2003 JEEP GRAND CHEROKEE Input speed sensor

(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
0.22-0.55 mm (0.009-0.021 in.). Adjust as necessary.
Install the chosen output shaft selective thrust plate
and re-measure end-play to verify selection.
(38) Apply a bead of RTV silicone and install the
extension/adapter housing onto the transmission
case.
(39) Install and torque the bolts to hold the exten-
sion/adapter housing onto the transmission case. The
correct torque is 54 N´m (40 ft.lbs.).
(40) Install the number 5 bearing and selective
thrust plate onto the 4C retainer/bulkhead (Fig. 44).
Be sure that the outer race of the bearing is against
the thrust plate.
(41) Install the input clutch assembly into the
transmission case (Fig. 44). Make sure that the input
clutch assembly is fully installed by performing a
visual inspection through the input speed sensor
hole. If the tone wheel teeth on the input clutch
assembly are centered in the hole, the assembly is
fully installed.
(42) Install the number 1 bearing with the outer
race up in the pocket of the input clutch assembly
(Fig. 44).(43) Install the oil pump into the transmission
case (Fig. 45).
(44) Install the bolts to hold the oil pump into the
transmission case. Tighten the oil pump bolts to 28
N´m (250 in.lbs.).
Fig. 43 Measure Output Shaft End Play
1 - TOOL 8261
2 - TOOL 8266
3 - TOOL C-3339
Fig. 44 Install Input Clutch Assembly
1 - BEARING NUMBER 5
2 - THRUST PLATE (SELECT)
3 - INPUT CLUTCH ASSEMBLY
4 - BEARING NUMBER 1
Fig. 45 Install Oil Pump
1 - OIL PUMP TO CASE BOLT (6)
2 - OIL PUMP
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 195
AUTOMATIC TRANSMISSION - 545RFE (Continued)

(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)

(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)

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)

(23) Install the reverse clutch pack into the input
clutch retainer (Fig. 77).
(24) Install the reverse reaction plate into the
input clutch retainer.
(25) Install the reverse reaction plate selective
snap-ring into the input clutch retainer.
(26) Mount a dial indicator to the assembly, push
down on the clutch discs, pull up on the reaction
plate to ensure the plate is properly seated and zero
the indicator against the reverse clutch discs (Fig.
81). Apply 20 psi of air pressure to the reverse clutch
and record the dial indicator reading. Measure and
record Reverse clutch pack measurement in four (4)
places, 90É apart. Take average of four measurements
and compare with Reverse clutch pack clearance
specification. The correct clutch clearance is 0.58-1.47
mm (0.023-0.058 in.). Adjust as necessary. Install the
chosen snap-ring and re-measure to verify selection.
(27) Remove the reverse clutch pack from the
input clutch retainer.
(28) Install the number 2 bearing onto the under-
drive hub with outer race against the hub with petro-
leum jelly.
(29) Install the underdrive hub into the input
clutch retainer.
(30) Install the number 3 bearing into the over-
drive hub with the outer race against the hub with
petroleum jelly.
(31) Install the overdrive hub into the input clutch
retainer.
(32) Install the number 4 bearing into the reverse
hub with outer race against the hub with petroleum
jelly.(33) Install the reverse hub into the input clutch
retainer.
(34) Install the complete reverse clutch pack.
(35) Install the reverse reaction plate and snap-
ring.
(36) Push up on reaction plate to allow reverse
clutch to move freely.
INPUT SPEED SENSOR
DESCRIPTION
The Input and Output Speed Sensors are two-wire
magnetic pickup devices that generate AC signals as
rotation occurs. They are mounted in the left side of
the transmission case and are considered primary
inputs to the Transmission Control Module (TCM).
OPERATION
The Input Speed Sensor provides information on
how fast the input shaft is rotating. As the teeth of
the input clutch hub pass by the sensor coil, an AC
voltage is generated and sent to the TCM. The TCM
interprets this information as input shaft rpm.
The Output Speed Sensor generates an AC signal
in a similar fashion, though its coil is excited by rota-
tion of the rear planetary carrier lugs. The TCM
interprets this information as output shaft rpm.
The TCM compares the input and output speed
signals to determine the following:
²Transmission gear ratio
²Speed ratio error detection
²CVI calculation
The TCM also compares the input speed signal and
the engine speed signal to determine the following:
²Torque converter clutch slippage
²Torque converter element speed ratio
REMOVAL
(1) Raise vehicle.
(2) Place a suitable fluid catch pan under the
transmission.
(3) Remove the wiring connector from the input
speed sensor (Fig. 82).
(4) Remove the bolt holding the input speed sensor
to the transmission case.
(5) Remove the input speed sensor from the trans-
mission case.
INSTALLATION
(1) Install the input speed sensor into the trans-
mission case.
(2) Install the bolt to hold the input speed sensor
into the transmission case. Tighten the bolt to 11.9
N´m (105 in.lbs.).
Fig. 81 Measuring Reverse Clutch Clearance
1 - TOOL C-3339
2 - REVERSE CLUTCH PACK
21 - 244 AUTOMATIC TRANSMISSION - 545RFEWJ
INPUT CLUTCH ASSEMBLY (Continued)

(3) Install the wiring connector onto the input
speed sensor
(4) Verify the transmission fluid level. Add fluid as
necessary.
(5) Lower vehicle.
LINE PRESSURE (LP) SENSOR
DESCRIPTION
The TCM utilizes a closed-loop system to control
transmission line pressure. The system contains a
variable force style solenoid, the Pressure Control
Solenoid, mounted on the side of the solenoid and
pressure switch assembly. The solenoid is duty cycle
controlled by the TCM to vent the unnecessary line
pressure supplied by the oil pump back to the sump.
The system also contains a variable pressure style
sensor, the Line Pressure Sensor, which is a direct
input to the TCM. The line pressure solenoid moni-
tors the transmission line pressure and completes the
feedback loop to the TCM. The TCM uses this infor-
mation to adjust its control of the pressure control
solenoid to achieve the desired line pressure.
OPERATION
The TCM calculates the desired line pressure
based upon inputs from the transmission and engine.
The TCM calculates the torque input to the trans-
mission and uses that information as the primary
input to the calculation. The line pressure is set to a
predetermined value during shifts and when the
transmission is in the PARK and NEUTRAL posi-tions. This is done to ensure consistent shift quality.
During all other operation, the actual line pressure is
compared to the desired line pressure and adjust-
ments are made to the pressure control solenoid duty
cycle.
REMOVAL
(1) Raise vehicle.
(2) Place a suitable fluid catch pan under the
transmission.
(3) Remove the wiring connector from the line
pressure sensor (Fig. 83).
(4) Remove the bolt holding the line pressure sen-
sor to the transmission case.
(5) Remove the line pressure sensor from the
transmission case.
INSTALLATION
(1) Install the line pressure sensor into the trans-
mission case.
(2) Install the bolt to hold the line pressure sensor
into the transmission case. Tighten the bolt to 11.9
N´m (105 in.lbs.).
(3) Install the wiring connector onto the line pres-
sure sensor
(4) Verify the transmission fluid level. Add fluid as
necessary.
(5) Lower vehicle.
Fig. 82 Input Speed Sensor
1 - OUTPUT SPEED SENSOR
2 - LINE PRESSURE SENSOR
3 - INPUT SPEED SENSOR
Fig. 83 Line Pressure Sensor
1 - OUTPUT SPEED SENSOR
2 - LINE PRESSURE SENSOR
3 - INPUT SPEED SENSOR
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 245
INPUT SPEED SENSOR (Continued)

OUTPUT SPEED SENSOR
DESCRIPTION
The Input and Output Speed Sensors are two-wire
magnetic pickup devices that generate AC signals as
rotation occurs. They are mounted in the left side of
the transmission case and are considered primary
inputs to the Transmission Control Module (TCM).
OPERATION
The Input Speed Sensor provides information on
how fast the input shaft is rotating. As the teeth of
the input clutch hub pass by the sensor coil, an AC
voltage is generated and sent to the TCM. The TCM
interprets this information as input shaft rpm.
The Output Speed Sensor generates an AC signal
in a similar fashion, though its coil is excited by rota-
tion of the rear planetary carrier lugs. The TCM
interprets this information as output shaft rpm.
The TCM compares the input and output speed
signals to determine the following:
²Transmission gear ratio
²Speed ratio error detection
²CVI calculation
The TCM also compares the input speed signal and
the engine speed signal to determine the following:
²Torque converter clutch slippage
²Torque converter element speed ratio
REMOVAL
(1) Raise vehicle.
(2) Place a suitable fluid catch pan under the
transmission.
(3) Remove the wiring connector from the output
speed sensor (Fig. 96).
(4) Remove the bolt holding the output speed sen-
sor to the transmission case.
(5) Remove the output speed sensor from the
transmission case.
INSTALLATION
(1) Install the output speed sensor into the trans-
mission case.
(2) Install the bolt to hold the output speed sensor
into the transmission case. Tighten the bolt to 11.9
N´m (105 in.lbs.).
(3) Install the wiring connector onto the output
speed sensor
(4) Verify the transmission fluid level. Add fluid as
necessary.
(5) Lower vehicle.
OVERDRIVE SWITCH
DESCRIPTION
The overdrive OFF (control) switch is located in
the shifter handle. The switch is a momentary con-
tact device that signals the PCM to toggle current
status of the overdrive function.
OPERATION
At key-on, fourth and fifth gear operation is
allowed. Pressing the switch once causes the over-
drive OFF mode to be entered and the overdrive OFF
switch lamp to be illuminated. Pressing the switch a
second time causes normal overdrive operation to be
restored and the overdrive lamp to be turned off. The
overdrive OFF mode defaults to ON after the ignition
switch is cycled OFF and ON. The normal position
for the control switch is the ON position. The switch
must be in this position to energize the solenoids and
allow upshifts to fourth and fifth gears. The control
switch indicator light illuminates only when the over-
drive switch is turned to the OFF position, or when
illuminated by the transmission control module.
Fig. 96 Output Speed Sensor
1 - OUTPUT SPEED SENSOR
2 - LINE PRESSURE SENSOR
3 - INPUT SPEED SENSOR
21 - 254 AUTOMATIC TRANSMISSION - 545RFEWJ

HISTORICAL FAULT CODES
Input faults 33 = IR thermister circuit was open
34 = IR thermister circuit was shorted
35 = Fan pot was shorted
36 = Fan pot was open
37 = Mode pot was shorted
38 = Mode pot was open
39 = IR sensor delta was too large
40 = Reserved
41 = Reserved
42 = One of four motor drivers had drive9A9shorted to
ground
43 = Engine air intake temperature Buss message
missing
44 = Country code Buss message missing
System Faults 45 = Mode motor was not responding
46 = AI (Recirc) motor was not responding
47 = Left temperature door was not responding
48 = Right temperature door was not responding
49 = Mode door travel range too small
50 = Mode door travel range too large
51 = AI (Recirc) door travel range too small
52 = AI (Recirc) door travel range too large
53 = Left temperature door travel too small
54 = Left temperature door travel too large
55 = Right temperature door travel too small
56 = Right temperature door travel too large
57 = Calibration check sum error
58 = Engine coolant temp bus message missing
59 = Vehicle speed bus message missing
60 = Engine RPM bus message missing
61 = OAT bus message missing
62 = Display intensity bus message missing
63 = VIN number bus message missing
64 = Raw OAT bus message was missing
65 = Reserved
66 = Reserved
67 = Reserved
NOTE: A battery disconnect will erase all faults
stored in Random Access Memory (RAM) of the
AZC control module. It is recommended that all
faults be recorded before they are erased.RETRIEVING FAULT CODES
(1) To begin the fault code tests, depress the A/C
and Recirc buttons at the same time and rotate the
left temperature control knob clockwise (CW) one
detent, then release the push-button.
24 - 20 CONTROLSWJ
A/C HEATER CONTROL (Continued)