Toad "technical" issue

[KJINTF]

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.

[j-d]

Outstanding combination of skill and cunning! Congratulations!

[KJINTF]

An update/fix - if interested

Found what had been expected - Pump Valve Spring broken
Exactly matched up to the broken piece of spring attached to the magnet
All good now
Good to be back in operation even better for less than $100 in parts

[KJINTF]

Posted earlier the spring is 0.33" diameter with a height of 0.13"
The dipstick tube inside diameter is 0.5"

NO way did it come from outside NO WAY! it is from inside the tranny

Just completed cutting the paper filter apart
Lots of tell tale signs - small flakes of broken spring and bits of rubber

Best guess now
TCC accumulator valve in pump
Or drain back valve in the back of input shaft

Either way the tranny has to come out
Not exactly having fun at this point in time
On the positive side my shop's HVAC system is fully function
Needed the "H" function today

[Larry202br]

Does the diameter exactly match that of the inner diameter of your dipstick tube?

[KJINTF]

A few possibilities remain without removing the transmission from the Jeep

Might be a small piece of the TCC "Torque Converter Clutch" spring or maybe a Pump valve spring but there were zero other incorrect parts in the pan. No way I can see for a pump valve spring to get there with out other parts being tossed in there as well. Continue working the issue.

Ordered a TransGo accumulator upgrade kit along with a upgraded "White" OEM Solenoid pack. Took the old Black Solenoid pack apart - WOW what a mess to get that thing back together correctly. Chrysler came out with an improved version in 2006.

Currently in a holding pattern waiting on parts and researching issues with my other GM-TH350, GM-4L85E and Chrysler-42RLE transmissions. Always something to keep me busy spending money on around this place.

Life is good and getting better - I enjoy this sort of stuff

[NinerBikes]

Alright, whatcha gonna do to fix the case of the missing broken spring source?

[KJINTF]

Hi RJ,

Thanks for the comments

YES YES YES it did indeed come out of the transmission
Not sure why folks are questioning the FACT it did indeed come out of inside the Transmission

I have had a few of older manual units apart myself
These "newer" (yes this thing was built in 2001 and many consider it old now) transmissions are a bit different from the older Ford C6 and GM 350/450 hydro transmissions, those things were a Piece of cake to get operational.

To date I've found the Solenoid Pack and the Accumulators needing attention. Not wanting to drop the transmission from the Jeep just yet and have yet to find the source of the broken spring which is driving me out of my mind.

[RJsfishin]

I used to overhaul trannys on the GM tech job in the 60s,.....they haven't changed much. And IMO, if the tranny is operating normally, especially no abnormal slippage tween gears, it will never hurt anything,.....and that's if it really did come out of that tranny.

[KJINTF]

Looks to most like a simple stress fracture and premature failure
One end ground down flush factory finish the other stress fracture and failure
Pictures attached in previous posts

Broken due to stress fracture
But from where did it come is the real question
Yes it did come from inside this tranny but not sure exactly where from inside this tranny

[NinerBikes]

KJINTF wrote:
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

Yes, but look at the ends of the spring, and take pictures of it and post them up of the ends... the question is HOW DID IT BREAK?

[KJINTF]

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

[PRodacy]

Take it to your Jeep dealer. One of the service techs can probably identify it.

[KJINTF]

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

[time2roll]

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.