Chrysler PT Cruiser, Service & Repair Manual, Page: 1536 / 2078

Measure and Adjust Side Gear End-Play
(1) Rotate the assembly two full revolutions both
clockwise and counterclockwise.Set up dial indicator
as shown and record end play (Fig. 87) (Fig. 88).
Rotate side gear 90 degrees and take another mea-
surement. Again, rotate side gear 90 degrees and
record a final measurement.
(2) 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.
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.
ADJUSTMENTS
DIFFERENTIAL BEARING PRELOAD
ADJUSTMENT / SHIM SELECTION
Measure and adjust differential side bearing pre-
load during any transaxle service, especially when
the following components are replaced:
•
Transaxle gear case
•
Clutch bellhousing case
•
Differential case
•
Differential bearings
NOTE: True bearing turning torque readings can be
obtained only with the geartrain removed from the
case.
(1) Remove bearing cup and existing shim from
clutch bellhousing case.
(2) Press in new bearing cup into bellhousing case
(or use a cup that has been ground down on the
outer edge for ease of measurement).
(3) Press in new bearing cup into gear case side.
(4) Oil differential bearings with transmission
fluid. Install differential assembly in transaxle gear
case. Install clutch bellhousing over gear case. Install
and torque case bolts to 29 N·m (21 ft. lbs.).
(5) Position transaxle with bellhousing facing
down on workbench with C-clamps. Position dial
indicator.
NOTE: Indicator is set up as shown for illustrative
purposes only (Fig. 89). Indicator must be parallel
to T-Handle to obtain the most accurate reading.
(6) Apply a medium load to differential with Tool
C-4995 and a T-handle, in the downward direction.
Roll differential assembly back and forth a number of
times. This will settle the bearings. Zero the dial
indicator. To obtain end play readings, apply a
medium load in an upward direction while rolling
differential assembly back and forth (Fig. 89). Record
end play.
(7) The shim required for proper bearing preload is
the total of end play, plus (constant) preload of
0.18 mm (0.007 in.). Never combine shims to obtain
the required preload.
(8) Remove case bolts. Remove clutch bellhousing
differential bearing cup. Install shim(s) selected in
Step 7. Then press the bearing cup into clutch bell-
housing.
Fig. 87 Checking Side Gear End Play (Typical)
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
4 - SIDE GEAR
Fig. 88 Checking Side Gear End Play—Typical
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
3 - DIFFERENTIAL ASSEMBLY
21 - 124 T350 MANUAL TRANSAXLE
PT
DIFFERENTIAL (Continued)