LEMON Manuals: Even more car manuals for everyone
Home >> Jeep >> 2009 >> Commander Overland, RWD >> Repair and Diagnosis (Single Page) >> Transmission >> Transmission Control Systems >> 545RFE Automatic Transmission (Service Information) >> Installation >> Installation

545RFE Automatic Transmission (Service Information): Installation: 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 transmission.
  3. Lubricate oil pump seal lip with transmission fluid.
  4. Align converter and oil pump.
  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. Surface of converter lugs should be at least 13 mm (1/2 in.) to rear of straightedge when converter is fully seated.
  7. Temporarily secure converter with C-clamp.
    Fig 1: Removing/Installing Transmission
    GC0082966Courtesy of CHRYSLER LLC
    1 - ENGINE
    2 - TRANSMISSION
  8. Position transmission on jack and secure it with chains.
  9. Check condition of converter drive plate. 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 Mopar® High Temp Grease to the torque converter hub pocket in the rear pocket of the engine's crankshaft.
  11. Raise transmission and align the torque converter with the drive plate and the transmission converter housing with the engine block.
    NOTE: Before aligning the transmission to the engine block fit the transmission fill tube to the vehicle.
  12. Move transmission forward. Then raise, lower, or tilt transmission (2) to align the converter housing with the engine (1) 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.
    Fig 2: Remove Transmission to Engine Bolts
    GC0118998Courtesy of CHRYSLER LLC
    1 - ENGINE
    2 - TRANSMISSION
    3 - BOLTS
    4 - WIRING HARNESS CLIPS
  14. Install two bolts (3) to attach the transmission (2) to the engine (1).
  15. Install remaining torque converter housing to engine bolts. Tighten to 68 N.m (50 ft.lbs.).
    Fig 3: Oil Pan To Transmission Bolts
    GC0092084Courtesy of CHRYSLER LLC
    1 - BOLTS
  16. Install both the left and right side oil pan to transmission bolts (1) , 5.7L only. Torque the bolts to 54 N.m (40 ft. lbs.).
    Fig 4: Transmission Lines
    GC0118997Courtesy of CHRYSLER LLC
    1 - TRANSMISSION
    2 - TRANSMISSION OIL COOLER LINES
  17. Connect cooler lines (2) to transmission (1).
    Fig 5: Transmission Fill Tube
    GC0118996Courtesy of CHRYSLER LLC
    1 - TRANSMISSION
    2 - FILL TUBE
    3 - DIPSTICK
    4 - BOLTS
  18. Install transmission fill tube (2) to the transmission (1).
    Fig 6: Transmission Shift Cable
    GC0118994Courtesy of CHRYSLER LLC
    1 - TRANSMISSION
    2 - MANUAL LEVER
    3 - SHIFT CABLE
    4 - SHIFT CABLE BRACKET
    5 - BOLT
  19. Install rear transmission crossmember. Tighten crossmember to frame bolts to 68 N.m (50 ft.lbs.).
  20. Install rear support to transmission. Tighten bolts to 47 N.m (35 ft.lbs.).
  21. Lower transmission onto crossmember and install bolts attaching transmission mount to crossmember. 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.).
  22. Remove engine support fixture.
  23. Install new plastic retainer grommet on any shift cable that was disconnected. Grommets should not be reused. Use pry tool to remove rod from grommet and cut away old grommet. Use pliers to snap new grommet into cable and to snap grommet onto lever.
  24. Connect gearshift cable (3) to the shift cable bracket (4) and the transmission manual lever (2).
    Fig 7: Disconnect Input Speed Sensor
    GC0082963Courtesy of CHRYSLER LLC
    1 - TRANSMISSION
    2 - INPUT SPEED SENSOR
  25. Connect wires to the input speed sensor (2) . Be sure transmission harnesses are properly routed.
    Fig 8: Disconnect Output Speed Sensor
    GC0082962Courtesy of CHRYSLER LLC
    1 - TRANSMISSION
    2 - OUTPUT SPEED SENSOR
  26. Connect wires to the output speed sensor (2) . Be sure transmission harnesses are properly routed.
    Fig 9: Disconnect Transmission Solenoid/Transmission Range Selector Assembly
    GC0082964Courtesy of CHRYSLER LLC
    1 - TRANSMISSION
    2 - TRANSMISSION SOLENOID/TRS ASSEMBLY
  27. Connect wires to the transmission solenoid/TRS assembly (2) . Be sure transmission harnesses are properly routed.
    Fig 10: Disconnect Line Pressure Sensor
    GC0082965Courtesy of CHRYSLER LLC
    1 - TRANSMISSION
    2 - LINE PRESSURE SENSOR
  28. Connect wires to the line pressure sensor (2) . Be sure transmission harnesses are properly routed.
    Fig 11: Remove Torque Converter Bolts
    GC0118993Courtesy of CHRYSLER LLC
    1 - TRANSMISSION
    2 - DRIVE PLATE
    3 - TORQUE CONVERTER BOLTS
    CAUTION: It is essential that the correct length bolts are used to attach the converter to the drive plate. Bolts that are too long will damage the clutch surface inside the converter.
  29. Install all torque converter-to-driveplate bolts (3) by hand.
  30. Verify that the torque converter is pulled flush to the drive plate. Tighten bolts to 31 N.m (270 in. lbs.).
    Fig 12: Structural Dust Cover
    GC0085486Courtesy of CHRYSLER LLC
    1 - STRUCTURAL COVER
    2 - BOLTS
  31. Install the structural cover (1) , 5.7L shown in Fig 12. Refer to Engine/Engine Block/COVER, Structural Dust - Installation
    Fig 13: Removing/Installing Transfer Case
    GC0118644Courtesy of CHRYSLER LLC
    1 - NV140 TRANSFER CASE
    2 - NUTS
    3 - TRANSMISSION
    4 - TRANSFER CASE VENT TUBE
  32. If necessary, install the NV140 transfer case (1) . Refer to Transmission and Transfer Case/Transfer Case - Installation
    Fig 14: Removing/Installing NV245 Transfer Case
    GC0118995Courtesy of CHRYSLER LLC
    1 - NV245 TRANSFER CASE
    2 - NUTS
    3 - TRANSMISSION
    4 - TRANSFER CASE VENT TUBE
  33. If necessary, install the NV245 transfer case (1) . Refer to Transmission and Transfer Case/Transfer Case - Installation
  34. Install starter motor. Refer to Electrical - Engine Systems/Starting/STARTER - Installation
  35. Install exhaust components.
  36. Align and connect propeller shaft(s). Refer to Differential and Driveline/Propeller Shaft/SHAFT, Drive - Installation
  37. Adjust gearshift cable if necessary. See Transmission and Transfer Case/Automatic - 45RFE/545RFE/CABLE, Shift - Adjustments 
  38. Lower vehicle.
  39. Fill transmission with appropriate fluid. Refer to Vehicle Quick Reference/Capacities and Recommended Fluids - Description
scientia non olet · About LEMON Manuals