Chrysler PT Cruiser. Manual — part 408
(12) Hold inner tripod joint and interconnecting
shaft of halfshaft assembly (Fig. 11). Remove inner tri-
pod joint from transaxle by pulling it straight out of
transaxle side gear and transaxle oil seal. When
removing tripod joint, do not let spline or snap
ring drag across sealing lip of the transaxle to
tripod
joint
oil
seal.
When
tripod
joint
is
removed from transaxle, some fluid will leak out.
CAUTION: The halfshaft, when installed, acts as a
bolt and secures the front hub/bearing assembly. If
vehicle is to be supported or moved on its wheels
with a halfshaft removed, install a PROPER–SIZED
BOLT AND NUT through front hub. Tighten bolt and
nut to 244 N·m (180 ft. lbs.). This will ensure that
the hub bearing cannot loosen.
REMOVAL—DIESEL AND TURBO MODELS
CAUTION: Boot sealing is vital to retain special
lubricants and to prevent foreign contaminants
from entering the C/V joint. Mishandling, such as
allowing the assemblies to dangle unsupported, or
pulling or pushing the ends can cut boots or dam-
age C/V joints. During removal and installation pro-
cedures, always support both ends of the halfshaft
to prevent damage.
CAUTION: The halfshaft, when installed, acts as a
bolt and secures the front hub/bearing assembly. If
vehicle is to be supported or moved on its wheels
with a halfshaft removed, install a PROPER–SIZED
BOLT AND NUT through front hub. Tighten bolt and
nut to 244 N·m (180 ft. lbs.). This will ensure that
the hub bearing cannot loosen.
(1) Disconnect battery negative cable.
(2) Place transaxle in gated park.
(3) Raise vehicle on hoist.
(4) Remove wheel and tire assembly (Fig. 12).
Fig. 9 Halfshaft Isolation Washer
1 - ISOLATION WASHER
Fig. 10 Disengaging Left Inner Tripod Joint from
Transaxle
1 - FRONT SUSPENSION CROSSMEMBER
2 - PUNCH
3 - TRANSAXLE
4 - HALFSHAFT INNER TRIPOD JOINT
5 - NOTCH
Fig. 11 Tripod Joint Removal from Transaxle
1 - INNER TRIPOD JOINT
2 - TRANSAXLE
3 - SPLINE
4 - OIL SEAL
5 - SNAP RING
6 - INTERCONNECTING SHAFT
3 - 6
HALF SHAFT
PT
HALF SHAFT (Continued)
(5) Remove the cotter pin, nut lock, and spring
washer, and hub nut from the end of the outer C/V
joint stub axle (Fig. 13).
(6) If equipped with ABS, disconnect the front
wheel speed sensor and secure harness out of the
way.
(7) Remove nut and bolt (Fig. 14) retaining ball
joint stud into steering knuckle.
NOTE: Use caution when separating ball joint stud
from steering knuckle, so ball joint seal does not
get damaged.
(8) Separate ball joint stud from steering knuckle
by prying down on lower control arm (Fig. 15).
NOTE: Care must be taken not to separate the inner
C/V joint during this operation. Do not allow half-
shaft to hang by inner C/V joint, halfshaft must be
supported.
(9) Remove halfshaft from steering knuckle by
pulling outward on knuckle while pressing in on half-
shaft. Support outer end of halfshaft assembly. If dif-
ficulty
in
separating
halfshaft
from
hub
is
encountered, do not strike shaft with hammer,
instead use puller 1026 to separate (Fig. 16).
Fig. 12 Wheel and Tire Removal
1 - WHEEL/TIRE ASSY.
2 - LUG NUT (5)
3 - HUB
Fig. 13 Halfshaft Retaining Hardware
1 - COTTER KEY
2 - WASHER
3 - HUB NUT
4 - SPRING WASHER
5 - NUT LOCK
Fig. 14 Steering Knuckle at Lower Control Arm Ball
Joint
1 - NUT
2 - BOLT
3 - BALL JOINT
Fig. 15 Separating Lower Control Arm from Steering
Knuckle
1 - STEERING KNUCKLE
2 - PRY BAR
3 - LOWER CONTROL ARM
4 - BALL JOINT STUD
PT
HALF SHAFT
3 - 7
HALF SHAFT (Continued)
(10) Remove halfshaft isolation washer (Fig. 17)
and support outer end of the halfshaft assembly.
NOTE: When left halfshaft is removed from trans-
axle, some fluid may leak out.
NOTE: Removal of the inner tripod joints is made
easier if you apply outward pressure on the joint as
you strike the punch with a hammer. DO NOT PULL
ON INTERCONNECTING SHAFT TO REMOVE, AS
THE INNER JOINT WILL BECOME SEPARATED.
(11) Remove halfshaft(s) (Fig. 18) (Fig. 19). Left
halfshaft: While applying outward pressure on joint
by hand, dislodge inner tripod joint from differential
side gear by striking outward with a punch at extrac-
tion groove. When removing tripod joint and half-
shaft, do not let spline or snap ring drag across
sealing lip of the transaxle to tripod joint oil seal.
Right halfshaft: Slide inner tripod joint off of inter-
mediate shaft. If difficulty is encountered, dislodge
joint from intermediate shaft using punch.
(12) If intermediate shaft is to be removed, remove
three (3) intermediate shaft bearing-to-bracket bolts
(Fig. 18). 2.4L turbo models utilize two (2) interme-
diate shaft bearing-to-bracket bolts. Remove interme-
diate shaft bearing/shaft assembly from transaxle.
CAUTION: The halfshaft, when installed, acts as a
bolt and secures the front hub/bearing assembly. If
vehicle is to be supported or moved on its wheels
with a halfshaft removed, install a PROPER–SIZED
BOLT AND NUT through front hub. Tighten bolt and
nut to 244 N·m (180 ft. lbs.). This will ensure that
the hub bearing cannot loosen.
Fig. 16 Separating Halfshaft from Hub/Bearing
1 - PULLER 1026
2 - HALFSHAFT
Fig. 17 Halfshaft Isolation Washer
1 - ISOLATION WASHER
3 - 8
HALF SHAFT
PT
HALF SHAFT (Continued)
INSTALLATION
INSTALLATION—EXCEPT DIESEL AND TURBO
MODELS
CAUTION: Boot sealing is vital to retain special
lubricants and to prevent foreign contaminants
from entering the C/V joint. Mishandling, such as
allowing the assemblies to dangle unsupported, or
pulling or pushing the ends can cut boots or dam-
age C/V joints. During removal and installation pro-
cedures, always support both ends of the halfshaft
to prevent damage.
(1) Thoroughly clean spline and oil seal sealing
surface, on tripod joint. Lightly lubricate oil seal
sealing surface on tripod joint with fresh clean trans-
mission lubricant.
(2) Holding halfshaft assembly by tripod joint and
interconnecting shaft, install tripod joint into trans-
axle side gear as far as possible by hand.
(3) Carefully align tripod joint with transaxle side
gears. Then grasp halfshaft interconnecting shaft
and push tripod joint into transaxle side gear until
fully seated. Test that snap ring is fully engaged
with side gear by attempting to remove tripod
joint from transaxle by hand. If snap ring is
fully engaged with side gear, tripod joint will
not be removable by hand.
(4) Clean all debris and moisture out of steering
knuckle (Fig. 20).
(5) Ensure that front of outer C/V joint, which fits
into steering knuckle (Fig. 21), is free of debris and
moisture before assembling into steering knuckle.
(6) Install halfshaft isolation washer (Fig. 22) and
slide halfshaft back into front hub.
(7) Install steering knuckle onto the ball joint stud
(Fig. 23).
NOTE: At this point, the outer joint will not seat
completely into the front hub. The outer joint will be
pulled into hub and seated when the hub nut is
installed and torqued.
Fig. 18 Halfshaft and Intermediate Shaft—2.2L Turbo Diesel
1 - HALFSHAFT (LH)
2 - TRANSAXLE
3 - INTERMEDIATE SHAFT
4 - BOLT (3)
5 - HALFSHAFT (RH)
PT
HALF SHAFT
3 - 9
HALF SHAFT (Continued)
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