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KJINTF's avatar
KJINTF
Explorer
Sep 13, 2015

Toad "technical" issue

My '02 Jeep WJ Overland w/ 545RFE tranny as can be seen has an extra part in the oil pan in addition to the magnet.

While up on the hoist doing the typical filters and fluid change I find this not a good way to start the day.

Maybe you good folks can steer me in the right direct
Anyone know where this unwanted part came from?
Are there typical failure modes on this tranny?

I have this posted on a few Jeep sites with limited response to date

My DRBIII shows zero TCM/ECM DTC's and the tranny has been acting fine since the last change a full ten years ago. Currently 80K miles on the tranny.


  • Would have done - Sunday maybe not

    Nearest dealer that has a clue is 125 miles away
    Dealt with them a few times over the years - One time had to explain to the service manager how to download a flash file from tech Connect for the DRBIII
    his tech guys could not figure it out
  • Take it to your Jeep dealer. One of the service techs can probably identify it.
  • Hi Guys

    Sure appreciate the comments and suggestions

    This Jeep is my baby - It's a Jeep thing that many do not or can not undsertand

    Have had 20 or more Jeeps over the years but this one has been the best ever.
    Check out the WJ Overland - only thing missing are the cooling seats which the newer ones have. All of them have the heated seats rain sensors TPMS system dual IR controlled climate system etc... along with a 4 wheel drive systen that can put 100% of the engine torque to any tire any time.

    Purchased it new in November 2001 and have done 100% of the maintainance on it from day one myself.

    The Jeep is sitting on my 4 post 14Klb capable hoist in a climate and dust controlled work shop. Before you ask yes the shop includes a frig with cold beverage and a nice stereo system as well as a few large HDTV's.

    A broken part inside the tranny is a VERY BIG concern the way I am thinking.
    It was not there 10 years ago when I last had it opened up

    Just got through removing the valve body assembly and looking at the accumulator springs - none of them that small. The yet to arrive "kit" includes new accumulator seals and springs. Took the 6 pack solinoid assemby apart (wow what a pain to get the two halfs back together) all springs inside were in good shape with no signs of any internal issues.

    Still wondering where that small broken spring came from???????
    This issue will keep me up at night - watched 3 hours of Chrysler training videos on the tranny thsi morning - kept my Tech Connect subscription active helps with getting updated Flash files for the DRBIII

    The broken piece measures
    0.33" width
    0.13" heigh
    and looks as if just less than 2 full turns broke off the larger spring
  • Could be something that just fell in during the build.

    Examine the end of the metal closely to see if it looks broken or cut.

    cut is probably scrap. broken is more likely component failure.

    Just my WAG. Good luck.
  • Looks like a portion of a spring that broke, perhaps inside the valve body? Does it drive and shift OK still?

    If so, I'd celebrate that you found the part, when and where you did... go crack a Moose Drool, or IPA later on today on Sunday, and watch some football, while contemplating the navel, or your next move, on Monday to fix it. Seriously, if it was still shifting and driving fine before the routine ATF service, I'd change the ATF and run it another 40k miles and then see what comes out.

    I'd be more worried about all the other dust and dirt and stuff showing up in the bottom of that oil pan?

    Metal flecks, flakes, and indications of grinding or wear is what concerns me the most when I see it in the bottom of the pan, long term wear and tear stuff. No other junk stuck to the magnet except a spring bit? Keep driving, keep doing what you're doing, and run it till it breaks, with continued routine maintenance.
  • I don't know what it is but, please let us know when you find out.

    Fortunately the magnet did its job.
  • Thanks for the suggestions

    Yes I posted at the Jeep Garage and a few other places

    Right now getting the valve body out of the tranny - simple 6 bolts and it's out

    Just ordered the TransGo 45RFE-HD2 kit
    Best guess so far is that it's a piece of an accumulator spring

    This tranny has been great and easy to work on as compared the my TJ Rubicon's 42RFE what POS that is
  • It looks like part of a coil spring to me. I am not familiar with that transmission but most of the older ones hade a number of springs that controlled shift points and shift quality etc.. If you only lost one turn out of 10 you probably wouldn't notice the difference.

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