Chrysler PT Cruiser. Manual — part 768
(15) Using a suitable prybar(s), separate reverse
shaft assembly from clutch bellhousing.
(16) Remove differential assembly from transaxle
housing.
(17) Place Tool 8869-2 into input and output shafts
at rear of case. Set transaxle and tool on press bed as
shown in (Fig. 55).
(18) Set Tool 8869-1 across case flange as shown in
(Fig. 56). Press Tool 8869-1 to remove input shaft,
output shaft, and fork/rail assemblies from case.
(19) Remove input and output shaft oil troughs
(Fig. 57) (Fig. 58).
Fig. 55 Geartrain Housing on 8869-2
1 - TOOL 8869-2
2 - GEARTRAIN HOUSING
Fig. 56 Geartrain Removal from Housing
1- TOOL 8869-1
Fig. 57 Input Shaft Oil Trough
1 - OIL TROUGH
Fig. 58 Output Shaft Oil Trough
1 - OIL TROUGH
21 - 26
G288 MANUAL TRANSAXLE
PT
G288 MANUAL TRANSAXLE (Continued)
ASSEMBLY
(1) Install input and output shaft oil troughs to
transaxle housing as shown in.
(2) Install output shaft roller bearing to clutch
bellhousing (Fig. 59).
(3) Install differential assembly (Fig. 60).
(4) Using heat gun, heat reverse shaft bearing
boss in transaxle case to expand for reverse shaft/
bearing installation (Fig. 61).
(5) Install reverse shaft and fork/rod as shown in
(Fig. 62).
Fig. 59 Output Shaft Bearing Installation
1 - INPUT SHAFT BEARING
2 - OUTPUT SHAFT BEARING
Fig. 60 Differential Assembly
1 - DIFFERENTIAL ASSEMBLY
Fig. 61 Heating Reverse Shaft Bearing Bore
1 - HEAT GUN
2 - BEARING BORE
Fig. 62 Reverse Shaft and Fork Assembly
1 - FORK/ROD ASSY.
2 - REVERSE SHAFT ASSY.
PT
G288 MANUAL TRANSAXLE
21 - 27
G288 MANUAL TRANSAXLE (Continued)
(6) Install geartrain (with forks/rods) into case
(Fig. 63). Verify proper installation of input and out-
put shaft assemblies, as well as proper orientation of
shift rod/fork assemblies (Fig. 64).
(7) Install chip collector magnet to case and retain
with grease.
(8) Apply a bead of Mopar
t Gasket Maker or
Omnifit FD-40 to clutch bellhousing flange. Install
geartrain housing and install transaxle housing-to-
clutch bellhousing bolts by hand (Fig. 65) (Fig. 66)
(Fig. 67).
Fig. 63 Install Geartrain to Clutch Bellhousing
1 - GEARTRAIN
2 - REVERSE SHAFT ASSY.
Fig. 64 Properly Installed Geartrain
1 - INTERMEDIATE SHAFT
2 - INPUT SHAFT
Fig. 65 Install Geartrain Housing
1 - TRANSAXLE HOUSING
2 - CLUTCH BELLHOUSING
3 - SEALER BEAD
Fig. 66 Geartrain Housing-to-Clutch Bellhousing
Bolts (Short)
1 - BOLTS (18-SHORT)
21 - 28
G288 MANUAL TRANSAXLE
PT
G288 MANUAL TRANSAXLE (Continued)
(9) Torque twenty (18 short, 2 long) geartrain
housing-to-clutch bellhousing bolts to 28 N·m (21 ft.
lbs.) torque (Fig. 68).
(10) Using an arbor press and Tools C-4171 and
8871, install input and output shaft roller bearings
as shown in (Fig. 69) (Fig. 70).
Fig. 67 Geartrain Housing-to-Clutch Bellhousing
Bolts (Long)
1 - BOLTS (2-LONG)
Fig. 68 Torquing Transaxle Housing to Clutch
Bellhousing Bolts
1 - TORQUE WRENCH
Fig. 69 Install Input Shaft Roller Bearing
1 - TOOL C-4171
2 - TOOL 8871
3 - SNAP RING
4 - BEARING
Fig. 70 Install Output Shaft Bearing
1 - TOOL C-4171
2 - TOOL 8871
3 - BEARING
PT
G288 MANUAL TRANSAXLE
21 - 29
G288 MANUAL TRANSAXLE (Continued)
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