PT Cruiser, 2001 - 2005

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Place the transaxle in the P position, for automatic and neutral for manual.
  4.  
  5. Remove or disconnect the following:
    WARNING
    Be careful when separating the ball joint stud from the steering knuckle, so the ball joint seal does not get damaged.


    WARNING
    Be careful when separating the inner CV-joint during this operation. Do not let the driveshaft hang by the inner CV-joint, the driveshaft must be supported.


    NOTE
    Inner Tri-Pot joint removal is easier by applying outward pressure on the joint while hitting the punch with a hammer.



    Negative battery cable
     
    Front wheel
     
    Cotter pin, locknut and spring washer from the end of the outer Constant Velocity (CV) joint stub axle
     
    Driveshaft to hub and bearing nut
     
    Front wheel speed sensor, if equipped
     
    Steering knuckle from the ball joint
     
    Driveshaft from the steering knuckle and support the outer end of the driveshaft
     

  6.  
  7. Inner Tri-Pot joints from the transmission side gears using a punch to dislodge the inner Tri-Pot joint retaining ring from the transmission side gear. If removing the right side inner Tri-Pot joint, position the punch against the inner Tri-Pot joint. Hit the punch sharply with a hammer to dislodge the right inner joint from the side gear. If removing the left side inner Tri-Pot joint, position the punch in the groove of the inner Tri-Pot joint. Hit the punch sharply with a hammer to dislodge the left inner Tri-Pot joint from the side gear.
  8.  
  9. Hold the inner Tri-Pot joint and interconnecting shaft of the driveshaft assembly. Remove the inner Tri-Pot joint from the transaxle by pulling it straight out of the transaxle side gear and transmission oil seal. When removing the Tri-Pot joint, do not let the spline or snapring drag across the sealing lip of the transaxle-to-Tri-Pot joint oil seal.
    WARNING
    The driveshaft, when installed, acts as a bolt which secures the front hub and bearing assembly. If the vehicle is to be supported or moved on its wheels with a driveshaft removed, install a proper-sized bolt and nut through the front hub. Tighten the bolt and nut to 135 ft. lbs. (183 Nm). This will ensure that the hub bearing cannot loosen.



    Click image to see an enlarged view

    Fig. Remove the Tri-Pot joint from the transaxle

  10.  

To install:

  1. Thoroughly clean the spline and oil seal sealing surface on the Tri-Pot joint. Lightly lubricate the oil seal sealing surface on the Tri-Pot joint with fresh, clean transmission fluid.
  2.  
  3. Holding the driveshaft assembly by the Tri-Pot joint and interconnecting shaft, install the Tri-Pot joint into the transaxle side gear as far as possible by hand
  4.  
  5. Align the Tri-Pot joint with the transmission side gears, grasp the driveshaft interconnecting shaft and push the Tri-Pot joint into the transaxle side gear until fully seated. Be sure the snapring is fully engaged with the side gear by trying to remove the Tri-Pot joint from the transaxle by hand. If the snapring is fully seated with the side gear, the Tri-Pot joint will not be removable by hand.
  6.  
  7. Install or connect the following:

    Driveshaft back into the front hub
     
    Steering knuckle into the ball joint stud
     
    New steering knuckle-to-ball joint stud bolt and nut. Torque the nut and bolt to 70 ft. lbs. (95 Nm).
     
    Washer and hub nut to the stub axle and torque the nut to 180 ft. lbs. (244 Nm)
     
    Spring washer, locknut and cotter pin
     
    VSS, if equipped
     
    Front wheel
     
    Negative battery cable
     

  8.  
  9. Check the transaxle fluid and adjust if needed.
  10.  

 
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