Chrysler PT Cruiser 2001 Service Manual Supplement page 1222

PT
DISASSEMBLY AND ASSEMBLY (Continued)
OUTPUT SHAFT
CAUTION: The output shaft is serviced as an
assembly. Do not try to repair any component on
the output shaft. If the 1-2 synchronizer or gear
fails, it is necessary to replace the output shaft
assembly.
It is necessary to check the synchronizer stop ring
gap. Use a feeler gauge to measure the gaps between
the stop rings and the speed gears. The correct gaps
are listed below:
• 1st—0.522-2.208 mm (0.021-0.087 in)
• 2nd—0.522-2.208 mm (0.021-0.087 in)
• 3rd—0.73-1.53 mm (0.029-0.060 in)
• 4th—0.77-1.57 mm (0.030-0.062 in)
• 5th—0.73-1.53 mm (0.029-0.060 in)
If a stop ring gap does not fall within the specifi-
cations it must be inspected for wear and replaced. If
the 1st or 2nd synchronizer stop ring is worn beyond
specifications, the complete output shaft assembly
must be replaced.
The output shaft incorporates the 1st and 2nd
gears and synchronizers on the assembly (Fig. 123).
Fig. 123 Output Shaft
1 – 1ST GEAR
2 – SLEEVE
3 – STOP RING
4 – OUTPUT SHAFT
5 – 2ND SPEED GEAR
6 – REVERSE GEAR
7 – STOP RING
DIFFERENTIAL
Shim thickness need be determined only if any of
the following parts are replaced:
• Transaxle gear case
• Clutch bellhousing case
• Differential case
• Differential bearings
Refer to Bearing Adjustment Procedure in the
Adjustments section at the end of this section to
determine proper shim thickness. This will provide
correct bearing preload and proper bearing turning
torque.
DIFFERENTIAL BEARINGS
Fig. 124 Remove Differential Bearing Cone
1 – SPECIAL TOOL C-293-PA
2 – SPECIAL TOOL C-4996
3 – DIFFERENTIAL ASSEMBLY
4 – SPECIAL TOOL C-293-45
RING GEAR
CAUTION: Always install new ring gear bolts.
Tighten ring gear bolts to 81 N·m (60 ft. lbs.) torque.
SPEEDOMETER DRIVE GEAR
NOTE: The plastic speedometer drive gear must be
removed from the differential case in order to ser-
vice the differential gears
TRANSAXLE 21 - 37