Chrysler PT Cruiser. Manual — part 850
(31) TRANSFER GEAR BEARING ADJUST-
MENT:
(a) Install a 4.66 mm (0.184 in.) gauging shim
on the transfer shaft (Fig. 123).
(b) Install transfer shaft gear using Tool 6261.
Using Tool 6259, install transfer shaft gear retain-
ing nut to 271 N·m (200 ft. lbs.).
(c) Measure end play. Attach Tool L4432 to the
transfer gear.
(d) Mount a steel ball with grease into the end
of the transfer shaft.
(e) Push and pull the gear while rotating back
and forth to ensure seating of the bearing rollers.
(f) Using a dial indicator, measure transfer shaft
end play.
(g) Refer to the transfer shaft bearing shim
chart for the required shim combination to obtain
the proper bearing setting.
(h) Use Tool 6259 to remove the retaining nut
and washer. Remove the transfer shaft gear using
Tool L4407A.
(i) Remove the gauging shim (Fig. 123) and
install the proper shim indicated by the chart.
TRANSFER SHAFT BEARING SHIM CHART
End Play
Shim Needed
Part Number
End Play
Shim Needed
Part Number
0.05mm (0.002
in.)
4.66mm (0.183
in.)
4505588AB
0.76mm (0.030
in.)
3.94mm (0.155
in.)
4412818AB
0.08mm (0.003
in.)
4.62mm (0.182
in.)
4412835AB
0.79mm (0.031
in.)
3.90mm (0.154
in.)
4412817AB
0.10mm (0.004
in.)
4.58mm (0.180
in.)
4412834AB
0.81mm (0.032
in.)
3.90mm (0.154
in.)
4412817AB
0.13mm (0.005
in.)
4.58mm (0.180
in.)
4412834AB
0.84mm (0.033
in.)
3.86mm (0.152
in.)
4412816AB
0.15mm (0.006
in.)
4.54mm (0.178
in.)
4412833AB
0.86mm (0.034
in.)
3.82mm (0.150
in.)
4412815AB
0.18mm (0.007
in.)
4.50mm (0.177
in.)
4412832AB
0.89mm (0.035
in.)
3.82mm (0.150
in.)
4412815AB
0.20mm (0.008
in.)
4.50mm (0.177
in.)
4412832AB
0.91mm (0.036
in.)
3.78mm (0.149
in.)
4412814AB
0.23mm (0.009
in.)
4.46mm (0.175
in.)
4412831AB
0.94mm (0.037
in.)
3.74mm (0.147
in.)
4412813AB
0.25mm (0.010
in.)
4.46mm (0.175
in.)
4412831AB
0.97mm (0.038
in.)
3.74mm (0.147
in.)
4412813AB
0.28mm (0.011
in.)
4.42mm (0.174
in.)
4412830AB
0.99mm (0.039
in.)
3.70mm (0.146
in.)
4412812AB
0.30mm (0.012
in.)
4.38mm (0.172
in.)
4412829AB
1.02mm (0.040
in.)
3.66mm (0.144
in.)
4412811AB
0.33mm (0.013
in.)
4.38mm (0.172
in.)
4412829AB
1.04mm (0.041
in.)
3.66mm (0.144
in.)
4412811AB
Fig. 123 Install Transfer Shaft Gear and (Select)
Shim
1 - TRANSFER SHAFT GEAR
2 - BEARING CUP RETAINER
3 - SHIM (SELECT)
21 - 354
41TE AUTOMATIC TRANSAXLE
PT
41TE AUTOMATIC TRANSAXLE (Continued)
End Play
Shim Needed
Part Number
End Play
Shim Needed
Part Number
0.36mm (0.014
in.)
4.34mm (0.171
in.)
4412828AB
1.07mm (0.042
in.)
3.62mm (0.143
in.)
4412810AB
0.38mm (0.015
in.)
4.30mm (0.169
in.)
4412827AB
1.08mm (0.043
in.)
3.62mm (0.143
in.)
4412810AB
0.41mm (0.016
in.)
4.30mm (0.169
in.)
4412827AB
1.12mm (0.044
in.)
3.58mm (0.141)
4412809AB
0.43mm (0.017
in.)
4.26mm (0.168
in.)
4412826AB
1.14mm (0.045
in.)
3.54mm (0.139
in.)
4412808AB
0.46mm (0.018
in.)
4.22mm (0.166
in.)
4412825AB
1.17mm (0.046
in.)
3.54mm (0.139
in.)
4412808AB
0.48mm (0.019
in.)
4.22mm (0.166
in.)
4412825AB
1.19mm (0.047
in.)
3.50mm (0.138
in.)
4412807AB
0.50mm (0.020
in.)
4.18mm (0.165
in.)
4412824AB
1.22mm (0.048
in.)
3.46mm (0.136
in.)
4412806AB
0.53mm (0.021
in.)
4.18mm (0.165
in.)
4412824AB
1.24mm (0.049
in.)
3.46mm (0.136
in.)
4412806AB
0.56mm (0.022
in.)
4.14mm (0.163
in.)
4412823AB
1.27mm (0.050
in.)
3.42mm (0.135
in.)
4412805AB
0.58mm (0.023
in.)
4.10mm (0.161
in.)
4412822AB
1.30mm (0.051
in.)
3.38mm (0.133
in.)
4412804AB
0.61mm (0.024
in.)
4.10mm (0.161
in.)
4412822AB
1.32mm (0.052
in.)
3.38mm (0.133
in.)
4412804AB
0.64mm (0.025
in.)
4.06mm (0.160
in.)
4412821AB
1.35mm (0.053
in.)
3.34mm (0.132
in.)
4412803AB
0.66mm (0.026
in.)
4.02mm (0.158
in.)
4412820AB
1.37mm (0.054
in.)
3.34mm (0.132
in.)
4412803AB
0.69mm (0.027
in.)
4.02mm (0.158
in.)
4412820AB
1.40mm (0.055
in.)
3.30mm (0.130
in.)
4412802AB
0.71mm (0.028
in.)
3.98mm (0.157
in.)
4412819AB
1.45mm (0.057
in
3.26mm (0.128
in.)
4412801AB
0.74mm (0.029
in.)
3.94mm (0.155
in.)
4412818AB
1.47mm (0.058
in.)
2.22mm (0.127
in.)
4505570AB
PT
41TE AUTOMATIC TRANSAXLE
21 - 355
41TE AUTOMATIC TRANSAXLE (Continued)
(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 Transfer Gear 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 - 356
41TE AUTOMATIC TRANSAXLE
PT
41TE 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 Pack
1 - CLUTCH PLATES (5)
2 - CLUTCH DISCS (5)
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
41TE AUTOMATIC TRANSAXLE
21 - 357
41TE AUTOMATIC TRANSAXLE (Continued)
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