Chrysler PT Cruiser. Manual — part 810
(32) Install the transfer shaft gear using Tool 6261
(Fig. 124).
CAUTION: Install a NEW retaining nut, as the origi-
nal nut MUST NOT be reused.
(33) Install the new retaining nut and washer.
(34) Using Tool 6259, torque transfer gear retain-
ing nut to 271 N·m (200 ft. lbs.) (Fig. 125).
(35) Measure transfer shaft end play. Transfer
shaft end play should be within 0.05-0.10 mm
(0.002-0.004 in.). If the end play is too high, install a
0.04 mm (0.0016 in.) thicker shim. If the end play is
too low, install a 0.04 mm (0.0016 in.) thinner shim.
Repeat until 0.05-0.10 mm (0.002-0.004 in.) end play
is obtained.
(36) Install a bead of Mopar
t ATF RTV (MS-GF41)
to transfer gear cover (Fig. 126).
(37) Install transfer gear cover-to-case bolts and
torque to 20 N·m (175 in. lbs.) torque (Fig. 127).
Fig. 124 Install Transfer Shaft Gear
1 - WRENCHES
2 - SPECIAL TOOL 6261
3 - OUTPUT GEAR
4 - TRANSFER SHAFT GEAR
Fig. 125 Tighten Nut to 271 N
•
m (200 ft. lbs.)
1 - TRANSFER SHAFT GEAR
2 - 200 FT. LBS.
3 - TORQUE WRENCH
4 - SPECIAL TOOL 6259
Fig. 126 Install Rear Cover
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPAR
T
ATF RTV (MS-GF41) AS SHOWN
Fig. 127 Install Rear Cover Bolts
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
21 - 194
40TE AUTOMATIC TRANSAXLE
PT
40TE AUTOMATIC TRANSAXLE (Continued)
(38) Install low/reverse clutch pack (Fig. 128).
Leave uppermost disc out until snap ring is installed.
(39) Install low/reverse reaction plate flat snap
ring (Fig. 129).
(40) Install remaining low/reverse clutch disc (Fig.
130).
(41) Install low/reverse reaction plate with flat
side up (Fig. 131).
Fig. 128 Install Low/Reverse Clutch
1 - CLUTCH PLATE
2 - CLUTCH DISC
Fig. 129 Install Low/Reverse Reaction Plate Snap
Ring
1 - SCREWDRIVER
2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
3 - DO NOT SCRATCH CLUTCH PLATE
Fig. 130 Install One Disc
1 - ONE DISC FROM LOW/REVERSE CLUTCH
Fig. 131 Install Low/Reverse Reaction Plate
1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
PT
40TE AUTOMATIC TRANSAXLE
21 - 195
40TE AUTOMATIC TRANSAXLE (Continued)
(42) Install tapered snap ring (with tapered side
up) as shown in (Fig. 132) (Fig. 133).
(43) Set up dial indicator as shown in (Fig. 134) to
measure low/reverse clutch clearance. Press down on
clutch pack with finger and zero dial indicator. Low/
Reverse clutch pack clearance is 0.89-1.47 mm
(0.035-0.058 in.). Set up indicator and record mea-
surement in four (4) places. Take average of readings
and select the proper low/reverse reaction plate to
achieve specifications.
LOW/REVERSE REACTION PLATE CHART
PART NUMBER
THICKNESS
4799846AA
5.88 mm (0.232 in.)
4799847AA
6.14 mm (0.242 in.)
4799848AA
6.40 mm (0.252 in.)
4799849AA
6.66 mm (0.262 in.)
4799855AA
6.92 mm (0.273 in.)
(44) Install 2/4 clutch pack (Fig. 135).
Fig. 132 Tapered Snap Ring Instructions
Fig. 133 Snap Ring Installed
1 - SCREWDRIVER
2 - TAPERED SNAP RING (INSTALL AS SHOWN)
Fig. 134 Check Low/Reverse Clutch Clearance
1 - DIAL INDICATOR
2 - DIAL INDICATOR TIP TOOL 6268
3 - HOOK TOOL
Fig. 135 Install 2/4 Clutch
1 - CLUTCH DISC
2 - CLUTCH PLATE
21 - 196
40TE AUTOMATIC TRANSAXLE
PT
40TE AUTOMATIC TRANSAXLE (Continued)
NOTE: The 2/4 Clutch Piston has bonded seals
which are not individually serviceable. Seal replace-
ment requires replacement of the piston assembly.
(45) Orient 2/4 clutch return spring to retainer as
shown in (Fig. 136), and install to transaxle (Fig.
137).
(46) Using tool 5058, compress 2/4 clutch return
spring just enough to install snap ring (Fig. 138).
(47) Install snap ring.
(48) Set up dial indicator as shown in (Fig. 139)
and measure 2/4 clutch clearance. Press down on
clutch pack with finger and zero dial indicator. 2/4
clutch
pack
clearance
is
0.76-2.64
mm
(0.030-0.104 in.). Set up indicator and record mea-
surement in four (4) places. Take average of read-
ings. If clearance is outside this range, the clutch is
assembled improperly. There is no adjustment for
2/4 clutch clearance.
Fig. 136 Proper Orientation of 2/4 Clutch Retainer
and Spring
1 - NOTE POSITION
2 - RETURN SPRING
3 - 2/4 CLUTCH RETAINER
Fig. 137 2/4 Clutch Retainer
1 - 2/4 CLUTCH RETAINER
2 - 2/4 CLUTCH RETURN SPRING
Fig. 138 Install 2/4 Clutch Retainer Snap Ring
1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
Fig. 139 Check 2/4 Clutch Clearance
1 - DIAL INDICATOR
2 - HOOK TOOL
3 - DIAL INDICATOR TIP TOOL 6268
PT
40TE AUTOMATIC TRANSAXLE
21 - 197
40TE AUTOMATIC TRANSAXLE (Continued)
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