Chrysler PT Cruiser. Manual - part 408

(12) Hold inner tripod joint and interconnecting

shaft of halfshaft assembly (Fig. 11). Remove inner tri-
pod joint from transaxle by pulling it straight out of
transaxle side gear and transaxle oil seal. When
removing tripod joint, do not let spline or snap
ring drag across sealing lip of the transaxle to
tripod

joint

oil

seal.

When

tripod

joint

removed from transaxle, some fluid will leak out.

CAUTION: The halfshaft, when installed, acts as a
bolt and secures the front hub/bearing assembly. If
vehicle is to be supported or moved on its wheels
with a halfshaft removed, install a PROPER–SIZED
BOLT AND NUT through front hub. Tighten bolt and
nut to 244 N·m (180 ft. lbs.). This will ensure that
the hub bearing cannot loosen.

REMOVAL—DIESEL AND TURBO MODELS

CAUTION: Boot sealing is vital to retain special
lubricants and to prevent foreign contaminants
from entering the C/V joint. Mishandling, such as
allowing the assemblies to dangle unsupported, or
pulling or pushing the ends can cut boots or dam-
age C/V joints. During removal and installation pro-
cedures, always support both ends of the halfshaft
to prevent damage.

(1) Disconnect battery negative cable.
(2) Place transaxle in gated park.
(3) Raise vehicle on hoist.
(4) Remove wheel and tire assembly (Fig. 12).

Fig. 9 Halfshaft Isolation Washer

1 - ISOLATION WASHER

Fig. 10 Disengaging Left Inner Tripod Joint from

Transaxle

1 - FRONT SUSPENSION CROSSMEMBER
2 - PUNCH
3 - TRANSAXLE
4 - HALFSHAFT INNER TRIPOD JOINT
5 - NOTCH

Fig. 11 Tripod Joint Removal from Transaxle

1 - INNER TRIPOD JOINT
2 - TRANSAXLE
3 - SPLINE
4 - OIL SEAL
5 - SNAP RING
6 - INTERCONNECTING SHAFT

3 - 6

HALF SHAFT

HALF SHAFT (Continued)

(5) Remove the cotter pin, nut lock, and spring

washer, and hub nut from the end of the outer C/V
joint stub axle (Fig. 13).

(6) If equipped with ABS, disconnect the front

wheel speed sensor and secure harness out of the
way.

(7) Remove nut and bolt (Fig. 14) retaining ball

joint stud into steering knuckle.

NOTE: Use caution when separating ball joint stud
from steering knuckle, so ball joint seal does not
get damaged.

(8) Separate ball joint stud from steering knuckle

by prying down on lower control arm (Fig. 15).

NOTE: Care must be taken not to separate the inner
C/V joint during this operation. Do not allow half-
shaft to hang by inner C/V joint, halfshaft must be
supported.

(9) Remove halfshaft from steering knuckle by

pulling outward on knuckle while pressing in on half-
shaft. Support outer end of halfshaft assembly. If dif-
ficulty

separating

halfshaft

from

hub

encountered, do not strike shaft with hammer,
instead use puller 1026 to separate (Fig. 16).

Fig. 12 Wheel and Tire Removal

1 - WHEEL/TIRE ASSY.
2 - LUG NUT (5)
3 - HUB

Fig. 13 Halfshaft Retaining Hardware

1 - COTTER KEY
2 - WASHER
3 - HUB NUT
4 - SPRING WASHER
5 - NUT LOCK

Fig. 14 Steering Knuckle at Lower Control Arm Ball

Joint

1 - NUT
2 - BOLT
3 - BALL JOINT

Fig. 15 Separating Lower Control Arm from Steering

Knuckle

1 - STEERING KNUCKLE
2 - PRY BAR
3 - LOWER CONTROL ARM
4 - BALL JOINT STUD

HALF SHAFT

3 - 7

HALF SHAFT (Continued)

(10) Remove halfshaft isolation washer (Fig. 17)

and support outer end of the halfshaft assembly.

NOTE: When left halfshaft is removed from trans-
axle, some fluid may leak out.

NOTE: Removal of the inner tripod joints is made
easier if you apply outward pressure on the joint as
you strike the punch with a hammer. DO NOT PULL
ON INTERCONNECTING SHAFT TO REMOVE, AS
THE INNER JOINT WILL BECOME SEPARATED.

(11) Remove halfshaft(s) (Fig. 18) (Fig. 19). Left

halfshaft: While applying outward pressure on joint
by hand, dislodge inner tripod joint from differential
side gear by striking outward with a punch at extrac-
tion groove. When removing tripod joint and half-
shaft, do not let spline or snap ring drag across
sealing lip of the transaxle to tripod joint oil seal.
Right halfshaft: Slide inner tripod joint off of inter-
mediate shaft. If difficulty is encountered, dislodge
joint from intermediate shaft using punch.

(12) If intermediate shaft is to be removed, remove

three (3) intermediate shaft bearing-to-bracket bolts
(Fig. 18). 2.4L turbo models utilize two (2) interme-
diate shaft bearing-to-bracket bolts. Remove interme-
diate shaft bearing/shaft assembly from transaxle.

Fig. 16 Separating Halfshaft from Hub/Bearing

1 - PULLER 1026
2 - HALFSHAFT

Fig. 17 Halfshaft Isolation Washer

1 - ISOLATION WASHER

3 - 8

HALF SHAFT

HALF SHAFT (Continued)

INSTALLATION

INSTALLATION—EXCEPT DIESEL AND TURBO
MODELS

(1) Thoroughly clean spline and oil seal sealing

surface, on tripod joint. Lightly lubricate oil seal
sealing surface on tripod joint with fresh clean trans-
mission lubricant.

(2) Holding halfshaft assembly by tripod joint and

interconnecting shaft, install tripod joint into trans-
axle side gear as far as possible by hand.

(3) Carefully align tripod joint with transaxle side

gears. Then grasp halfshaft interconnecting shaft
and push tripod joint into transaxle side gear until
fully seated. Test that snap ring is fully engaged
with side gear by attempting to remove tripod
joint from transaxle by hand. If snap ring is
fully engaged with side gear, tripod joint will
not be removable by hand.

(4) Clean all debris and moisture out of steering

knuckle (Fig. 20).

(5) Ensure that front of outer C/V joint, which fits

into steering knuckle (Fig. 21), is free of debris and
moisture before assembling into steering knuckle.

(6) Install halfshaft isolation washer (Fig. 22) and

slide halfshaft back into front hub.

(7) Install steering knuckle onto the ball joint stud

(Fig. 23).

NOTE: At this point, the outer joint will not seat
completely into the front hub. The outer joint will be
pulled into hub and seated when the hub nut is
installed and torqued.

Fig. 18 Halfshaft and Intermediate Shaft—2.2L Turbo Diesel

1 - HALFSHAFT (LH)
2 - TRANSAXLE
3 - INTERMEDIATE SHAFT

4 - BOLT (3)
5 - HALFSHAFT (RH)

HALF SHAFT

3 - 9

HALF SHAFT (Continued)

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