Chrysler PT Cruiser. Manual — part 827
(10) Install the UD clutch pack. Leave out upper
disc, until snap ring is installed (Fig. 263).
(11) Install the UD clutch flat snap ring (Fig. 264).
(12) Install the last UD clutch disc (Fig. 265).
(13) Install the OD/UD clutch reaction plate and
snap ring (Fig. 266) (Fig. 267). The OD/UD clutches
reaction plate has a step on both sides. Install the
OD/UD clutches reaction plate tapered step side up.
NOTE: Snap ring ends must be located within one
finger of the input clutch hub. Be sure that snap
ring is fully seated, by pushing with screwdriver,
into snap ring groove all the way around.
Fig. 263 Install Underdrive Clutch Pack
1 - CLUTCH DISC
2 - CLUTCH PLATE
Fig. 264 UD Clutch Flat Snap Ring
1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
2 - SCREWDRIVER
Fig. 265 Install Last UD Clutch Disc
1 - ONE UNDERDRIVE CLUTCH DISC
Fig. 266 OD/UD Reaction Plate
1 - OD/UD CLUTCH REACTION PLATE (TAPERED STEP SIDE
UP)
Fig. 267 Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
21 - 262
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PT
INPUT CLUTCH ASSEMBLY (Continued)
(14) Seat tapered snap ring to ensure proper
installation (Fig. 268) (Fig. 269).
(15) Install input clutch assembly to the Input
Clutch Pressure Fixture–Tool 8391 (Fig. 270).
Fig. 268 Seating Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER
Fig. 269 Underdrive Clutch Assembly
1 - SNAP RING (TAPERED)
2 - OD/UD REACTION PLATE
3 - CLUTCH DISC (3)
4 - SNAP RING (FLAT)
5 - CLUTCH PLATE (3)
6 - INPUT CLUTCH ASSEMBLY
PT
40TE AUTOMATIC TRANSAXLE
21 - 263
INPUT CLUTCH ASSEMBLY (Continued)
(16) Set up dial indicator on the UD clutch pack as
shown in (Fig. 271).
(17) Using moderate pressure, press down and
hold (near indicator) the UD clutch pack with screw-
driver or suitable tool and zero dial indicator (Fig.
272). When releasing pressure on clutch pack, indica-
tor reading should advance 0.005–0.010.
CAUTION: Do not apply more than 30 psi (206 kPa)
to the underdrive clutch pack.
(18) Apply 30 psi (206 kPa) to the underdrive hose
on Tool 8391 and measure UD clutch clearance. Mea-
sure and record UD clutch pack measurement in four
(4) places, 90° apart.
(19) Take average of four measurements and com-
pare with UD clutch pack clearance specification.
Underdrive clutch pack clearance must be 0.94-
1.50 mm (0.037-0.059 in.).
(20) If necessary, select the proper reaction plate
to achieve specifications:
UNDERDRIVE REACTION PLATE THICKNESS
4659939AB
5.837-5.937 mm (0.230-0.234 in.)
4659940AB
6.147-6.248 mm (0.242-0.246 in.)
4659941AB
6.457-6.557 mm (0.254-0.258 in.)
Fig. 270 Input Clutch Assembly on Pressure Fixture
Tool 8391
1 - INPUT CLUTCH ASSEMBLY
2 - INPUT CLUTCH PRESSURE FIXTURE 8391
Fig. 271 Set Up Dial Indicator to Measure UD Clutch
Clearance
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
Fig. 272 Press Down on UD Clutch Pack and Zero
Dial Indicator
1 - DIAL INDICATOR
2 - UNDERDRIVE CLUTCH
21 - 264
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INPUT CLUTCH ASSEMBLY (Continued)
(21) Install the OD clutch pack (Fig. 273).
(22) Install OD pressure plate waved snap ring
(Fig. 274).
(23) Install the OD/Reverse pressure plate with
large step down (towards OD clutch pack) (Fig. 275).
(24) Install OD pressure plate flat snap ring (Fig.
276) (Fig. 277).
Fig. 273 Install Overdrive Clutch Pack
1 - CLUTCH DISC
2 - CLUTCH PLATE
Fig. 274 Install Waved Snap Ring
1 - OVERDRIVE PRESSURE PLATE WAVED SNAP RING
2 - SCREWDRIVER
Fig. 275 OD/Reverse Reaction Plate
1 - OVERDRIVE/REVERSE PRESSURE PLATE
2 - (STEP SIDE DOWN)
Fig. 276 Install Flat Snap Ring
1 - ARBOR PRESS RAM
2 - TOOL 5059A
3 - FLAT SNAP RING
PT
40TE AUTOMATIC TRANSAXLE
21 - 265
INPUT CLUTCH ASSEMBLY (Continued)
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