Chrysler PT Cruiser. Manual — part 780
(3) Install 3rd gear (Fig. 185).
(4) Install 3rd gear blocker ring (Fig. 186).
(5) Install 3rd gear thrust bearing (Fig. 187).
(6) Install 3rd gear thrust washer.
(7) Install 3rd/4th gear synchronizer to shaft.
Before pressing synchronizer onto shaft, lift
upward on 3rd gear and blocker ring to engage
the guides of the blocker ring to the recesses of
the synchronizer body (Fig. 188). Press synchro-
nizer into place using Tool 6448A.
Fig. 185 3rd Gear Installation
1 - 3RD GEAR
Fig. 186 3rd Gear Blocker Ring Installation
1 - BLOCKER RING
Fig. 187 3rd Gear Thrust Bearing Installation
1 - THRUST BEARING
Fig. 188 3/4 Synchro Installation
1 - TOOL 6448A
2 - 3/4 SYNCHRONIZER
3 - BLOCKER RING
4 - 3RD GEAR
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INPUT SHAFT (Continued)
(8) Install 4th gear blocker ring (Fig. 189), engag-
ing guides in ring to recesses in synchronizer body.
(9) Install and press 4th gear needle bearing bush-
ing using Tool 6448A (Fig. 190) (Fig. 191).
(10) Install 4th gear needle bearing (Fig. 192).
Fig. 189 4th Gear Blocker Ring Installation
1 - BLOCKER RING
Fig. 190 Install 4th Gear Bushing
1 - BUSHING
Fig. 191 4th Gear Bushing Installation
1 - TOOL 6448A
2 - BUSHING
Fig. 192 Install 4th Gear Needle Bearing
1 - NEEDLE BEARING
PT
G288 MANUAL TRANSAXLE
21 - 75
INPUT SHAFT (Continued)
(11) Install 4th gear (Fig. 193).
(12) Install 5th gear bushing (Fig. 194).
(13) Install 5th gear needle bearing (Fig. 195).
(14) Install 5th gear (Fig. 196).
Fig. 193 Install 4th Gear
1 - 4TH GEAR
Fig. 194 Install 5th Gear Bushing
1 - TOOL 6448A
2 - BUSHING
Fig. 195 Install 5th Gear Needle Bearing
1 - NEEDLE BEARING
2 - BUSHING
Fig. 196 Install 5th Gear
1 - 5TH GEAR
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INPUT SHAFT (Continued)
(15) Install 5th gear blocker ring (Fig. 197).
(16) Install 5th gear synchronizer to shaft (Fig.
198). Position Tool 6448A over synchronizer and
begin press operation. While pressing synchro-
nizer onto shaft, lift upward on 5th gear and
blocker ring to engage the guides of the blocker
ring to the recesses of the synchronizer body
(Fig. 199).
Fig. 197 Install 5th Gear Blocker Ring
1 - BLOCKER RING
Fig. 198 Install 5th Gear Synchronizer
1 - 5TH GEAR SYNCHRONIZER
Fig. 199 5th Gear Synchronizer Installation
1 - TOOL 6448A
2 - 5TH GEAR SYNCHRONIZER
3 - BLOCKER RING
4 - 5TH GEAR
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G288 MANUAL TRANSAXLE
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INPUT SHAFT (Continued)
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