Chrysler PT Cruiser. Manual — part 811
(49) Install rear sun gear and #7 needle bearing
(Fig. 141).
NOTE: The number seven needle bearing has three
anti-reversal tabs and is common with the number
five and number two position. The orientation
should allow the bearing to seat flat against the
rear sun gear (Fig. 140). A small amount of petrola-
tum can be used to hold the bearing to the rear sun
gear.
(50) Install front carrier/rear annulus assembly
and #6 needle bearing (Fig. 142).
(51) Install front sun gear assembly and #4 thrust
washer (Fig. 143).
Fig. 140 Number 7 Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 141 Install Rear Sun Gear and #7 Needle
Bearing
1 - #7 NEEDLE BEARING
2 - REAR SUN GEAR
Fig. 142 Install Front Carrier/Rear Annulus
Assembly
1 - #6 NEEDLE BEARING
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
Fig. 143 Install Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
21 - 198
40TE AUTOMATIC TRANSAXLE
PT
40TE AUTOMATIC TRANSAXLE (Continued)
(52) DETERMINING
#4
THRUST
PLATE
THICKNESS / INPUT SHAFT END PLAY:
(a) Select the thinnest #4 thrust plate thickness
and install to input clutch assembly (Fig. 144). Use
petrolatum to retain.
(b) Install input clutch assembly into position
and verify that it is completely seated by viewing
through input speed sensor hole. If view through
input speed sensor hole is not as shown in (Fig.
145), the input clutch assembly is not seated prop-
erly.
(c) Remove oil pump o-ring (Fig. 146). Be sure
to reinstall oil pump o-ring after selecting the
proper #4 thrust plate.
(d) Install pump and gasket to transmission.
Install and torque bolts.
(e) Set up input shaft for measurement with
Indicator Set C3339 and End Play Set 8266 as
shown in (Fig. 147).
(f) Measure the input shaft end play with the
transaxle in the vertical position. Input shaft end
play must be within 0.005 to 0.025 inch. For
example, if end play reading is 0.055 inch, select
No. 4 Thrust Plate which is 0.071 to 0.074 thick.
This should provide an input shaft end play read-
ing of 0.020 inch which is within specifications.
(g) Refer to the No. 4 thrust plate chart to select
the proper No. 4 thrust plate:
Fig. 144 Select Thinnest No. 4 Thrust Plate
1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
Fig. 145 View Through Input Speed Sensor Hole
1 - INPUT CLUTCH RETAINER
2 - INPUT SPEED SENSOR HOLE
3 - OIL COOLER FITTINGS
Fig. 146 Remove Oil Pump O-Ring
1 - OIL PUMP ASSEMBLY
2 - O-RING
Fig. 147 Measure Input Shaft End Play Using Tool
8266—Typical
1 - TOOL 8266–8
2 - TOOL 8266–2
3 - TOOL C-3339
PT
40TE AUTOMATIC TRANSAXLE
21 - 199
40TE AUTOMATIC TRANSAXLE (Continued)
NO. 4 THRUST PLATE CHART
PART NUMBER
THICKNESS
4431665AB
1.60mm (0.063 in.)
3836237AB
1.73mm (0.068 in.)
4431666AB
1.80mm (0.071 in.)
3836238AB
1.96mm (0.077 in.)
4431667AB
2.03mm (0.080 in.)
3836239AB
2.16mm (0.085 in.)
4431668AB
2.24mm (0.088 in.)
3836240AB
2.39mm (0.094 in.)
4431669AB
2.46mm (0.097 in.)
3836241AB
2.62mm (0.103 in.)
4446670AB
2.67mm (0.105 in.)
4446671AB
2.90mm (0.114 in.)
(53) Install input clutch assembly (Fig. 148).
(54) Install #1 caged needle bearing (Fig. 149).
CAUTION:
The
cooler
bypass
valve
must
be
replaced if transaxle failure has occurred. Do not
attempt to reuse or clean old valve.
(55) Install cooler bypass valve with o-ring end
towards rear of case (Fig. 150).
Fig. 148 Install Input Clutch Assembly
1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER
Fig. 149 Install No. 1 Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
Fig. 150 Install Cooler Bypass Valve
1 - COOLER BYPASS VALVE
21 - 200
40TE AUTOMATIC TRANSAXLE
PT
40TE AUTOMATIC TRANSAXLE (Continued)
(56) Install oil pump gasket (Fig. 151).
(57) Install oil pump assembly (Fig. 152).
(58) Install oil pump-to-case bolts and torque to 27
N·m (20 ft. lbs.) (Fig. 153).
(59) Install low/reverse accumulator (Fig. 154).
Fig. 151 Install Oil Pump Gasket
1 - PUMP GASKET
Fig. 152 Install Oil Pump
1 - OIL PUMP
2 - GASKET
Fig. 153 Install Pump-to-Case Bolts
1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
Fig. 154 Low/Reverse Accumulator
1 - PISTON
2 - RETURN SPRINGS
PT
40TE AUTOMATIC TRANSAXLE
21 - 201
40TE AUTOMATIC TRANSAXLE (Continued)
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