Chrysler PT Cruiser. Manual — part 860
DIFFERENTIAL SERVICE TOOLS
COMPONENT
REMOVER
INSTALLER
Diff. Bear. On
Retainer Side
5048, 5048-4
Collets,
L-4539-2
Button
5052, C-4171
Diff. Bear. On
Ext. Hous. Side
5048, 5048-3
Collets,
L-4539-2
Button
L-4410, C-4171
Diff. Race. On
Retainer Side
6062-A
6061, C-4171
Diff. Race. On
Ext. Hous. Side
L-4518
L-4520, C-4171
Extension
Housing Seal
7794-A, C-637
Slide Hammer
L-4520, C-4171
Bearing
Retainer Seal
794-A, C-637
Slide Hammer
L-4520, C-4171
ASSEMBLY
NOTE: Use Mopar
T
Silicone Rubber Adhesive Seal-
ant, or equivalent, on retainer and extension hous-
ing/adapter plate to seal to transaxle case.
(1) Position differential case to ring gear. Install
ring gear-to-differential case bolts and draw ring
gear into position (Fig. 189). Torque bolts to 95 N·m
(70 ft. lbs.).
(2) Install side gear thrust washers (Fig. 190).
(3) Install differential side gears (Fig. 191).
Fig. 189 Ring Gear Bolt Removal/Installation
1 - RING GEAR BOLTS
Fig. 190 Side Gear Washer
1 - SIDE GEAR THRUST WASHER
Fig. 191 Side Gear Removal/Installation
1 - SIDE GEAR
21 - 394
41TE AUTOMATIC TRANSAXLE
PT
FINAL DRIVE (Continued)
(4) Install pinion gears and thrust washers 180°
apart (Fig. 192).
(5) Rotate pinion gears into position, ensuring the
anti-rotate tabs are located into the differential case
as shown (Fig. 193).
(6) Install pinion shaft (Fig. 194).
(7) Install pinion shaft retainer (Fig. 195).
Fig. 192 Pinion Gear and Washer
1 - WASHER
2 - PINION GEAR
Fig. 193 Pinion Washer Anti-Rotate Tab
1 - ANTI-ROTATE TAB
2 - POCKET
Fig. 194 Pinion Shaft Removal/Installation
1 - PINION SHAFT
Fig. 195 Pinion Shaft Retainer
1 - PINION SHAFT RETAINER
PT
41TE AUTOMATIC TRANSAXLE
21 - 395
FINAL DRIVE (Continued)
(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 - 396
41TE 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
41TE AUTOMATIC TRANSAXLE
21 - 397
FINAL DRIVE (Continued)
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