMES & BUMPERS/BUMPERS/FRONT FASCIA
- INSTALLATION).
HOSES - 4.0L
DESCRIPTION
DESCRIPTION - PRESSURE LINE
The hose consists of two metal ends and rubber
center section that contains a tuning cable. The
pump end uses a quick connect fitting. Lubircation
must be used on the quick connect nut and o-ring
when installing.
DESCRIPTION - RETURN LINE
Power steering return line is a hose which is
clamped at the pump and the gear.
OPERATION
OPERATION - PRESSURE LINE
Power steering pressure line, is used to transfer
high pressure power steering fluid, from the power
steering pump to the power steering gear on the
4.0L. The 4.7L power steering pressure line, is used
to transfer high pressure power steering fluid, from
the power steering pump to the engine cooling fan
and the steering gear.
OPERATION - RETURN LINE
Power steering return line, is used to transfer low
pressure power steering fluid, from the power steer-
ing gear to the power steering pump.
REMOVAL
(1) Drain the power steering fluid from the reser-
voir.
(2) Remove the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(3) Disconnect the power steering pressure hose
from the power steering pump and then the power
steering gear (Fig. 7).
(4) Disconnect the power steering return hose from
the power steering cooler and the reservoir.
(5) Remove the hoses from the vehicle.
INSTALLATION
(1) Install the hoses to the vehicle.
(2) Reconnect the power steering return hose to
the power steering cooler and the reservoir.
(3) Reconnect the power steering pressure hose to
the power steering pump and then the power steer-
ing gear.
(4) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(5) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
Fig. 7 POWER STEERING HOSES
1 - RETURN HOSE
2 - HIGH PRESSURE HOSE
3 - STEERING GEAR
WJPUMP 19 - 37
FLUID COOLER (Continued)

Page 1515 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual HOSES - 4.7L
DESCRIPTION
DESCRIPTION - 1/2º PRESSURE HOSE
The hose consists of two metal ends and a rubber
center with quick connect nuts at both ends. The
hose connects the power steering pump to th

Page 1516 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual OPERATION - 3/8º PRESSURE HOSE
High pressure power steering fluid is transmitted
from the hydraulic fan motor to the steering gear by
the 3/8º steering line.
OPERATION - 3/8º GEAR OUTLET HOSE
The g

OPERATION - 3/8º PRESSURE HOSE
High pressure power steering fluid is transmitted
from the hydraulic fan motor to the steering gear by
the 3/8º steering line.
OPERATION - 3/8º GEAR OUTLET HOSE
The gear outlet hose transmits power steering fluid
under moderate low pressure to the power steering
cooler inlet tube.
OPERATION - 3/8ºRETURN HOSE
Low pressure power steering fluid is transmitted
from the steering cooler back to the power steering
pump by the 3/8º return hose.
REMOVAL
REMOVAL - 1/2(PRESSURE HOSE
(1)Drain the power steering fluid from the reservoir.
(2) Remove the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(3) Raise and support the vehicle.
(4) Remove the metal skid plate.
(5) Disconnect the high pressure hose from the
hydraulic fan motor (Fig. 8).
(6) Disconnect the high pressure hose from the
power steering pump (Fig. 8).
(7) Remove the hose from the clipped position on
the fan shroud.
(8) Remove the hose from the vehicle.
REMOVAL - 1/2(RETURN HOSE
(1) Drain the power steering fluid from the reser-
voir.
(2) Remove the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(3) Raise and support the vehicle.
(4) Remove the metal skid plate.
(5) Disconnect the rubber return hose from the
hydraulic fan motor (Fig. 9).
(6) Disconnect the rubber return hose from the
power steering reservoir .
(7) Remove the hose from the vehicle.
REMOVAL - 3/8(PRESSURE HOSE
(1) Drain the power steering fluid from the reser-
voir.
(2) Remove the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(3) Raise and support the vehicle.
(4) Remove the metal skid plate.
(5) Disconnect the high pressure hose from the
hydraulic fan motor (Fig. 10).
(6) Disconnect the high pressure hose from the
power steering gear (Fig. 10).
(7) Remove the hose from the clipped position on
the fan shroud.
(8) Remove the hose from the vehicle.
REMOVAL - 3/8(RETURN HOSE
(1) Drain the power steering fluid from the reser-
voir.
(2) Remove the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(3) Raise and support the vehicle.
(4) Disconnect the rubber hose from the steering
cooler outlet tube (Fig. 12).
Fig. 11 3/8(GEAR OUTLET HOSE
1 - HOSE CLAMP
2 - 3/89GEARR OUTLET HOSE
Fig. 12 3/8(RETURN HOSE
1 - HOSE CLAMP
2 - 3/89RETURN HOSE
3 - HYDRAULIC COOLING FAN MOTOR
WJPUMP 19 - 39
HOSES - 4.7L (Continued)

Page 1517 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual (5) Disconnect the rubber hose from the power
steering reservoir (Fig. 12).
(6) Remove the hose from the vehicle.
REMOVAL - 3/8(GEAR OUTLET HOSE
(1) Drain the power steering fluid from the reser-
voir

(5) Disconnect the rubber hose from the power
steering reservoir (Fig. 12).
(6) Remove the hose from the vehicle.
REMOVAL - 3/8(GEAR OUTLET HOSE
(1) Drain the power steering fluid from the reser-
voir.
(2) Remove the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(3) Raise and support the vehicle.
(4) Disconnect the rubber hose from the steering
cooler inlet tube (Fig. 11).
(5) Disconnect the metal tube from the power
steering gear (Fig. 11).
(6) Remove the hose from the vehicle.
REMOVAL - INLET COOLER HOSE
(1) Disconnect negative battery cable at battery.
(2) Drain the power steering fluid out of the reser-
voir.
(3) Remove the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(4) Remove the front fascia grille assembly,(Refer
to 13 - FRAMES & BUMPERS/BUMPERS/FRONT
FASCIA - REMOVAL).
(5) Remove the grille opening reinforcement panel
(6) Place a drain pan under the cooler.
(7) Disconnect the lower hose at cooler (Fig. 6).
(8) Disconnect the cooler hose at the gear.
(9) Remove the bracket holding the cooler hoses
(Fig. 13).
(10) Remove the cooler hose from the vehicle.
REMOVAL - OUTLET COOLER HOSE
(1) Disconnect negative battery cable at battery.
(2) Drain the power steering fluid out of the reser-
voir.
(3) Remove the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
(4) Remove the front fascia grille assembly,(Refer
to 13 - FRAMES & BUMPERS/BUMPERS/FRONT
FASCIA - REMOVAL).
(5) Remove the grille opening reinforcement panel
(6) Place a drain pan under the cooler.
(7) Disconnect the upper hose at cooler (Fig. 6).
(8) Disconnect the cooler hose at the reservoir.
(9) Remove the bracket holding the cooler hoses
(Fig. 13).
(10) Remove the cooler hose from the vehicle.
INSTALLATION
INSTALLATION - 1/2(PRESSURE HOSE
NOTE: Lubrication and a new o-ring must be used
when reinstalling.
(1) Install the hoses to the vehicle.
(2) Reconnect the high pressure hose to the power
steering pump (Fig. 8) Tighten the hose to 22.5 N´m
(17 ft.lbs.).
(3) Reconnect the high pressure hose to the
hydraulic fan motor (Fig. 8) Tighten the hose to 22.5
N´m (17 ft.lbs.).
(4) Install the hose to the clipped position on the
fan shroud.
(5) Install the metal skid plate.
(6) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(7) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
INSTALLATION - 1/2(RETURN HOSE
(1) Install the hoses to the vehicle.
(2) Reconnect the rubber return hose to the power
steering reservoir (Fig. 9) Tighten the hose clamp.
(3) Reconnect the rubber return hose to the
hydraulic fan motor (Fig. 9) Tighten the hose.
(4) Install the metal skid plate.
(5) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(6) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
Fig. 13 COOLER HOSES MOUNTING BRACKET
1 - RADIATOR
2 - COOLER HOSES MOUNTING BRACKET
2 - COOLER HOSE
19 - 40 PUMPWJ
HOSES - 4.7L (Continued)

Page 1518 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual INSTALLATION - 3/8(PRESSURE HOSE
NOTE: Lubrication and a new o-ring must be used
when reinstalling.
(1) Install the hoses to the vehicle.
(2) Reconnect the high pressure hose to the
hydraulic fan moto

INSTALLATION - 3/8(PRESSURE HOSE
NOTE: Lubrication and a new o-ring must be used
when reinstalling.
(1) Install the hoses to the vehicle.
(2) Reconnect the high pressure hose to the
hydraulic fan motor (Fig. 10) Tighten the hose to
22.5 N´m (17 ft.lbs.).
(3) Reconnect the high pressure hose to the power
steering gear (Fig. 10) Tighten the hose to 22.5 N´m
(17 ft.lbs.).
(4) Install the hose to the clipped position on the
fan shroud.
(5) Install the metal skid plate.
(6) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(7) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
INSTALLATION - 3/8(RETURN HOSE
(1) Install the hoses to the vehicle.
(2) Reconnect the rubber hose to the steering
cooler outlet tube (Fig. 12) Tighten the hose clamp.
(3) Reconnect the rubber hose to the power steer-
ing reservoir (Fig. 12) Tighten the hose clamp.
(4) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(5) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
INSTALLATION - 3/8(GEAR OUTLET HOSE
NOTE: Lubrication and a new o-ring must be used
when reinstalling.
(1) Install the hoses to the vehicle.
(2) Reconnect the rubber hose to the steering
cooler inlet tube (Fig. 11) Tighten the hose clamp.
(3)
Reconnect the metal tube to the power steering
gear (Fig. 11) Tighten the hose to 22.5 N´m (17 ft.lbs.).
(4) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(5) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
INSTALLATION - INLET COOLER HOSE
(1) Install the cooler hose to the vehicle.
(2) Reconnect the cooler hose at the gear.
(3) Reconnect the lower hose at cooler (Fig. 6).
Tighten the hose to 22.5 N´m (17 ft.lbs.)
(4) Install the bracket holding the cooler hoses
(Fig. 13).(5) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(6) Install the grille opening reinforcement panel
(7) Install the front fascia grille assembly, (Refer to
13 - FRAMES & BUMPERS/BUMPERS/FRONT
FASCIA - INSTALLATION).
(8) Reconnect negative battery cable at battery.
(9) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
INSTALLATION - OUTLET COOLER HOSE
(1) Install the cooler hose to the vehicle.
(2) Reconnect the cooler hose at the reservoir.
(3) Reconnect the upper hose at the cooler (Fig. 6).
Tighten the hose to 22.5 N´m (17 ft. lbs.)
(4) Install the bracket holding the cooler hoses
(Fig. 13). Tighten the bracket to 22.5 N´m (17 ft. lbs.)
(5) Install the air box,(Refer to 9 - ENGINE/AIR
INTAKE SYSTEM/AIR CLEANER HOUSING -
INSTALLATION).
(6) Install the grille opening reinforcement panel
(7) Install the front fascia grille assembly, (Refer to
13 - FRAMES & BUMPERS/BUMPERS/FRONT
FASCIA - INSTALLATION).
(8) Reconnect negative battery cable at battery.
(9) Refill the power steering fluid and bleed the
system,(Refer to 19 - STEERING/PUMP - STAN-
DARD PROCEDURE).
PULLEY
DESCRIPTION
POWER STEERING PUMP PULLEY - 3.1L
DIESEL
To service the power steering pump pulley on the
3.1L turbo diesel engine. Refer to the power steering
pump removal and installation procedure in this
group. The pulley must be removed to service the
pump assembly. Detailed instructions are provided in
the pump procedure.
REMOVAL
CAUTION: On vehicles equipped with the 4.0L or
4.7L, Do not reuse the old power steering pump
pulley it is not intended for reuse. A new pulley
must be installed if removed.
(1) Remove pump assembly.
(2) Remove pulley from pump with Puller C-4333
or equivalent puller (Fig. 14).
WJPUMP 19 - 41
HOSES - 4.7L (Continued)

Page 1519 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual INSTALLATION
NOTE: The pulley is marked front for installation.
CAUTION: On vehicles equipped with the 4.0L or
4.7L, Do not reuse the old power steering pump
pulley it is not intended for reuse. A new

Page 1520 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 42RE..........1
AUTOMATIC TRANSMISSION - 545RFE......177TRANSFER CASE - NV242................280
TRANSFER CASE - NV2

TRANSMISSION AND TRANSFER CASE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 42RE..........1
AUTOMATIC TRANSMISSION - 545RFE......177TRANSFER CASE - NV242................280
TRANSFER CASE - NV247................315
AUTOMATIC TRANSMISSION - 42RE
TABLE OF CONTENTS
page page
AUTOMATIC TRANSMISSION - 42RE
DESCRIPTION..........................3
OPERATION............................5
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - AUTOMATIC
TRANSMISSION......................11
DIAGNOSIS AND TESTING - PRELIMINARY . 11
DIAGNOSIS AND TESTING - ROAD
TESTING............................11
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TEST.....................12
DIAGNOSIS AND TESTING - AIR CHECKING
TRANSMISSION CLUTCH AND BAND
OPERATION.........................15
DIAGNOSIS AND TESTING - CONVERTER
HOUSING FLUID LEAK.................15
DIAGNOSIS AND TESTING - DIAGNOSIS
CHARTS............................16
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR......................26
REMOVAL.............................27
DISASSEMBLY.........................29
CLEANING............................34
INSPECTION..........................34
ASSEMBLY............................34
INSTALLATION.........................41
SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS..............43
SPECIFICATIONS
TRANSMISSION......................55
SPECIAL TOOLS
RE TRANSMISSIONS..................57
ACCUMULATOR
DESCRIPTION.........................60
OPERATION...........................60
INSPECTION..........................60BANDS
DESCRIPTION.........................61
OPERATION...........................61
ADJUSTMENTS
ADJUSTMENT - BANDS................62
BRAKE TRANSMISSION SHIFT INTERLOCK
MECHANISM
DESCRIPTION.........................63
OPERATION...........................63
DIAGNOSIS AND TESTING - BRAKE
TRANSMISSION SHIFT INTERLOCK.......63
ADJUSTMENTS - BRAKE TRANSMISSION
SHIFT INTERLOCK....................64
ELECTRONIC GOVERNOR
DESCRIPTION.........................65
OPERATION...........................65
REMOVAL.............................67
INSTALLATION.........................67
EXTENSION HOUSING BUSHING
REMOVAL.............................68
INSTALLATION.........................68
EXTENSION HOUSING SEAL
REMOVAL.............................69
INSTALLATION.........................69
FLUID AND FILTER
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EFFECTS OF
INCORRECT FLUID LEVEL..............69
DIAGNOSIS AND TESTING - CAUSES OF
BURNT FLUID........................69
DIAGNOSIS AND TESTING - FLUID
CONTAMINATION.....................70
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
CHECK.............................70
WJTRANSMISSION AND TRANSFER CASE 21 - 1

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