2003 JEEP GRAND CHEROKEE Bolts

CAUTION: Be sure the shoulder on the inside diam-
eter of the bearing is facing forward.
(8) Verify that splines in overdrive planetary gear
and overrunning clutch hub are aligned with Align-
ment Tool 6227-2. Overdrive unit cannot be installed
if splines are not aligned. If splines have rotated out
of alignment, unit will have to be disassembled to
realign splines.
(9) Carefully slide Alignment Tool 6227-2 out of
overdrive planetary gear and overrunning clutch
splines.
(10) Raise overdrive unit and carefully slide it
straight onto intermediate shaft. Insert park rod into
park lock reaction plug at same time. Avoid tilting
overdrive during installation as this could cause
planetary gear and overrunning clutch splines to
rotate out of alignment. If this occurs, it will be nec-essary to remove and disassemble overdrive unit to
realign splines.
(11) Work overdrive unit forward on intermediate
shaft until seated against transmission case.
(12) Install bolts attaching overdrive unit to trans-
mission unit. Tighten bolts in diagonal pattern to 34
N´m (25 ft-lbs).
(13) Connect the transmission speed sensor and
overdrive wiring connectors.
(14) Install the transfer case, if equipped.
(15) Align and install rear propeller shaft, if nec-
essary. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
PROPELLER SHAFT/PROPELLER SHAFT -
INSTALLATION)
OVERRUNNING CLUTCH
CAM/OVERDRIVE PISTON
RETAINER
DESCRIPTION
The overrunning clutch (Fig. 189) consists of an
inner race, an outer race (or cam), rollers and
springs, and the spring retainer. The number of roll-
ers and springs depends on what transmission and
which overrunning clutch is being dealt with.
OPERATION
As the inner race is rotated in a clockwise direction
(as viewed from the front of the transmission), the
race causes the rollers to roll toward the springs,
causing them to compress against their retainer. The
compression of the springs increases the clearance
Fig. 187 Trimming Overdrive Case Gasket
1 - GASKET
2 - SHARP KNIFE
Fig. 188 Intermediate Shaft Selective Spacer
Location
1 - SELECTIVE SPACER
2 - SPACER GROOVE
3 - INTERMEDIATE SHAFT
Fig. 189 Overrunning Clutch
1 - OUTER RACE (CAM)
2 - ROLLER
3 - SPRING
4 - SPRING RETAINER
5 - INNER RACE (HUB)
WJAUTOMATIC TRANSMISSION - 42RE 21 - 105
OVERDRIVE UNIT (Continued)

between the rollers and cam. This increased clear-
ance between the rollers and cam results in a free-
wheeling condition. When the inner race attempts to
rotate counterclockwise, the action causes the rollers
to roll in the same direction as the race, aided by the
pushing of the springs. As the rollers try to move in
the same direction as the inner race, they are
wedged between the inner and outer races due to the
design of the cam. In this condition, the clutch is
locked and acts as one unit.
DISASSEMBLY
NOTE: To service the overrunning clutch cam and
the overdrive piston retainer, the transmission
geartrain and the overdrive unit must be removed
from the transmission.
(1) Remove the overdrive piston (Fig. 190).
(2) Remove the overdrive piston retainer bolts.
(3) Remove overdrive piston retainer.
(4) Remove case gasket.
(5) Mark the position of the overrunning clutch
cam in the case (Fig. 191).
(6) Remove the overrunning clutch cam bolts.
(7) Remove the overrunning clutch cam.
CLEANING
Clean the overrunning clutch assembly, clutch cam,
low-reverse drum, and overdrive piston retainer in
solvent. Dry them with compressed air after clean-
ing.
INSPECTION
Inspect condition of each clutch part after cleaning.
Replace the overrunning clutch roller and spring
assembly if any rollers or springs are worn or dam-
aged, or if the roller cage is distorted, or damaged.
Replace the cam if worn, cracked or damaged.
Replace the low-reverse drum if the clutch race,
roller surface or inside diameter is scored, worn or
damaged.Do not remove the clutch race from
the low-reverse drum under any circumstances.
Replace the drum and race as an assembly if
either component is damaged.
Examine the overdrive piston retainer carefully for
wear, cracks, scoring or other damage. Be sure the
retainer hub is a snug fit in the case and drum.
Replace the retainer if worn or damaged.
ASSEMBLY
(1) Examine bolt holes in overrunning clutch cam.
Note that one hole isnot threaded(Fig. 192). This
hole must align with blank area in clutch cam bolt
circle (Fig. 193). Mark hole location on clutch cam
and blank area in case with grease pencil, paint
stripe, or scribe mark for assembly reference.
(2) Mark location of non-threaded hole in clutch
cam and blank area in bolt circle with grease pencil.
(3) Align and install overrunning clutch and cam
in case (Fig. 194). Be sure cam is correctly installed.
Bolt holes in cam are slightly countersunk on one
side. Be sure this side of cam faces rearward (toward
piston retainer).
(4) Verify that non-threaded hole in clutch cam is
properly aligned. Check alignment by threading a
bolt into each bolt hole. Adjust clutch cam position if
necessary.
Fig. 190 Overdrive Piston Removal
1 - OVERDRIVE CLUTCH PISTON
2 - INTERMEDIATE SHAFT
3 - SELECTIVE SPACER
4 - PISTON RETAINER
Fig. 191 Overrunning Clutch Cam Removal
1 - ALIGN MARKS IDENTIFYING NON-THREADED HOLE IN
CAM AND CASE
2 - OVERRUNNING CLUTCH ASSEMBLY
21 - 106 AUTOMATIC TRANSMISSION - 42REWJ
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)

(5) Install and tighten overrunning clutch cam
bolts to 17 N´m (13 ft. lbs.) torque. Note that clutch
cam bolts are shorter than piston retainer bolts.
(6) Install new gasket at rear of transmission case.
Use petroleum jelly to hold gasket in place. Be sure
to align governor feed holes in gasket with feed pas-
sages in case (Fig. 195). Also install gasket before
overdrive piston retainer. Center hole in gasket is
smaller than retainer and cannot be installed over
retainer.(7) Position overdrive piston retainer on transmis-
sion case and align bolt holes in retainer, gasket and
case (Fig. 196). Then install and tighten retainer
bolts to 17 N´m (13 ft. lbs.) torque.
Fig. 192 Location Of Non-Threaded Hole In Clutch
Cam
1 - NON-THREADED HOLE
2 - OVERRUNNING CLUTCH CAM
Fig. 193 Location Of Blank Area In Clutch Cam Bolt
Circle
1 - OVERRUNNING CLUTCH CAM SEAT IN CASE
2 - NON-THREADED HOLE IN CLUTCH CAM ALIGNS HERE
(BLANK AREA) OF SEAT
Fig. 194 Overrunning Clutch Installation
1 - ALIGN MARKS IDENTIFYING NON-THREADED HOLE IN
CAM AND CASE
2 - OVERRUNNING CLUTCH ASSEMBLY
Fig. 195 Installing/Aligning Case Gasket
1 - CASE GASKET
2 - BE SURE GOVERNOR TUBE FEED HOLES IN CASE AND
GASKET ARE ALIGNED
WJAUTOMATIC TRANSMISSION - 42RE 21 - 107
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)

(8) Install new seals on over drive piston.
(9) Stand transmission case upright on bellhous-
ing.
(10) Position Guide Ring 8114-1 on outer edge of
overdrive piston retainer.
(11) Position Seal Guide 8114-2 on inner edge of
overdrive piston retainer.
(12) Install overdrive piston in overdrive piston
retainer by: aligning locating lugs on overdrive piston
to the two mating holes in retainer.
(a) Aligning locating lugs on overdrive piston to
the two mating holes in retainer.
(b) Lubricate overdrive piston seals with Mopart
Door Ease, or equivalent.
(c) Install piston over Seal Guide 8114-2 and
inside Guide Ring 8114-1.
(d) Push overdrive piston into position in
retainer.
(e) Verify that the locating lugs entered the lug
bores in the retainer.
NOTE: Install the remaining transmission compo-
nents and the overdrive unit.
PARK LOCK CABLE
REMOVAL
(1) Place the shifter in the PARK position.
(2) Lower the steering column cover.
(3) With the ignition switch in the ªRUNº position
depress the park lock cable locking tab, located on
top of the cable connector at the steering column and
pull the park lock cable straight out.
(4) Remove the park lock cable from steering col-
umn (Fig. 197).
(5) Remove the floor console and related trim.
(Refer to 23 - BODY/INTERIOR/FLOOR CONSOLE -
REMOVAL)
(6) Disconnect the park lock cable from the shift
BTSI lever and remove the cable from the shifter
assembly bracket.
(7) Release the park lock cable from any remaining
clips.
(8) Remove park lock cable from the vehicle.
INSTALLATION
NOTE: The gearshift cable must be secured into
position and properly adjusted before the installa-
tion of the Park Lock Cable.
(1) Verify that the shifter is in the PARK position.
(2) Push the park lock cable straight into the
square mounting hole in the steering column until
cable snaps in place.
(3) Route park lock cable to the shifter mecha-
nism.
(4) Install the park lock cable end fitting into
shifter BTSI lever.
(5) Pull rearward on the cable housing to snap
park lock cable adjuster ears into floor shifter
bracket.
(6) Place the ignition key cylinder in the ACCES-
SORY position.
(7) Push the cable adjuster lock clamp downward
to lock it.
(8) Test the park lock cable operation.
(9) Install the floor console and related trim.
(Refer to 23 - BODY/INTERIOR/FLOOR CONSOLE -
INSTALLATION)
Fig. 196 Aligning Overdrive Piston Retainer
1 - PISTON RETAINER
2 - GASKET
3 - RETAINER BOLTS
21 - 108 AUTOMATIC TRANSMISSION - 42REWJ
OVERRUNNING CLUTCH CAM/OVERDRIVE PISTON RETAINER (Continued)

BOOST VALVE
The boost valve (Fig. 277) provides increased fluid
apply pressure to the overdrive clutch during 3-4
upshifts (Fig. 278), and when accelerating in fourth
gear. The boost valve also serves to increase line
pressure during torque converter lock-up.
REMOVAL
The valve body can be removed for service without
having to remove the transmission assembly.
The valve body can be disassembled for cleaning
and inspection of the individual components.
The only replaceable valve body components are:
²Manual lever.
²Manual lever washer, seal, E-clip, and shaft
seal.
²Manual lever detent ball.
²Throttle lever.
²Fluid filter.
²Pressure adjusting screw bracket.
²Governor pressure solenoid.
²Governor pressure sensor (includes transmission
temperature thermistor).
²Converter clutch/overdrive solenoid assembly
and harness.
²Governor housing gasket.
²Solenoid case connector O-rings.
(1) Shift transmission into NEUTRAL.
(2) Raise vehicle.
(3) Remove gearshift and throttle levers from shaft
of valve body manual lever.
(4) Disconnect wires at solenoid case connector
(Fig. 279).
(5) Position drain pan under transmission oil pan.
(6) Remove transmission oil pan and gasket.
(7) Remove fluid filter from valve body.
(8) Remove bolts attaching valve body to transmis-
sion case.
(9) Lower valve body enough to remove accumula-
tor piston and springs.
(10) Work manual lever shaft and electrical con-
nector out of transmission case.
(11) Lower valve body, rotate valve body away
from case, pull park rod out of sprag, and remove
valve body (Fig. 280).
Fig. 277 Boost Valve Before Lock-up
Fig. 278 Boost Valve After Lock-up
Fig. 279 Transmission Case Connector
1 - SOLENOID CASE CONNECTOR
2 - PARK/NEUTRAL POSITION SWITCH
21 - 154 AUTOMATIC TRANSMISSION - 42REWJ
VALVE BODY (Continued)

GOVERNOR BODY, SENSOR AND SOLENOID
(1) Turn valve body assembly over so accumulator
side of transfer plate is facing down.
(2) Install new O-rings on governor pressure sole-
noid and sensor.
(3) Lubricate solenoid and sensor O-rings with
clean transmission fluid.
(4) Install governor pressure sensor in governor
body.
(5) Install governor pressure solenoid in governor
body. Push solenoid in until it snaps into place in
body.
(6) Position governor body gasket on transfer
plate.
(7) Install retainer plate on governor body and
around solenoid. Be sure solenoid connector is posi-
tioned in retainer cutout.
(8) Align screw holes in governor body and trans-
fer plate. Then install and tighten governor body
screws to 4 N´m (35 in. lbs.) torque.
(9) Connect harness wires to governor pressure
solenoid and governor pressure sensor.
(10) Install fluid filter and pan.
(11) Lower vehicle.
(12) Fill transmission with recommended fluid and
road test vehicle to verify repair.
INSTALLATION
(1) Check condition of O-ring seals on valve body
harness connector (Fig. 330). Replace seals on con-
nector body if cut or worn.
(2) Check condition of manual lever shaft seal in
transmission case. Replace seal if lip is cut or worn.
Install new seal with 15/16 deep well socket (Fig.
331).
(3) Check condition of seals on accumulator piston
(Fig. 332). Install new piston seals, if necessary.
(4) Place valve body manual lever in low (1 posi-
tion) so ball on park lock rod will be easier to install
in sprag.
(5) Lubricate shaft of manual lever with petroleum
jelly. This will ease inserting shaft through seal in
case.
(6) Lubricate seal rings on valve body harness con-
nector with petroleum jelly.
(7) Position valve body in case and work end of
park lock rod into and through pawl sprag. Turn pro-
peller shaft to align sprag and park lock teeth if nec-
essary. The rod will click as it enters pawl. Move rod
to check engagement.
CAUTION: It is possible for the park rod to displace
into a cavity just above the pawl sprag during
installation. Make sure the rod is actually engaged
in the pawl and has not displaced into this cavity.(8) Install accumulator springs and piston into
case. Then swing valve body over piston and outer
spring to hold it in place.
(9) Align accumulator piston and outer spring,
manual lever shaft and electrical connector in case.
(10) Then seat valve body in case and install one
or two bolts to hold valve body in place.
(11) Tighten valve body bolts alternately and
evenly to 11 N´m (100 in. lbs.) torque.
(12) Install new fluid filter on valve body. Tighten
filter screws to 4 N´m (35 in. lbs.) torque.
(13) Install throttle and gearshift levers on valve
body manual lever shaft.
(14) Check and adjust front and rear bands if nec-
essary.
(15) Connect solenoid case connector wires.
(16) Install oil pan and new gasket. Tighten pan
bolts to 13.6 N´m (125 in. lbs.) torque.
(17) Lower vehicle and fill transmission with
MopartATF +4, type 9602, fluid.
(18) Check and adjust gearshift and throttle valve
cables, if necessary.
ADJUSTMENTS - VALVE BODY
CONTROL PRESSURE ADJUSTMENTS
There are two control pressure adjustments on the
valve body;
²Line Pressure
²Throttle Pressure
Line and throttle pressures are interdependent
because each affects shift quality and timing. As a
result, both adjustments must be performed properly
and in the correct sequence. Adjust line pressure first
and throttle pressure last.
Fig. 330 Valve Body Harness Connector O-Ring Seal
1 - CONNECTOR O-RINGS
2 - VALVE BODY HARNESS CONNECTOR
3 - HARNESS
WJAUTOMATIC TRANSMISSION - 42RE 21 - 175
VALVE BODY (Continued)

TORQUE CONVERTER LEAK POINTS
Possible sources of converter leaks are:
(1) Leaks at the weld joint around the outside
diameter weld (Fig. 7).
(2) Leaks at the converter hub weld (Fig. 7).
STANDARD PROCEDURE - ALUMINUM
THREAD REPAIR
Damaged or worn threads in the aluminum trans-
mission case and valve body can be repaired by the
use of Heli-CoilsŸ, or equivalent. This repair con-
sists of drilling out the worn-out damaged threads.
Then tap the hole with a special Heli-CoilŸ tap, or
equivalent, and installing a Heli-CoilŸ insert, or
equivalent, into the hole. This brings the hole back to
its original thread size.
Heli-CoilŸ, or equivalent, tools and inserts are
readily available from most automotive parts suppli-
ers.
REMOVAL
CAUTION: The transmission and torque converter
must be removed as an assembly to avoid compo-
nent damage. The converter driveplate, converter
hub o-ring, or oil seal can be damaged if the con-
verter is left attached to the driveplate during
removal. Be sure to remove the transmission and
converter as an assembly.
(1) Disconnect the negative battery cable.
(2) Raise and support the vehicle
(3) Mark propeller shaft and axle yokes for assem-
bly alignment.
(4) Remove the rear propeller shaft
(5) Remove the front propeller shaft.
(6) Remove the engine to transmission collar (Fig.
8).
(7) Remove the exhaust support bracket from the
rear of the transmission.
(8) Disconnect and lower or remove any necessary
exhaust components.
(9) Remove the starter motor.
(10) Rotate crankshaft in clockwise direction until
converter bolts are accessible. Then remove bolts one
at a time. Rotate crankshaft with socket wrench on
dampener bolt.
(11) Disconnect wires from solenoid and pressure
switch assembly, input and output speed sensors, and
line pressure sensor.
Fig. 7 Torque Converter Assembly
1 - TURBINE ASSEMBLY
2-STATOR
3 - CONVERTER HUB
4 - O-RING
5 - IMPELLER ASSEMBLY
6 - CONVERTER CLUTCH PISTON
7 - TURBINE HUB
Fig. 8 Transmission Collar
1 - ENGINE
2 - ENGINE TO TRANSMISSION COLLAR
3 - TRANSMISSION
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 183
AUTOMATIC TRANSMISSION - 545RFE (Continued)

(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)