2003 JEEP GRAND CHEROKEE Workshop Manual

seat adjustment gas tank size turn signal bulb fuse box location flat tire steering

Load previous 8 pages

Page 1713 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual 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 S

Page 1714 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual (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.

Page 1715 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual (45) Using Adapter 8266-1 from End-Play Tool Set
8266 and Dial Indicator C-3339, measure and record
the input shaft end-play (Fig. 46). The correct end-
play is 0.46-0.89 mm (0.018-0.035 in.). Adjust

Page 1716 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual (51) Install a new primary oil filter seal in the oil
pump inlet bore. Seat the seal in the bore with the
butt end of a hammer, or other suitable tool.
CAUTION: The primary oil filter seal MUST be ful

(51) Install a new primary oil filter seal in the oil
pump inlet bore. Seat the seal in the bore with the
butt end of a hammer, or other suitable tool.
CAUTION: The primary oil filter seal MUST be fully
installed flush against the oil pump body. DO NOT
install the seal onto the filter neck and attempt to
install the filter and seal as an assembly. Damage to
the transmission will result.
(52) Install the primary oil filter and the oil cooler
return filter (Fig. 50). Tighten the screw to hold the
primary oil filter to the valve body to 4.5 N´m (40
in.lbs.). Using Oil Filter Wrench 8321, tighten the
cooler return oil filter to the transmission case to 14
N´m (125 in.lbs.).
(53) Apply RTV silicone to the oil pan and install
the transmission oil pan. Tighten the bolts to 12 N´m
(105 in.lbs.).
(54) Install the input, output, and line pressure
sensors (Fig. 51). Tighten the bolts to 12 N´m (105
in.lbs.).
(55) Install the manual shift lever from the trans-
mission. Torque the retaining cross-bolt to 16 N´m
(140 in.lbs.).
INSTALLATION
(1) Check torque converter hub and hub drive flats
for sharp edges burrs, scratches, or nicks. Polish the
hub and flats with 320/400 grit paper and crocus
cloth if necessary. Verify that the converter hub
o-ring is properly installed and is free of any debris.
The hub must be smooth to avoid damaging pump
seal at installation.(2) If a replacement transmission is being
installed, transfer any components necessary, such as
the manual shift lever and shift cable bracket, from
the original transmission onto the replacement trans-
mission.
(3) Lubricate oil pump seal lip with transmission
fluid.
(4) Align converter and oil pump.
Fig. 49 Install Valve Body Assembly
1 - VALVE BODY TO CASE BOLT (6)
Fig. 50 Install Primary Oil and Cooler Filters
1 - PRIMARY OIL FILTER
2 - COOLER RETURN FILTER
3 - COOLER RETURN FILTER BYPASS VALVE
4 - VALVE BODY
Fig. 51 Install Input, Output, and Line Pressure
Sensors
1 - OUTPUT SPEED SENSOR
2 - LINE PRESSURE SENSOR
3 - INPUT SPEED SENSOR
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 197
AUTOMATIC TRANSMISSION - 545RFE (Continued)

Page 1717 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual (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 c

(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)

Page 1718 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual SCHEMATICS AND DIAGRAMS
HYDRAULIC SCHEMATICS
545RFE HYDRAULIC SCHEMATIC
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 199
AUTOMATIC TRANSMISSION - 545RFE (Continued)

Page 1719 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual 545RFE HYDRAULIC SCHEMATIC
21 - 200 AUTOMATIC TRANSMISSION - 545RFEWJ
AUTOMATIC TRANSMISSION - 545RFE (Continued)

Page 1720 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual 545RFE HYDRAULIC SCHEMATIC
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 201
AUTOMATIC TRANSMISSION - 545RFE (Continued)

Load next 8 pages

Page: < prev 1-10 ... 1681-1688 1689-1696 1697-1704 1705-1712 1713-1720 1721-1728 1729-1736 1737-1744 1745-1752 ... 2200 next >

brake rotor battery check engine light weight tire pressure reset ground clearance