Content .. 807 808 809 810 ..

Chrysler PT Cruiser. Manual - part 809

(23) Bend tabs on strap up against flats of bolts

(Fig. 115).

(24) Install transfer shaft bearing cone using Tool

6052 (Fig. 116).

(25) Install bearing cup and oil baffle to transfer

shaft (Fig. 117).

(26) Using Tool 5049A, install transfer shaft (Fig.

118).

Fig. 115 Bend Tabs On Strap Up Against Flats Of

Bolts

1 - RETAINING STRAP TABS
2 - RETAINING STRAP
3 - STIRRUP

Fig. 116 Install Transfer Shaft Bearing Cone

1 - TOOL 6052
2 - NEW BEARING CONE
3 - TRANSFER SHAFT
4 - ARBOR PRESS RAM

Fig. 117 Install Bearing Cup to Shaft

1 - BEARING CUP
2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING

Fig. 118 Install Transfer Shaft

1 - SPECIAL TOOL 5049–A
2 - TRANSFER SHAFT
3 - OUTPUT GEAR

21 - 190

40TE AUTOMATIC TRANSAXLE

40TE AUTOMATIC TRANSAXLE (Continued)

(27) Using Tool 6051, install transfer shaft bearing

snap ring (Fig. 119).

(28) Install transfer shaft bearing cup into retainer

using Tool 6061 (Fig. 120).

(29) Install bearing cup retainer to transaxle (Fig.

121).

(30) Install transfer gear bearing cone to transfer

gear using Tool 5052 (Fig. 122).

Fig. 119 Install Transfer Shaft Bearing Snap Ring

1 - SNAP RING PLIERS TOOL 6051
2 - TRANSFER SHAFT BEARING SNAP RING
3 - TRANSFER SHAFT

Fig. 120 Install Transfer Shaft Bearing Cup Into

Retainer

1 - ARBOR PRESS RAM
2 - HANDLE C-4171
3 - TOOL 6061
4 - TRANSFER SHAFT BEARING CUP RETAINER
5 - USE REMOVED BEARING CUP TO SUPPORT RETAINER

Fig. 121 Install Bearing Cup Retainer

1 - ALIGN INDEXING TAB TO SLOT
2 - BEARING CUP RETAINER

Fig. 122 Install Transfer Gear Bearing Cone

1 - ARBOR PRESS RAM
2 - HANDLE C-4171
3 - NEW BEARING CONE
4 - TRANSFER SHAFT GEAR
5 - TOOL 5052

40TE AUTOMATIC TRANSAXLE

21 - 191

40TE AUTOMATIC TRANSAXLE (Continued)

(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.).

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 - 192

40TE AUTOMATIC TRANSAXLE

40TE 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

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

40TE AUTOMATIC TRANSAXLE

21 - 193

40TE AUTOMATIC TRANSAXLE (Continued)

Content .. 807 808 809 810 ..