2003 JEEP GRAND CHEROKEE Bolts

ASSEMBLY
(1) Clean and inspect all components. Make sure
that all passages are thoroughly cleaned and are free
from dirt or debris. Make sure that all valves move
freely in their proper bore. Make sure that all gear
pockets and bushings are free from excessive wear
and scoring. Replace the oil pump if any excessive
wear or scoring is found.
(2) Coat the gears with MopartATF +4, type 9602,
and install into their original locations.
(3) Lubricate the oil pump valves with Mopart
ATF +4, type 9602, and install the valve, spring and
retainer into the appropriate oil pump valve body
bore (Fig. 93) (Fig. 94).
(4) Place the separator plate onto the oil pump
body (Fig. 92).
(5) Install the screws to hold the separator plate
onto the oil pump body (Fig. 92). Tighten the screws
to 4.5 N´m (40 in.lbs.).
(6) Position the oil pump cover onto the locating
dowels (Fig. 91).
(7) Seat the two oil pump halves together and
install all bolts finger tight.
(8) Torque all bolts down slowly starting in the
center and working outward. The correct torque is
4.5 N´m (40 in.lbs.).
(9) Verify that the oil pump gears rotate freely and
smoothly.
(10) Position the reaction shaft support into the oil
pump (Fig. 91).
(11) Install and torque the bolts to hold the reac-
tion shaft support to the oil pump (Fig. 91). The cor-
rect torque is 12 N´m (105 in.lbs.).
OIL PUMP FRONT SEAL
REMOVAL
(1) Remove transmission from the vehicle.
(2) Remove the torque converter from the trans-
mission.
(3) Using a screw mounted in a slide hammer,
remove the oil pump front seal.
INSTALLATION
(1) Clean seal bore of the oil pump of any residue
or particles from the original seal.
(2) Install new oil seal in the oil pump housing
using Seal Installer C-3860-A (Fig. 95).
Fig. 95 Install Oil Pump Front Seal
1 - TOOL C-3860-A
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 253
OIL PUMP (Continued)

REMOVAL
(1) Remove the valve body from the transmission
(Fig. 119).
(2) Remove the screws holding the transmission
solenoid/TRS assembly onto the valve body (Fig. 120).
(3) Separate the transmission solenoid/TRS assem-
bly from the valve body.
INSTALLATION
(1) Place TRS selector plate in the PARK position.
(2) Position the transmission solenoid/TRS assem-
bly onto the valve body. Be sure that both alignment
dowels are fully seated in the valve body and that
the TRS switch contacts are properly positioned in
the selector plate
(3) Install the screws to hold the transmission
solenoid/TRS assembly onto the valve body.
(4) Tighten the solenoid assembly screws adjacent
to the arrows cast into the bottom of the valve body
first. Tighten the screws to 5.7 N´m (50 in.lbs.).
(5) Tighten the remainder of the solenoid assembly
screws to 5.7 N´m (50 in.lbs.).
(6) Install the valve body into the transmission.
TRANSMISSION
TEMPERATURE SENSOR
DESCRIPTION
The transmission temperature sensor is a ther-
mistor that is integral to the Transmission Range
Sensor (TRS).
OPERATION
The transmission temperature sensor is used by
the TCM to sense the temperature of the fluid in the
sump. Since fluid temperature can affect transmis-
sion shift quality and convertor lock up, the TCM
requires this information to determine which shift
schedule to operate in.
Calculated Temperature
A failure in the temperature sensor or circuit will
result in calculated temperature being substituted for
actual temperature. Calculated temperature is a pre-
dicted fluid temperature which is calculated from a
combination of inputs:
²Battery (ambient) temperature
²Engine coolant temperature
²In-gear run time since start-up
Fig. 119 Valve Body Bolts
1 - VALVE BODY TO CASE BOLT (6)
Fig. 120 Ttransmission Solenoid/TRS Assembly
Screws
1 - SOLENOID PACK BOLTS (15)
21 - 272 AUTOMATIC TRANSMISSION - 545RFEWJ
TRANSMISSION SOLENOID/TRS ASSEMBLY (Continued)

(7) Remove bolts attaching valve body to transmis-
sion case (Fig. 125).
(8) Lower the valve body and work the electrical
connector out of transmission case.
(9) Separate the valve body from the transmission.
DISASSEMBLY
(1) Remove the screws holding the solenoid and
pressure switch assembly to the valve body (Fig.
126). Do not remove the screws on the top of the sole-
noid and pressure switch assembly.
(2) Separate the solenoid and pressure switch
assembly from the valve body.
(3) Remove the screw holding the detent spring
(Fig. 127) onto the valve body.
(4) Remove the detent spring from the valve body.
(5) Remove the TRS selector plate from the valve
body and the manual valve.
(6) Remove the clutch passage seals from the valve
body, if necessary.
Fig. 125 Valve Body Bolts
1 - VALVE BODY TO CASE BOLT (6)
Fig. 126 Solenoid and Pressure Switch Assembly
Screws
1 - SOLENOID PACK BOLTS (15)
Fig. 127 Valve Body External Components
1 - TRS SELECTOR PLATE
2 - DETENT SPRING
3 - CLUTCH PASSAGE SEALS
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 275
VALVE BODY (Continued)

(8) Position the accumulator cover onto the valve
body.
(9) Install the screws to hold the accumulator
cover onto the valve body. Tighten the screws to 4.5
N´m (40 in. lbs.).
(10) Install the TRS selector plate onto the valve
body and the manual valve.
(11) Install the solenoid and pressure switch
assembly onto the valve body.
(12) Install the screws to hold the solenoid and
pressure switch assembly onto the valve body.
Tighten the screws to 5.7 N´m (50 in. lbs.). Tighten
the screws adjacent to the arrows cast into the bot-
tom of the transfer plate first.
(13) Position the detent spring onto the valve body.
(14) Install the screw to hold the detent spring
onto the valve body. Tighten the screw to 4.5 N´m (40
in. lbs.).
(15) Install new clutch passage seals onto the
valve body, if necessary
INSTALLATION
(1) Check condition of seals on valve body and the
solenoid and pressure switch assembly. Replace seals
if cut or worn.
(2) Place TRS selector plate in the PARK position.
(3) Place the transmission in the PARK position.
(4) Lubricate seal on the solenoid and pressure
switch assembly connector with petroleum jelly.(5) Position valve body in transmission and align
the manual lever on the valve body to the pin on the
transmission manual shift lever.
(6) Seat valve body in case and install one or two
bolts to hold valve body in place.
(7) Tighten valve body bolts alternately and evenly
to 12 N´m (105 in. lbs.) torque.
(8) 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.
(9) Place replacement filter in position on valve
body and into the oil pump.
(10) Install screw to hold filter to valve body.
Tighten screw to 4.5 N´m (40 in. lbs.) torque.
(11) Connect the solenoid and pressure switch
assembly connector.
(12) Install oil pan. Tighten pan bolts to 12 N´m
(105 in. lbs.) torque.
(13) Lower vehicle and fill transmission with
MopartATF +4, type 9602, fluid.
(14) Check and adjust gearshift cable, if necessary.
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 279
VALVE BODY (Continued)

TRANSFER CASE - NV242
TABLE OF CONTENTS
page page
TRANSFER CASE - NV242
DESCRIPTION........................280
OPERATION..........................281
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV242.......................281
REMOVAL............................282
DISASSEMBLY........................282
CLEANING...........................292
INSPECTION.........................293
ASSEMBLY...........................295
INSTALLATION........................307
SPECIFICATIONS
TRANSFER CASE - NV242.............308
SPECIAL TOOLS
TRANSFER CASE - NV242.............308
FLUID
STANDARD PROCEDURE - FLUID DRAIN/
REFILL............................310FRONT OUTPUT SHAFT SEAL
REMOVAL............................310
INSTALLATION........................310
POSITION SENSOR
DESCRIPTION........................311
OPERATION..........................311
REMOVAL............................312
INSTALLATION........................312
REAR RETAINER BUSHING AND SEAL -
NV242HD
REMOVAL............................312
INSTALLATION........................312
SHIFT CABLE
REMOVAL............................313
INSTALLATION........................313
TRANSFER CASE - NV242
DESCRIPTION
The NV242 is a full transfer case (Fig. 1). It pro-
vides full time 2-wheel, or 4-wheel drive operation.
A differential in the transfer case is used to control
torque transfer to the front and rear axles. A low
range gear provides increased low speed torque capa-
bility for off road operation. The low range provides a
2.72:1 reduction ratio.
The geartrain is mounted in two aluminum case
halves attached with bolts. The mainshaft front and
rear bearings are mounted in aluminum retainer
housings bolted to the case halves.
TRANSFER CASE IDENTIFICATION
Two versions of the NV242 are used in the WJ
vehicles, NV242LD and NV242HD. The two transfer
cases can be distinguished from one another by the
rear output shaft retainer. The NV242LD uses a rub-
ber boot to cover the rear output shaft, while the
NV242HD uses a cast aluminum housing. Other than
this difference, the two transfer cases are serviced
the same.
A circular ID tag is attached to the rear case of
each transfer case (Fig. 2). The ID tag provides the
transfer case model number, assembly number, serial
number, and low range ratio.The transfer case serial number also represents
the date of build.
SHIFT MECHANISM
Operating ranges are selected with a lever in the
floor mounted shifter assembly. The shift lever is con-
nected to the transfer case range lever by an adjust-
able cable. A straight line shift pattern is used.
Range positions are marked on the shifter bezel.
Fig. 1 NV242 Transfer Case
21 - 280 TRANSFER CASE - NV242WJ

(2) Using puller MD-998056-A, remove rear slinger
(Fig. 6).
(3) Remove rear seal from retainer (Fig. 7). Use
pry tool, or collapse seal with punch to remove it.(4) Remove rear output bearing I.D. retaining ring
(Fig. 8).
(5) Remove rear retainer bolts.
(6) Remove rear retainer. Tap retainer with mallet
and pry upward to break sealer bead. Then slide
retainer off case and output shaft (Fig. 9).
Fig. 6 Rear Slinger Removal
1 - TRANSFER CASE
2 - SPECIAL TOOL MD998056-A
3 - SLINGER
Fig. 7 Rear Retainer Seal
1 - REAR RETAINER
2 - OUTPUT SHAFT SEAL
Fig. 8 Output Shaft Rear Bearing Retaining Ring
1 - SNAP-RING PLIERS
2 - RETAINING RING
Fig. 9 Rear Retainer Removal
1 - MAINSHAFT
2 - REAR RETAINER
WJTRANSFER CASE - NV242 21 - 283
TRANSFER CASE - NV242 (Continued)

REAR RETAINER - NV242HD
(1) Remove extension housing bolts.
(2) Tap extension housing with plastic or rawhide
mallet to loosen sealer (Fig. 10).
(3) Separate extension housing from rear retainer.
(4) Remove rear bearing snap-ring (Fig. 11).
(5) Remove bolts holding rear retainer to rear case
half.
(6) Loosen rear retainer with pry tool to break
sealer bead. Pry only against retainer boss as shown
(Fig. 12).
(7) Slide retainer off case and output shaft (Fig.
13).
OIL PUMP AND REAR CASE HALF
(1) Remove rear bearing O.D. retaining ring with
snap ring pliers. Then tilt pump and slide it off out-
put shaft (Fig. 14)
(2) Remove pickup tube O-ring from pump (Fig.
15) but do not disassemble pump; it is not a repair-
able part.
(3) Remove seal from oil pump with pry tool.
(4) Remove bolts attaching rear case to front case
(Fig. 16). Note position of the two black finish bolts
at each end of the case. These bolts go through the
case dowels and require a washer under the bolt
head.
Fig. 10 Remove Extension Housing
1 - EXTENSION HOUSING
2 - PLASTIC HAMMER
3 - REAR RETAINER
Fig. 11 Remove the Output Bearing Snap-ring
1 - REAR RETAINER
2 - SNAP-RING
3 - REAR BEARING
Fig. 12 Loosening Rear Retainer
1 - REAR RETAINER
2-TAB(2)
3 - SCREWDRIVER
4-TAB
Fig. 13 Rear Retainer Removal
1 - MAINSHAFT
2 - REAR RETAINER
21 - 284 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

(5) Remove rear case from front case (Fig. 17).
Insert screwdrivers into slots cast into each end of
case. Then pry upward to break sealer bead and
remove rear case.
CAUTION: Do not pry on the sealing surface of
either case half as the surfaces will become dam-
aged.
(6) Remove oil pickup tube and screen from rear
case (Fig. 18).
Fig. 14 Oil Pump Removal
1 - OIL PUMP
Fig. 15 Pickup Tube O-Ring Location
1 - OIL PUMP
2 - O-RING
Fig. 16 Spline And Dowel Bolt Locations
1 - DOWEL BOLT AND WASHER (2)
2 - CASE BOLTS
3 - SPLINE HEAD BOLT (1)
Fig. 17 Loosening/Removing Rear Case
1 - MAINSHAFT
2 - SCREWDRIVER
3 - FRONT CASE
4 - SCREWDRIVER
5 - REAR CASE
Fig. 18 Oil Pickup Screen, Hose And Tube Removal
1 - CONNECTING HOSE
2 - PICKUP SCREEN
3 - PICKUP TUBE
WJTRANSFER CASE - NV242 21 - 285
TRANSFER CASE - NV242 (Continued)