5 speed question

[brngrhd]

here is some info on the recall, and there are no tsb's on clutch noise.


Safety Recall No. C09
Dual Mass Flywheel and Clutch Assembly
2003 (PT) Chrysler PT Cruiser
NOTE: This recall applies only to the above vehicles equipped with a 2.4L Turbo
engine (Sales Code EDV) and a manual transaxle (Sales Code DDD) built
through November 29, 2002 (MDH 112919).
A flywheel pin on about 865 of the above vehicles may loosen and become lodged
between the clutch disc and the flywheel. If this occurs, the clutch may not
disengage when the pedal is depressed, which could cause an accident without
warning.
The dual mass flywheel and clutch assembly must be replaced.
Models
IMPORTANT: Some of the involved vehicles may be in dealer new vehicle
inventory. Federal law requires you to stop sale and complete this recall
service on these vehicles before retail delivery. Dealers should also consider this
requirement to apply to used vehicle inventory and should perform this recall on
vehicles in for service. Involved vehicles can be determined by using the VIP
inquiry process.
Subject
Repair
Safety Recall No. C09 – Dual Mass Flywheel and Clutch Assembly Page 2
A. Dual Mass Flywheel and Clutch Assembly
Part Number Description
CAA0C090 Dual Mass Flywheel and Clutch Assembly
Due to the small number of involved vehicles, no parts will be distributed
initially. Dealers should order clutch assemblies at the time appointments
are scheduled to assure that the part is available when the customer
arrives.
B. Automatic Transmission Fluid
Part Number Description
05013457AA Mopar ATF+4 (MS-9602) Automatic
Transmission Fluid (Quart bottle)
1. Disconnect the negative battery cable.
NOTE: To enhance customer satisfaction, remember to reset the clock
when you have completed the service procedure.
2. Disconnect the air inlet tube from the turbocharger and then remove the air
cleaner and air inlet tube as an assembly.
3. Remove the Power Distribution
Center (PDC) from its bracket and
then set the PDC aside.
4. Remove the PDC/air cleaner
mounting bracket (Figure 1).
5. Disconnect the positive battery
cable.
6. Remove the battery hold down and
then remove the battery.
7. Disconnect the battery temperature
sensor electrical connector.
Parts Information
Service Procedure
Figure 1
PDC/AIR
CLEANER
BRACKET
Safety Recall No. C09 – Dual Mass Flywheel and Clutch Assembly Page 3
8. Remove the battery tray.
9. Disconnect the gearshift cables
from the shift mechanism
(Figure 2).
10. Remove the gearshift cable
bracket (Figure 2). Set the
bracket and cables aside.
11. Disconnect the back-up lamp
switch electrical connector
(Figure 3).
12. Disconnect the vehicle speed
sensor electrical connector
(Figure 3).
Service Procedure (Continued)
Figure 2
Figure 3
TRANSAXLE
CABLE
BRACKET
GEARSHIFT
CABLE
CABLE
CLIP
BACK-UP
LAMP
SWITCH
VEHICLE
SPEED
SENSOR
Safety Recall No. C09 – Dual Mass Flywheel and Clutch Assembly Page 4
13. Using Special Tool 6638A,
disconnect the clutch master
cylinder hydraulic tube from the
clutch slave cylinder (Figure 4).
14. Remove the upper starter bolt.
15. Remove the two (2) transaxle
upper bell housing-to-engine
cylinder block bolts.
16. Raise the vehicle on an
appropriate hoist.
17. Remove both front tire and
wheel assemblies.
18. Remove the transaxle drain plug
and drain the fluid into a suitable
container (Figure 5). Reinstall
the drain plug and tighten it to
32 ft-lbs (43 N·m).
19. Remove the left axle shaft nut
cap and cotter pin.
20. Remove the left axle shaft
retaining nut.
21. Remove the two (2) left steering
knuckle-to-front strut fasteners.
22. Remove the left front brake tube
bracket bolt.
23. Remove the left steering knuckle from the strut and then remove the left axle
shaft from the steering knuckle.
Service Procedure (Continued)
Figure 4
Figure 5
SLAVE
CYLINDER
MASTER
CYLINDER
TUBE
FILL
PLUG
RIGHT
AXLE
SEAL
DRAIN
PLUG
Safety Recall No. C09 – Dual Mass Flywheel and Clutch Assembly Page 5
24. Remove the left halfshaft

[026TB4U]

how does it shift if you hear a grind like i did shifting into fifth or anyu other gear for that matter then their is a good chance that your blocker rings are gone . shift normally into fifth it should be smooth . i had to wait 1 or 2 seconds and then engage fifth to prevent hearing the noise.[8)]

[Batman]

quote:Originally posted by 026TB4U

how does it shift if you hear a grind like i did shifting into fifth or anyu other gear for that matter then their is a good chance that your blocker rings are gone . shift normally into fifth it should be smooth . i had to wait 1 or 2 seconds and then engage fifth to prevent hearing the noise.[8)]

My GT's 5-sp is one of the nicest I've ever experienced. I've been driving manual transmissions for 30+ years (everything from a '26 Model T pickup(which I currently own)to English roadsters '50s and '60s era) and my experience tells me that if you hear grinding when you shift, it's either the synchro is gone or the clutch isn't engaging properly (to include operator error).

Good luck in geeting it resolved.

[bigdogdad]

Batman

Foxylady (give credit where crdit is due)posted this on another forum. Is this you.[)][]

[Batman]

There are always imposters trying to steal an individual's identity. The picture is obviously one of those imposters. This guy's wings (everybody knows that Batman does not have wings) would never fit in a PT Cruiser.

Thanks for the opportunity to clear this up![8]

[PTGT Redman]

yup.clunk

[karl]

Dear crazyjoe,

We also have a similar warranty here in Canada - 7 years or 100,000 kilometers (or maybe it's 110,000). However, this does NOT cover what DM considers to be "wear and tear" items such as brakes, mufflers and clutch plates. I think you'll find this to be also true in the U.S.

[Denny Moore]

quote:Originally posted by Gary04GT

Can't say that I have heard it. My car was built 1/30/03 and I never received a recall notice.