Chrysler PT Cruiser. Manual — part 778
(18) Install battery and hold-down clamp (Fig.
164).
(19) Install the air cleaner assembly (Fig. 165).
(20) Connect battery cables.
ADJUSTMENTS
ADJUSTMENT - GEARSHIFT CROSSOVER
CABLE
(1) Remove center console from vehicle. (Refer to
23
-
BODY/INTERIOR/CENTER
CONSOLE
-
REMOVAL)
(2) Loosen adjusting screw on crossover cable at
shifter (Fig. 166).
(3) The gearshift mechanism and transaxle cross-
over lever are spring-loaded and self-centering. Align-
ment pins used in the past are not required anymore.
Allow gearshift mechanism and transaxle crossover
lever to relax in their neutral positions. To ensure
the gearshift lever is in the proper position, place the
shifter in 3rd or 4th gear if necessary. Torque adjust-
ment screw to 8 N·m (70 in. lbs.). Care must be
taken to avoid moving the shift mechanism off-center
during screw tightening.
(4) Reinstall center console. Reinstall boot and
knob. (Refer to 23 - BODY/INTERIOR/CENTER
CONSOLE - INSTALLATION)
Fig. 164 Battery Removal/Installation
1 - BATTERY
Fig. 165 Air Cleaner Assembly Removal/Installation
1 - AIR CLEANER ASSEMBLY
Fig. 166 Loosen Crossover Cable Adjustment Screw
1 - CROSSOVER ADJUSTMENT SCREW
21 - 66
G288 MANUAL TRANSAXLE
PT
GEAR SHIFT CABLE (Continued)
GEAR SHIFT KNOB
REMOVAL
(1) Pull up on gearshift knob with moderate force
to remove from gearshift mechanism (Fig. 167).
INSTALLATION
(1) Position knob hole over the gearshift mecha-
nism and align the shift pattern (Fig. 167).
(2) Strike knob with rubber mallet to engage knob
to mechanism.
(3) Verify that shift pattern is aligned properly.
GEAR SHIFT MECHANISM
REMOVAL
(1) Pull up on gearshift knob with moderate force
to remove from gearshift mechanism (Fig. 168).
(2) Remove shifter boot/bezel assembly from con-
sole by lifting up at mounting ring area (Fig. 169).
(3) Remove the center console assembly as shown
in (Fig. 170). Remove rear power window switch (if
equipped) and disconnect harness from console.
(4) Remove crossover cable retaining clip and dis-
connect from shift lever (Fig. 171).
(5) Remove selector cable retaining clip and dis-
connect from shift lever (Fig. 172).
(6) Remove four shifter assy.-to-floor pan nuts and
remove shifter from vehicle (Fig. 173).
INSTALLATION
(1) Install shifter assy. to floor pan (Fig. 173).
Install and tighten four nuts to 12 N·m (105 in. lbs.)
torque.
(2) Install selector cable to shifter lever and secure
cable to shifter bracket. Install clip (Fig. 172).
(3) Install crossover cable to shifter lever and
secure cable to shifter bracket. Install clip (Fig. 171).
NOTE: Only the crossover cable is adjustable. The
selector cable does not have any adjustment capa-
bilities.
(4) Adjust crossover cable. (Refer to 21 - TRANS-
MISSION/TRANSAXLE/MANUAL/GEAR
SHIFT
CABLE - ADJUSTMENTS)
Fig. 167 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
Fig. 168 Gearshift Knob Removal/Installation
1 - GEARSHIFT KNOB
Fig. 169 Gearshift Boot Removal/Installation
1 - GEARSHIFT BOOT
PT
G288 MANUAL TRANSAXLE
21 - 67
(5) Install center console assembly (Fig. 170).
Install rear power window switch (if equipped) and
fasten harness to console.
(6) Position gearshift boot (Fig. 169) over the gear-
shift mechanism and engage tab on mount ring at
front to opening in console. Apply hand pressure to
engage bosses on mount ring of boot to console open-
ing slots.
(7) Position gearshift knob hole over the gearshift
mechanism (Fig. 168) and align the shift pattern.
(8) Strike knob with rubber mallet to engage knob
to mechanism.
(9) Verify that shift pattern is aligned properly.
Fig. 170 Center Console Removal/Installation—
Typical
1 - CENTER CONSOLE
Fig. 171 Crossover Cable at Shifter Assembly
1 - GROMMET PLATE NUT
2 - SHIFTER
3 - CROSSOVER CABLE
4 - CLIP
Fig. 172 Selector Cable at Shifter Assembly
1 - SHIFTER
2 - CLIP
3 - SELECTOR CABLE
Fig. 173 Shifter Assy. Removal/Installation
1 - SHIFTER ASSEMBLY
21 - 68
G288 MANUAL TRANSAXLE
PT
GEAR SHIFT MECHANISM (Continued)
INPUT SHAFT
DESCRIPTION
The input shaft assembly (Fig. 174) is part of the
transaxle geartrain, is driven by the clutch assembly,
and meshes with the intermediate shaft assembly.
The input shaft consists of the following major com-
ponents:
• Input mainshaft
• Third Speed Gear
• Fourth Speed Gear
• Fifth Speed Gear
• 1st Gear (Fixed)
• 2nd Gear (Fixed)
• 3/4 Synchronizer
• 5th Gear Synchronizer
The input shaft assembly is supported by a caged
roller bearing at the front of the transaxle, and a
sealed roller bearing at the rear of the transaxle.
Fig. 174 Input Shaft Cross Section
1 - 5TH SYNCRHONIZER
2 - 5TH SPEED GEAR
3 - 5TH GEAR BUSHING
4 - 4TH SPEED GEAR
5 - 3/4 SYNCHRONIZER
6 - 3RD SPEED GEAR
7 - THRUST PLATE
8 - 2ND GEAR (FIXED)
9 - 1ST GEAR (FIXED)
10 - INPUT SHAFT
11 - THRUST WASHER
12 - 3RD GEAR BEARING
13 - THRUST WASHER
14 - BLOCKER RING
15 - 4TH GEAR BEARING
16 - BUSHING
17 - BEARING
18 - BLOCKER RING
PT
G288 MANUAL TRANSAXLE
21 - 69
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