Chrysler PT Cruiser 2001 Service Manual Supplement page 1227

21 - 42 TRANSAXLE
DISASSEMBLY AND ASSEMBLY (Continued)
(3) Stake pinion shaft retaining pin with a suitable
chisel (Fig. 140).
Fig. 140 Staking Retaining Pin
1 – PINION SHAFT RETAINING PIN
2 – SPEEDOMETER DRIVE GEAR
(4) Rotate the assembly two full revolutions both
clockwise and counterclockwise.
(4) Set up dial indicator as shown and record end
play (Fig. 141) (Fig. 142). Rotate side gear 90 degrees
and record another end play. Again, rotate side gear
90 degrees and record a final end play.
Fig. 141 Checking Side Gear End Play (Typical)
1 – SPECIAL TOOL C-4996 (NOTE POSITION)
2 – DIAL INDICATOR SET
3 – DIFFERENTIAL ASSEMBLY
4 – SIDE GEAR
(5) Using the smallest end play recorded, shim
that side gear to within 0.001 to 0.013 inch. The
other side gear should be checked using the same
procedure.
Fig. 142 Checking Side Gear End Play (Typical)
1 – SPECIAL TOOL C-4996 (NOTE POSITION)
2 – DIAL INDICATOR SET
3 – DIFFERENTIAL ASSEMBLY
CAUTION: Side gear end play must be within 0.001
to 0.013 inch. Five select thrust washers are avail-
able: 0.027, 0.032, 0.037, 0.042, and 0.047 inch.
(6) After the end play is measured and adjusted,
replace speedometer drive gear with a new one.
Install drive gear lip downward. For service informa-
tion, refer to Speedometer Drive Gear service in this
section.
SYNCHRONIZER
DISASSEMBLY
Place synchronizer in a clean shop towel and wrap.
Press on inner hub. Carefully open up shop towel
and remove springs, balls, keys, hub, and sleeve.
ASSEMBLY
(1) Position synchronizer hub onto a suitable hold-
ing fixture (input shaft). The synchronizer hubs are
directional. The hubs must be installed with the U
facing upward.
(2) Install springs into hub slot (Fig. 143).
(3) Insert key into hub and spring.
(4) Apply petroleum jelly to the hole in the key.
Insert balls into each key (Fig. 144).
(5) Slide sleeve over the hub and depress balls as
you carefully slip the sleeve into position (Fig. 145).
(6) Line up stop ring tang over the keys in the hub
(Fig. 146). Install stop rings. Center the keys and
balls by pushing on both stop rings.
PT