PT Cruiser 2006-2007

Transaxle Removal & Installation

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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:

    The negative battery cable
     
    The air cleaner
     
    The Power Distribution Center (PDC) from the bracket
     
    The air cleaner/PDC mounting bracket
     
    The gearshift cable from the shift mechanism
     
    The gearshift cable bracket
     
    The back-up lamp switch wiring from the transaxle
     
    The Vehicle Speed Sensor (VSS) wire
     
    The clutch master cylinder hydraulic tube from the slave cylinder
     
    The upper transaxle bell housing bolts
     
    The transaxle drain plug, drain the fluid and reinstall the plug
     
    Both halfshafts
     
    The intermediate shaft/bearing bolts and the shaft assembly
     
    The 2 intercooler connector pipe-to-oil pan bolts and position aside
     
    The oil pan-to-bell housing bolts
     

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

    The 2 transaxle upper mount-to-bracket bolts and lower the engine onto the wood and screw jack
     
    The transaxle upper mount bracket
     
    The attach a transaxle jack to the transaxle
     
    The starter lower bolt and ground cable
     
    The 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
     
    The remaining transaxle-to-engine bolts
     
    The transaxle
     

  8.  

To install:

  1. Install or connect the following:

    The transaxle into position
     
    The accessible transaxle-to-engine mounting bolts and torque them to 80 ft. lbs. (108 Nm)
     
    The 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)
     
    The upper mount bracket
     
    The raise the transaxle using the jack until the mount bracket is aligned and install the bolts
     
    The starter motor bolt and ground cable
     
    The lower bell housing bolt
     
    The 2 intercooler connector pipe-to-oil pan bolts
     
    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)
     
    The intermediate/bearing assembly and tighten the bolts
     
    Both halfshafts
     
    The clutch master cylinder tube to the slave cylinder
     
    The VSS electrical connector
     
    The gearshift cable bracket and tighten the bolts
     
    The gearshift crossover and selector cables and secure using new clips
     
    The back-up lamp switch connector
     
    The PDC/air cleaner bracket
     
    The PDC
     
    The air cleaner assembly
     
    The 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.  

T-350 Transaxle



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

    The battery cables
     
    The battery and tray
     
    The air cleaner
     
    The back-up lamp switch wiring from the transaxle
     
    The shift selector and crossover cable and move them out of the way
     
    The Vehicle Speed Sensor (VSS) wire
     
    The clutch master cylinder hydraulic tube from the slave cylinder
     
    Both halfshafts
     
    The bell housing dust cover
     
    The power steering hose from the structural collar
     
    The left side engine-to-transaxle lateral bending brace and structural collar
     
    The right side engine-to-transaxle lateral bending brace
     
    The starter
     
    The driveplate-to-clutch module bolts and support the engine at the oil pan
     
    The transaxle upper mount bolts and lower the powertrain assembly onto the support
     
    The transaxle-to-engine mounting bolts
     
    The transaxle
     
    The clutch module from the input shaft
     
    The slave cylinder
     
    The upper transaxle mount

    Click image to see an enlarged view

    Fig. Remove the clutch module from the transaxle assembly

     

  6.  

To install:

  1. Install or connect the following:

    The clutch module to the transaxle input shaft and place the transaxle into position
     
    The transaxle-to-engine mounting bolts and torque them to 80 ft. lbs. (108 Nm)
     
    The upper transaxle mount and torque the bolts to 45 ft. lbs. (62 Nm)
     
    The driveplate-to-clutch module bolts and torque to 65 ft. lbs. (88 Nm)
     
    The starter
     
    The starter electrical connectors
     
    The bell housing dust cover
     
    The left side engine-to-transaxle bending brace and structural brace. Torque the bolts to 60 ft. lbs. (81 Nm).
     
    The right lateral bending brace and torque the bolts to 60 ft. lbs. (81 Nm)
     
    The power steering hose to the structural collar
     
    Both halfshafts
     
    The clutch master cylinder tube to the slave cylinder
     
    The VSS electrical connector
     
    The shift crossover and selector cables to the shift lever
     
    The cables to the bracket and install a new retainer clip
     
    The back-up lamp switch connector
     
    The battery tray
     
    The battery and cables
     
    The 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.  

 
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