Chrysler PT Cruiser. Manual — part 820
(8) Install pinion shaft retainer/ring gear-to-differ-
ential case bolts (Fig. 196) and torque to 95 N·m (70
ft. lbs.).
(9) Position differential side bearing cone onto dif-
ferential as shown (Fig. 197).
(10) Using Tools 5052 and C-4171, install differen-
tial bearing to differential (ring gear side) (Fig. 198).
(11) Using Tools L-4410 and C-4171, install differ-
ential bearing to differential (ring gear side) (Fig.
199).
Fig. 196 Remove/Install Retainer/Ring Gear Bolt
1 - PINION SHAFT RETAINER
Fig. 197 Position Bearing Cone Onto Differential
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL BEARING
Fig. 198 Side Bearing Installation (Ring Gear Side)
1 - C-4171
2 - INSTALLER 5052
Fig. 199 Side Bearing Installation (Extension
Housing Side)
1 - TOOL C-4171
2 - TOOL L-4410
21 - 234
40TE AUTOMATIC TRANSAXLE
PT
FINAL DRIVE (Continued)
(12) Using Miller Special Tool 6061 and C-4171,
install differential bearing race to bearing retainer
(Fig. 200).
(13) Using Miller Special Tool L–4520 and C-4171,
install differential bearing cup to extension housing.
(14) Measure and adjust differential bearing pre-
load (Refer to 21 - TRANSMISSION/TRANSAXLE/
AUTOMATIC
-
41TE/FINAL
DRIVE
-
ADJUSTMENTS) .
(15) Install differential assembly to case. Install
extension housing/adapter plate and bearing retainer.
(16) Install
bearing
retainer
with
a
bead
of
Mopar
t Silicone Rubber Adhesive Sealant and torque
bolts (Fig. 201) to 28 N·m (250 in. lbs.).
(17) Install extension housing/adapter plate with a
bead of Mopar
t Silicone Rubber Adhesive Sealant
and torque bolts to 28 N·m (250 in. lbs.).
(18) Install differential cover with a bead of
Mopar
t Silicone Rubber Adhesive Sealant (Fig. 202)
and torque bolts (Fig. 203) to 28 N·m (250 in. lbs.).
Fig. 200 Differential Bearing Retainer
1 - DIFFERENTIAL BEARING CUP
2 - DIFFERENTIAL BEARING RETAINER
Fig. 201 Differential Retainer Bolts
1 - DIFFERENTIAL RETAINER BOLTS
Fig. 202 Install Differential Cover
1 - DIFFERENTIAL ASSEMBLY
2 - DIFFERENTIAL COVER
Fig. 203 Differential Cover Bolts
1 - DIFFERENTIAL COVER BOLTS
2 - DIFFERENTIAL COVER
PT
40TE AUTOMATIC TRANSAXLE
21 - 235
FINAL DRIVE (Continued)
ADJUSTMENTS
DIFFERENTIAL BEARING PRELOAD
MEASUREMENT AND ADJUSTMENT
NOTE: Perform all differential bearing preload mea-
surements
with
the
transfer
shaft
and
gear
removed.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT USING
EXISTING SHIM
(1) Position the transaxle assembly vertically on
the support stand, differential bearing retainer side
up.
(2) Install Tool L-4436A into the differential and
onto the pinion mate shaft (Fig. 204).
(3) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
seated.
(4) Using Tool L-4436A and an inch-pound torque
wrench, check the turning torque of the differential
(Fig.
205).
The
turning
torque
should
be
between 5 and 18 inch-pounds.
(5) If the turning torque is within specifications,
remove tools. Setup is complete.
(6) If turning torque is not within specifications
proceed with the following steps.
(a) Remove differential bearing retainer from
the transaxle case.
(b) Remove the bearing cup from the differential
bearing retainer using Tool 6062A.
(c) Remove the existing shim from under the
cup.
(d) Measure the existing shim.
(e) If the turning torque was too high when mea-
sured, install a 0.05 mm (0.002 inch) thinner shim.
If the turning torque is was too low, install a 0.05
mm (0.002 inch) thicker shim. Repeat until 5 to 18
inch-pounds turning torque is obtained. Oil Baffle
is not required to be installed when making shim
selection.
(f) Install the proper shim under the bearing
cup. Make sure the oil baffle is installed properly
in the bearing retainer, below the bearing shim
and cup.
(g) Install the differential bearing retainer using
Tool 5052 and C-4171. Seal the retainer to the
housing with MOPAR
t Adhesive Sealant and
torque bolts to 28 N·m (250 in. lbs.).
(7) Using Tool L-4436A and an inch-pound torque
wrench, recheck the turning torque of the differential
(Fig.
205).
The
turning
torque
should
be
between 5 and 18 inch-pounds.
Shim thickness need be determined only if any of
the following parts are replaced:
• Transaxle case
• Differential carrier
• Differential bearing retainer
• Extension housing
• Differential bearing cups and cones
Fig. 204 Tool L-4436 and Torque Wrench
1 - SPECIAL TOOL L-4436–A
2 - TORQUE WRENCH
3 - DIFFERENTIAL BEARING RETAINER
Fig. 205 Checking Differential Bearings Turning
Torque
1 - SPECIAL TOOL L-4436–A
2 - TORQUE WRENCH
21 - 236
40TE AUTOMATIC TRANSAXLE
PT
FINAL DRIVE (Continued)
DIFFERENTIAL BEARING SHIM CHART
PART NUMBER
SHIM
THICKNESS
MM
INCH
4659257
.980
0.0386
4659258
1.02
0.0402
4659259
1.06
0.0418
4659260
1.10
0.0434
4659261
1.14
0.0449
4659262
1.18
0.0465
4659263
1.22
0.0481
4659264
1.26
0.0497
4659265
1.30
0.0512
4659266
1.34
0.0528
4659267
1.38
0.0544
4659268
1.42
0.0560
4659269
1.46
0.0575
4659270
1.50
0.0591
4659271
1.54
0.0607
4659272
1.58
0.0623
4659273
1.62
0.0638
4659274
1.66
0.0654
4659275
1.70
0.0670
4659283
2.02
0.0796
4659284
2.06
0.0812
PRELOAD ADJUSTMENT W/O SHIM
(1) Remove the bearing cup from the differential
bearing retainer using Miller special Tool 6062A.
(2) Remove existing shim from under bearing cup.
(3) Reinstall the bearing cup into the retainer
using Miller Special Tool 6061, and C-4171.
NOTE: Oil baffle is not required when making the
shim calculation.
(4) Install the bearing retainer into the case.
Torque bolts to 28 N
•m (250 in. lbs.).
(5) Position the transaxle assembly vertically on
the support stand and install Miller Special Tool
L-4436-A into the bearing retainer.
(6) Rotate the differential at least one full revolu-
tion to ensure the tapered roller bearings are fully
seated.
(7) Attach a dial indicator to the case and zero the
dial. Place the tip on the end of Special Tool
L-4436-A.
(8) Place a large screwdriver to each side of the
ring gear and lift. Check the dial indicator for the
amount of end play.
CAUTION: Do not damage the transaxle case and/or
differential retainer sealing surface.
(9) Using the end play measurement that was
determined, add 0.18mm (0.007 inch). This should
give you between 5 and 18 inch pounds of bearing
preload. Refer to the Differential Bearing Shim Chart
to determine which shim to use.
(10) Remove
the
differential
bearing
retainer.
Remove the bearing cup.
(11) Install the oil baffle. Install the proper shim
combination under the bearing cup.
(12) Install the differential bearing retainer. Seal
the retainer to the housing with Mopar
t Silicone
Rubber Adhesive Sealant. Torque bolts to 28 N
•m
(250 in. lbs.).
(13) Using Miller Special Tool L-4436-A and an
inch-pound torque wrench, check the turning torque
PT
40TE AUTOMATIC TRANSAXLE
21 - 237
FINAL DRIVE (Continued)
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