Chrysler PT Cruiser. Manual — part 799
(3) Insert key into hub and spring.
(4) Apply petroleum jelly to the hole in the key.
Insert balls into each key (Fig. 168).
(5) Slide sleeve over the hub and depress balls as
you carefully slip the sleeve into position (Fig. 169).
(6) Line up stop ring tang over the keys in the hub
(Fig. 170). Install stop rings. Center the keys and
balls by pushing on both stop rings.
Fig. 168 Synchronizer Balls
1 - INPUT SHAFT
2 - HUB
3 - KEY
4 - BALL
Fig. 169 Synchronizer Sleeve
1 - SLEEVE
2 - INPUT SHAFT
3 - KEY
Fig. 170 Keys in Hub
1 - SNAP RING
2 - CLUTCH
3 - KEY
4 - BALL
5 - SPRING
21 - 150
T350 MANUAL TRANSAXLE
PT
SYNCHRONIZER (Continued)
VEHICLE SPEED SENSOR
DESCRIPTION
VEHICLE SPEED SENSOR
The Vehicle Speed Sensor (VSS) is a pulse genera-
tor mounted to an adapter near the transmission out-
put shaft. The sensor is driven through the adapter
by a speedometer pinion gear. The VSS pulse signal
to the speedometer/odometer is monitored by the
PCM speed control circuitry to determine vehicle
speed and to maintain speed control set speed.
REMOVAL
(1) Raise vehicle on hoist.
(2) Disconnect the speed sensor connector (Fig.
171).
CAUTION: Clean area around speed sensor before
removing to prevent dirt from entering the transaxle
during speed sensor removal.
(3) Remove speed sensor retaining bolt (Fig. 171).
(4) Remove speed sensor from transaxle.
CAUTION: Carefully remove vehicle speed sensor
so that sensor drive gear does not fall into trans-
axle. Should sensor drive gear fall into the trans-
axle during sensor removal, drive gear must be
reattached to sensor.
(5) Remove speed sensor drive gear from speed
sensor.
INSTALLATION
(1) Install pinion gear to speed sensor (Fig. 171).
(2) Using a NEW o-ring, install the speed sensor
to the transaxle (Fig. 171).
(3) Install the bolt and torque to 7 N·m (60 in.
lbs.).
(4) Connect speed sensor connector (Fig. 171).
(5) Lower vehicle and road test to verify proper
speedometer operation.
Fig. 171 Speed Sensor and Pinion—Removal/
Installation
1 - CONNECTOR
2 - SENSOR
3 - O-RING
4 - SPEEDO PINION
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T350 MANUAL TRANSAXLE
21 - 151
40TE AUTOMATIC TRANSAXLE
TABLE OF CONTENTS
page
page
40TE AUTOMATIC TRANSAXLE
. . . . . . . . . . . . . . . . . . . . . . . . 153
. . . . . . . . . . . . . . . . . . . . . . . . . . 155
TRANSAXLE GENERAL DIAGNOSIS . . . . . . 155
DIAGNOSIS AND TESTING - ROAD TEST
DIAGNOSIS AND TESTING - HYDRAULIC
PRESSURE TESTS . . . . . . . . . . . . . . . . . . . 156
DIAGNOSIS AND TESTING - CLUTCH AIR
PRESSURE TESTS . . . . . . . . . . . . . . . . . . . 159
DIAGNOSIS AND TESTING - TORQUE
CONVERTER HOUSING FLUID LEAKAGE . . 160
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
. . . . . . . . . . . . . . . . . . . . . . . . 163
. . . . . . . . . . . . . . . . . . . . . . . . . . . 182
. . . . . . . . . . . . . . . . . . . . . . . . 204
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . 205
. . . . . . . . . . . . . . . . . . . . . . 217
. . . . . . . . . . . . . . . . . . . . . . . 219
ACCUMULATOR
. . . . . . . . . . . . . . . . . . . . . . . . 225
. . . . . . . . . . . . . . . . . . . . . . . . . . 225
DRIVING CLUTCHES
. . . . . . . . . . . . . . . . . . . . . . . . 225
. . . . . . . . . . . . . . . . . . . . . . . . . . 225
FINAL DRIVE
. . . . . . . . . . . . . . . . . . . . . . . . 226
. . . . . . . . . . . . . . . . . . . . . . . . . . 226
. . . . . . . . . . . . . . . . . . . . . . . . 227
. . . . . . . . . . . . . . . . . . . . . . . . . . . 232
MEASUREMENT AND ADJUSTMENT . . . . . . 236
FLUID
FLUID LEVEL AND CONDITION CHECK
STANDARD PROCEDURE - FLUID AND
FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . 239
GEAR SHIFT BEZEL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
. . . . . . . . . . . . . . . . . . . . . . . . 241
GEAR SHIFT CABLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
. . . . . . . . . . . . . . . . . . . . . . . . 244
. . . . . . . . . . . . . . . . . . 244
GEAR SHIFT KNOB
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
. . . . . . . . . . . . . . . . . . . . . . . . 246
GEARSHIFT MECHANISM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
. . . . . . . . . . . . . . . . . . . . . . . . 247
HOLDING CLUTCHES
. . . . . . . . . . . . . . . . . . . . . . . . 247
. . . . . . . . . . . . . . . . . . . . . . . . . . 247
INPUT CLUTCH ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . 248
. . . . . . . . . . . . . . . . . . . . . . . . . . . 257
OIL PUMP
. . . . . . . . . . . . . . . . . . . . . . . . 272
. . . . . . . . . . . . . . . . . . . . . . . . . . 272
. . . . . . . . . . . . . . . . . . . . . . . . 272
. . . . . . . . . . . . . . . . . . . . . . . . . . . 274
PLANETARY GEARTRAIN
. . . . . . . . . . . . . . . . . . . . . . . . 274
. . . . . . . . . . . . . . . . . . . . . . . . . . 274
SEAL - OIL PUMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
. . . . . . . . . . . . . . . . . . . . . . . . 275
SHIFT INTERLOCK CABLE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
. . . . . . . . . . . . . . . . . . . . . . . . 277
SHIFT INTERLOCK MECHANISM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
. . . . . . . . . . . . . . . . . . . . . . . . 279
SHIFT INTERLOCK SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . 279
DIAGNOSIS AND TESTING - BRAKE/
TRANSMISSION SHIFT INTERLOCK
SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . 279
BRAKE/TRANSMISSION SHIFT INTERLOCK
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
SOLENOID/PRESSURE SWITCH ASSY
. . . . . . . . . . . . . . . . . . . . . . . . 281
. . . . . . . . . . . . . . . . . . . . . . . . . . 281
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
. . . . . . . . . . . . . . . . . . . . . . . . 284
SPEED SENSOR - INPUT
. . . . . . . . . . . . . . . . . . . . . . . . 284
. . . . . . . . . . . . . . . . . . . . . . . . . . 285
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
. . . . . . . . . . . . . . . . . . . . . . . . 286
SPEED SENSOR - OUTPUT
. . . . . . . . . . . . . . . . . . . . . . . . 287
. . . . . . . . . . . . . . . . . . . . . . . . . . 287
21 - 152
40TE AUTOMATIC TRANSAXLE
PT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
. . . . . . . . . . . . . . . . . . . . . . . . 289
TORQUE CONVERTER
. . . . . . . . . . . . . . . . . . . . . . . . 289
. . . . . . . . . . . . . . . . . . . . . . . . . . 293
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
. . . . . . . . . . . . . . . . . . . . . . . . 294
TRANSMISSION CONTROL RELAY
. . . . . . . . . . . . . . . . . . . . . . . . 295
. . . . . . . . . . . . . . . . . . . . . . . . . . 295
TRANSMISSION RANGE SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . 296
. . . . . . . . . . . . . . . . . . . . . . . . . . 296
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
. . . . . . . . . . . . . . . . . . . . . . . . 300
VALVE BODY
. . . . . . . . . . . . . . . . . . . . . . . . 301
. . . . . . . . . . . . . . . . . . . . . . . . . . 301
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
. . . . . . . . . . . . . . . . . . . . . . . . 305
. . . . . . . . . . . . . . . . . . . . . . . . . . . 309
. . . . . . . . . . . . . . . . . . . . . . . . 314
40TE AUTOMATIC
TRANSAXLE
DESCRIPTION
The 40TE (Fig. 1) is a four-speed transaxle that is
a conventional hydraulic/mechanical assembly with
an integral differential, and is controlled with adap-
tive electronic controls and monitors. The hydraulic
system of the transaxle consists of the transaxle
fluid, fluid passages, hydraulic valves, and various
line pressure control components. An input clutch
assembly which houses the underdrive, overdrive,
and reverse clutches is used. It also utilizes separate
holding clutches: 2nd/4th gear and Low/Reverse. The
primary mechanical components of the transaxle con-
sist of the following:
• Three multiple disc input clutches
• Two multiple disc holding clutches
• Four hydraulic accumulators
• Two planetary gear sets
• Hydraulic oil pump
• Valve body
• Solenoid/Pressure switch assembly
• Integral differential assembly
Control of the transaxle is accomplished by fully
adaptive electronics. Optimum shift scheduling is
accomplished through continuous real-time sensor
feedback information provided to the Powertrain
Control Module (PCM) or Transmission Control Mod-
ule (TCM).
The PCM/TCM is the heart of the electronic control
system and relies on information from various direct
and indirect inputs (sensors, switches, etc.) to deter-
mine driver demand and vehicle operating condi-
tions. With this information, the PCM/TCM can
calculate and perform timely and quality shifts
through various output or control devices (solenoid
pack, transmission control relay, etc.).
The PCM/TCM also performs certain self-diagnos-
tic functions and provides comprehensive information
(sensor data, DTC’s, etc.) which is helpful in proper
diagnosis and repair. This information can be viewed
with the DRB scan tool.
PT
40TE AUTOMATIC TRANSAXLE
21 - 153
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