Chrysler PT Cruiser. Manual — part 808
(14) OUTPUT
GEAR
BEARING
ADJUST-
MENT:
(a) With output gear Installd, install a 4.50 mm
(0.177 in.) gauging shim (Fig. 106) on the rear car-
rier assembly hub, using grease to hold the shim in
place.
(b) Using Tool 6259, install output gear and
bearing assembly. Torque to 271 N·m (200 ft. lbs.).
(c) Measure bearing end play. Attach Tool L-4432
to the gear (Fig. 105).
(d) Push and pull the gear while rotating back
and forth to ensure seating of bearing rollers.
(e) Using a dial indicator mounted to the trans-
axle case, measure output gear end play as shown
in (Fig. 105).
(f) Refer to the output gear bearing shim chart
for the required shim to obtain proper bearing set-
ting.
(g) Use Tool 6259 to remove the output gear
retaining bolt and washer. To remove the output
gear, use Tool L4407A.
(h) Remove the gauging shim and install the
proper shim determined by the chart. Use grease
to hold the shim in place.
Fig. 105 Checking Output Gear Bearings End Play
1 - TOOL L-4432
2 - DIAL INDICATOR
3 - SPECIAL SCREWS TOOL 6260
4 - OUTPUT GEAR
Fig. 106 Output Gear and (Select) Shim
1 - REAR CARRIER ASSEMBLY
2 - SHIM (SELECT)
3 - OUTPUT GEAR
21 - 186
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PT
40TE AUTOMATIC TRANSAXLE (Continued)
OUTPUT GEAR BEARING SHIM CHART
End Play
Shim Needed
Part Number
End Play
Shim Needed
Part Number
0.05mm (0.002
in.)
4.42mm (0.174 in.)
4412830AB
0.53mm
(0.021 in.)
3.94mm (0.155 in.)
4412818AB
0.08mm (0.003
in.)
4.38mm (0.172 in.)
4412829AB
0.56mm
(0.022 in.)
3.90mm (0.154 in.)
4412817AB
0.10mm (0.004
in.)
4.38mm (0.172 in.)
4412829AB
0.58mm
(0.023 in.)
3.90mm (0.154 in.)
4412817AB
0.13mm (0.005
in.)
4.34mm (0.171 in.)
4412828AB
0.61mm
(0.024 in.)
3.86mm (0.152 in.)
4412816AB
0.15mm (0.006
in.)
4.30mm (0.169 in.)
4412827AB
0.64mm
(0.025 in.)
3.82mm (0.150 in.)
4412815AB
0.18mm (0.007
in.)
4.30mm (0.169 in.)
4412827AB
0.66mm
(0.026 in.)
3.82mm (0.150 in.)
4412815AB
0.20mm (0.008
in.)
4.26mm (0.168 in.)
4412826AB
0.69mm
(0.027 in.)
3.78mm (0.149 in.)
4412814AB
0.23mm (0.009
in.)
4.22mm (0.166 in.)
4412825AB
0.71mm
(0.028 in.)
3.74mm (0.147 in.)
4412813AB
0.25mm (0.010
in.)
4.22mm (0.166 in.)
4412825AB
0.74mm
(0.029 in.)
3.74mm (0.147 in.)
4412813AB
0.28mm (0.011
in.)
4.18mm (0.165 in.)
4412824AB
0.76mm
(0.030 in.)
3.70mm (0.146 in.)
4412812AB
0.30mm (0.012
in.)
4.14mm (0.163 in.)
4412823AB
0.79mm
(0.031 in.)
3.66mm (0.144 in.)
4412811AB
0.33mm (0.013
in.)
4.14mm (0.163 in.)
4412823AB
0.81mm
(0.032 in.)
3.66mm (0.144 in.)
4412811AB
0.36mm (0.014
in.)
4.10mm (0.161 in.)
4412822AB
0.84mm
(0.033 in.)
3.62mm (0.143 in.)
4412810AB
0.38mm (0.015
in.)
4.10mm (0.161 in.)
4412822AB
0.86mm
(0.034 in.)
3.62mm (0.143 in.)
4412810AB
0.41mm (0.016
in.)
4.06mm (0.160 in.)
4412821AB
0.89mm
(0.035 in.)
3.58mm (0.141)
4412809AB
0.43mm (0.017
in.)
4.02mm (0.158 in.)
4412820AB
0.91mm
(0.036in.)
3.54mm (0.139 in.)
4412808AB
0.46mm (0.018
in.)
4.02mm (0.158 in.)
4412820AB
0.94mm
(0.037 in.)
3.54mm (0.139 in.)
4412808AB
0.48mm (0.019
in.)
3.98mm (0.157 in.)
4412819AB
0.97mm
(0.038 in.)
3.50mm (0.138 in.)
4412807AB
0.51mm (0.020
in.)
3.94mm (0.155 in.)
4412818AB
PT
40TE AUTOMATIC TRANSAXLE
21 - 187
40TE AUTOMATIC TRANSAXLE (Continued)
(15) Install the output gear and bearing assembly
using Tool 6261 (Fig. 107).
(16) Install NEW output gear retaining bolt and
washer (Fig. 108). Using Tool 6259, torque output
gear retaining bolt to 271 N·m (200 ft. lbs.) (Fig.
109).
(17) Using an inch pound torque wrench (Fig. 110),
check output shaft turning torque. Output shaft
turning torque should be within 3-8 in. lbs. If
the turning torque is too high, install a 0.04 mm
(0.0016 in.) thicker shim. If the turning torque is too
low, install a 0.04 mm (0.0016 in.) thinner shim.
Repeat until the proper turning torque of 3-8 in. lbs.
is obtained.
Fig. 107 Install Output Gear
1 - WRENCHES
2 - TOOL 6261 WITH STUD
3 - OUTPUT GEAR
Fig. 108 Output Gear Bolt and Washer
1 - OUTPUT GEAR
2 - BOLT
3 - CONED LOCK WASHER
Fig. 109 Tighten Output Gear to 271 N
•
m (200 ft.
lbs.)
1 - OUTPUT GEAR
2 - TORQUE WRENCH
3 - 200 FT. LBS.
4 - TOOL 6259
Fig. 110 Check Output Gear Bearings Turning
Torque
1 - INCH-POUND TORQUE WRENCH
2 - OUTPUT GEAR
21 - 188
40TE AUTOMATIC TRANSAXLE
PT
40TE AUTOMATIC TRANSAXLE (Continued)
(18) Install output gear stirrup with serrated side
out (Fig. 111).
(19) Install retaining strap (Fig. 112).
(20) Install strap bolts but do not tighten at this
time (Fig. 112).
(21) Rotate
stirrup
clockwise
against
flats
of
retaining bolt (Fig. 113).
(22) Torque stirrup strap bolts to 23 N·m (200 in.
lbs.) (Fig. 114).
Fig. 111 Install Stirrup
1 - STIRRUP
2 - OUTPUT GEAR RETAINING BOLT
Fig. 112 Install Strap Bolts
1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
Fig. 113 Turn Stirrup Clockwise Against Flats Of
Output Gear Retaining Bolt
1 - RETAINING STRAP
2 - STIRRUP
Fig. 114 Tighten Stirrup Strap Bolts to 23 N·m (200
in. lbs.)
1 - RETAINING STRAP
2 - STIRRUP
PT
40TE AUTOMATIC TRANSAXLE
21 - 189
40TE AUTOMATIC TRANSAXLE (Continued)
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