PT Cruiser, 2001 - 2005

Removal & Installation

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T350 Transaxle



  1. Drain the transaxle fluid.
  2.  
  3. Remove or disconnect the following:

    Battery cables
     
    Battery and tray
     
    Air cleaner
     
    Back-up lamp switch wiring from the transaxle
     
    Shift selector and crossover cable and move them out of the way
     
    Vehicle Speed Sensor (VSS) wire
     
    Clutch master cylinder hydraulic tube from the slave cylinder
     
    Both halfshafts
     
    Bell housing dust cover
     
    Power steering hose from the structural collar
     
    Left side engine-to-transaxle lateral bending brace and structural collar
     
    Right side engine-to-transaxle lateral bending brace
     
    Starter
     
    Driveplate-to-clutch module bolts and support the engine at the oil pan
     
    Transaxle upper mount bolts and lower the powertrain assembly onto the support
     
    Transaxle-to-engine mounting bolts
     
    Transaxle
     
    Clutch module from the input shaft
     
    Slave cylinder
     
    Upper transaxle mount

    Click image to see an enlarged view

    Fig. Remove the clutch module from the transaxle assembly

     

  4.  

To install:

  1. Install or connect the following:

    Clutch module to the transaxle input shaft and place the transaxle into position
     
    Transaxle-to-engine mounting bolts and torque them to 80 ft. lbs. (108 Nm)
     
    Upper transaxle mount and torque the bolts to 45 ft. lbs. (62 Nm)
     
    Driveplate-to-clutch module bolts and torque to 65 ft. lbs. (88 Nm)
     
    Starter
     
    Starter electrical connectors
     
    Bell housing dust cover
     
    Left side engine-to-transaxle bending brace and structural brace. Torque the bolts to 60 ft. lbs. (81 Nm).
     
    Right lateral bending brace and torque the bolts to 60 ft. lbs. (81 Nm)
     
    Power steering hose to the structural collar
     
    Both halfshafts
     
    Clutch master cylinder tube to the slave cylinder
     
    VSS electrical connector
     
    Shift crossover and selector cables to the shift lever
     
    Cables to the bracket and install a new retainer clip
     
    Back-up lamp switch connector
     
    Battery tray
     
    Battery and cables
     
    Air cleaner assembly
     

  2.  
  3. Fill the transaxle fluid to the proper level.
  4.  
  5. Be sure the vehicle-s back-up lights and speedometer are functioning properly.
  6.  
  7. Start the vehicle and check for leaks, repair if necessary.
  8.  

G288 Transaxle
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the transaxle fluid.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner
     
    Power Distribution Center (PDC) from the bracket
     
    Air cleaner/PDC mounting bracket
     
    Gearshift cable from the shift mechanism
     
    Gearshift cable bracket
     
    Back-up lamp switch wiring from the transaxle
     
    Vehicle Speed Sensor (VSS) wire
     
    Clutch master cylinder hydraulic tube from the slave cylinder
     
    Upper transaxle bell housing bolts
     
    Transaxle drain plug, drain the fluid and reinstall the plug
     
    Both halfshafts
     
    Intermediate shaft/bearing bolts and the shaft assembly
     
    2 intercooler connector pipe-to-oil pan bolts and position aside
     
    Oil pan-to-bell housing bolts
     

  6.  
  7. Place a screw jack with a piece of wood on top onto the oil pan.

    2 transaxle upper mount-to-bracket bolts and lower the engine onto the wood and screw jack
     
    Transaxle upper mount bracket
     
    Attach a transaxle jack to the transaxle
     
    Starter lower bolt and ground cable
     
    4 modular clutch drive-to-drive plate bolts. While removing the bolts one tolerance (slotted) drive plate hole will be seen. When this bolt is removed, mark the drive plate and clutch assembly alignment to aid during reinstallation for proper alignment
     
    Remaining transaxle-to-engine bolts
     
    Transaxle
     

  8.  

To install:

  1. Install or connect the following:

    Transaxle into position
     
    Accessible transaxle-to-engine mounting bolts and torque them to 80 ft. lbs. (108 Nm)
     
    4 modular clutch-to-drive plate bolts, align the drive plate and clutch assembly marks made during removal, start with the slotted hole first and tighten the bolts to 65 ft. lbs. (88 Nm)
     
    Upper mount bracket
     
    Raise the transaxle using the jack until the mount bracket is aligned and install the bolts
     
    Starter motor bolt and ground cable
     
    Lower bellhousing bolt
     
    2 intercooler connector pipe-to-oil pan bolts
     
    Remove the drain plug and fill the transaxle with the correct type and amount of fluid. Install the plug and tighten to 35 ft. lbs. (47 Nm).
     
    Intermediate/bearing assembly and tighten the bolts
     
    Both halfshafts
     
    Clutch master cylinder tube to the slave cylinder
     
    VSS electrical connector
     
    Gearshift cable bracket and tighten the bolts
     
    Gearshift crossover and selector cables and secure using new clips
     
    Back-up lamp switch connector
     
    PDC/air cleaner bracket
     
    PDC
     
    Air cleaner assembly
     
    negative battery cable
     

  2.  
  3. Be sure the vehicle-s back-up lights and speedometer are functioning properly.
  4.  
  5. Start the vehicle and check for leaks, repair if necessary.
  6.  

 
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