PT Cruiser Forum  
Advertisements
       

Go Back   PT Cruiser Forum > General Forums > Tech & Performance Forum

PT Cruiser Forum

Advertisements
5 Speed trans removal,, clutch replace info?

 
Like Tree2Likes

Reply
 
LinkBack Thread Tools Display Modes
  #1 (permalink)  
Old 23 May 2014, 10:23 pm
Cool Cruiser
 
Join Date: Jul 2011
Location: somerset,ky
Posts: 223
Default 5 Speed trans removal,, clutch replace info?

anyone know of a good link on here about removing and installing the 5 speed trans on my PT..01 model?,,and clutch replacement ..a link would be nice thanks
Reply With Quote
  #2 (permalink)  
Old 24 May 2014, 07:31 am
Obsessed Cruiser
 
Join Date: Sep 2001
Posts: 27,744
Default Re: 5 Speed trans removal,, clutch replace info?

Here are some links......



http://www.justanswer.com/chrysler/2...iser-2002.html
__________________
Rules of the forum have been updated as of *07/07/2019* Please read them over.

- All decisions by the Moderator are semi-permanent, can and may be changed at his discretion but definitely will be the final word. Any action performed by the Administrator or Moderators are not to be discussed on the forum.
Reply With Quote
  #3 (permalink)  
Old 24 May 2014, 09:00 am
Veteran Cruiser
 
Join Date: Mar 2012
Location: darien il
Posts: 4,592
Default Re: 5 Speed trans removal,, clutch replace info?

while it's still on the ground, start by loosening the big axle nuts and lug nuts. also remove the battery and battery tray. disconnect the wiring connectors and shift linkage on the trans(i used a visegrip and a small hammer to tap the shifter linkage clips off as they were stubborn and rusty)

THEN jack the car up and put it on jackstands.

drain the transmission

remove the wheels, and axle nuts, and the large axle washers.

if you remove the 2 large bolts holding the strut to the knuckle, you can push the axles out of the hub IF the wheel is turned ALL the way. i find this faster than disconnecting the ball joint like people recommend.

pop the axles out of the trans with a large flat head or small prybar, remove and set the axles to the side.

take off the clutch inspection cover/clutch slave cylinder where the trans meets the engine by the oilpan. leave the clutch hydraulics hooked up, just tuck the slave cyl out of the way.

now you can see the 4 18mm bolts holding the flywheel to the flexplate. those are next.

i remove those by using a cut down 18mm socket. it will prevent the flywheel from spinning because the wrench will touch the block. -most people jam stuff in the flywheel ring gear or put a breaker bar on the balancer bolt to stop it from spinning, the socket method is definitely easier.

once those 4 bolts are out, unbolt the starter and tuck it aside leaving the wires connected, take off all the trans to engine block bolts except the top bolt, including starter bolts.

support the oilpan with a jack and a block of wood

remove the transmission mount under the battery tray

slightly lower the jack supporting the engine

take out the top transmission bolt (i had my girlfriend remove the last bolt while i was under the car holding the trans)

trans will come right out. you might have to play with the height of the jack to get the trans to clear the crossmember.

from experience....when you put the trans back in, remember that this car is goofy. the clutch assembly goes in the trans. if you bolt it to the engine with the trans out, the trans will not fit back in.

this should only take 2-3 hours to remove and it goes back together quicker than it comes out. i used loctite on the flywheel bolts


------

below is the alldata.com version, i wouldn't use this method as it likely has a lot of extra steps, but i'm providing it for you because it has torque specs.

------

2001 Chrysler Truck PT Cruiser L4-2.4L VIN B
Vehicle Transmission and Drivetrain Manual Transmission/Transaxle Service and Repair Removal and Installation

Removal and Installation

TRANSAXLE
REMOVAL

Raise hood.




Remove air cleaner assembly (Fig. 37).
Disconnect both battery cables.




Remove battery hold down clamp and bolt, and remove battery (Fig. 38).




Remove battery tray from bracket (Fig. 39).




Disconnect back-up lamp switch connector (Fig. 40).




Remove shift cable-to-bracket clips (Fig. 41).
Disconnect shift selector and crossover cable from levers (Fig. 41). Remove cables and secure out of the way.




Disconnect the vehicle speed sensor connector (Fig. 42).
Raise vehicle on hoist.




Remove transaxle oil drain plug (Fig. 43) and drain oil into a suitable container. Reinstall drain plug and torque to 28 Nm (250 inch lbs.) torque.






Using tool 6638A (Fig. 44), disconnect clutch master cylinder hydraulic tube from the hydraulic clutch slave cylinder (Fig. 45).
Remove both axle half shafts.




Disconnect power steering hose from structural collar (Fig. 46)




Remove the left engine-to-transaxle lateral bending brace and structural collar (Fig. 47). See: Engine, Cooling and Exhaust\Engine\Engine Mount




Remove bellhousing dust cover (Fig. 48).




Remove the right engine-to-transaxle lateral bending brace (Fig. 49).




Remove starter motor (Fig. 50).




Remove drive plate-to-clutch module bolts (Fig. 52).
Support engine at oil pan with screw jack and wood block.




Remove transaxle upper mount bolts (Fig. 51).
Carefully lower engine and transaxle on screw jack until proper removal clearance is obtained.
Obtain a helper to assist in holding transaxle while removing transaxle-to-engine mounting bolts (Fig. 52).
Remove transaxle from vehicle (Fig. 52).
Remove clutch module (Fig. 52) from transaxle input shaft.




If installing a new or replacement transaxle, remove the clutch slave cylinder as shown in (Fig. 53), and transfer to the replacement unit.




If installing a new or replacement transaxle, remove the upper mount as shown in (Fig. 54), transfer to the replacement unit and torque all bolts to 62 Nm (45 ft. lbs.) torque.

INSTALLATION

Install clutch module onto input shaft. Install transaxle into position.
Install transaxle-to-engine mounting bolts (Fig. 52) and tighten to 108 Nm (80 ft. lbs.) torque.
Raise engine and transaxle with screw jack until upper mount bracket aligns with upper mount. Install mount bolts and tighten to 68 Nm (50 ft. lbs.) torque (Fig. 51).
Remove screw jack.
Install drive plate-to-clutch module bolts and torque to 88 Nm (65 ft. lbs.) torque.
Install starter motor and tighten bolts to 54 Nm (40 ft. lbs.) torque. Make sure to fasten ground cable to upper starter bolt as shown in (Fig. 50).
Connect starter electrical harness and tighten positive cable nut to 10 Nm (90 inch lbs.) torque.
Install bellhousing dust cover (Fig. 48).
Install left engine-to-transaxle bending brace and structural collar (Fig. 47).
Install power steering hose to structural collar.
Install the right lateral bending brace and tighten bolts to 81 Nm (60 ft. lbs.) torque (Fig. 49).
Install both front axle driveshafts.
Fill transaxle with suitable amount of Mopar Manual Transaxle Lubricant (PN 04874465).
Connect clutch master cylinder tube to the hydraulic clutch slave cylinder (Fig. 45). An audible click should be heard. Verify connection by pushing and pulling quick connect.
Lower vehicle.
Connect vehicle speed sensor connector (Fig. 42).
Connect shift crossover and selector cables to shift lever. Install cables to bracket and install retaining clips (Fig. 41).
Connect back-up lamp switch connector (Fig. 40).
Install battery tray (Fig. 39).
Install battery and tighten hold down clamp to secure battery (Fig. 38).
Install the air cleaner assembly (Fig. 37).
Connect the battery cables.
Road test vehicle and inspect for leaks.
sanatanadharma and Fk5 like this.

Last edited by rob342; 25 May 2014 at 09:17 am.
Reply With Quote
  #4 (permalink)  
Old 24 May 2014, 11:29 am
JDB JDB is offline
Young Cruiser
 
Join Date: May 2014
Posts: 81
Default Re: 5 Speed trans removal,, clutch replace info?

GREAT info guys!

And Rooster. A word of advice since I'm new and don't know anyones experience. Just in case this is your first rodeo, replace or rebuild EVERYTHING that you have to take off while you're at it.

Don't just do the clutch and pressure plate. Pilot bearing...if this car has 'um...wheel bearings, ANYthing that has to be unbolted and has similar wear time as the part you need to replace should be done while you're at it. Inspect and clean speed sensors, seals...the whole nine yards.

It's not something a shop would do, but it could save ya a LOT of aggravation later if you plan on driving the car for a long time.

Not to mention knuckle skin. ;~)
Reply With Quote
  #5 (permalink)  
Old 24 May 2014, 12:27 pm
Veteran Cruiser
 
Join Date: Mar 2012
Location: darien il
Posts: 4,592
Default Re: 5 Speed trans removal,, clutch replace info?

^ new $8 axle seals might be a good idea. it's only 5 minutes extra work. i did the rear main seal on the engine since i was in there. it's cheap and easy.

Last edited by rob342; 25 May 2014 at 09:18 am.
Reply With Quote
  #6 (permalink)  
Old 24 May 2014, 09:12 pm
Cool Cruiser
 
Join Date: Jul 2011
Location: somerset,ky
Posts: 223
Default Re: 5 Speed trans removal,, clutch replace info?

awesome man thanks..I"d see the you tube stuff but needed more info..done alot of chevy stuff but no front wheel drives..

I guess i"ll go with a stock style clutch set up..and throw out bearing..seen em on the bay for around $150...shipped..also seen one for $165 that red and supposed to be higher performance?...any thought s on a clutch set up for this car?..
Reply With Quote
  #7 (permalink)  
Old 25 May 2014, 07:21 am
Veteran Cruiser
 
Join Date: Mar 2012
Location: darien il
Posts: 4,592
Default Re: 5 Speed trans removal,, clutch replace info?

Quote:
Originally Posted by drumrooster View Post
awesome man thanks..I"d see the you tube stuff but needed more info..done alot of chevy stuff but no front wheel drives..

I guess i"ll go with a stock style clutch set up..and throw out bearing..seen em on the bay for around $150...shipped..also seen one for $165 that red and supposed to be higher performance?...any thought s on a clutch set up for this car?..
the stock clutch is more than adequate. i chirp third with my $150 rock auto clutch. performance clutches in a stock car are a bad idea. the increased pressure is bad for the crappy hydraulics and the increased grip is bad for the axles and transmission. unless you plan to do burnouts by dumping the clutch in third gear there's no need. the exedy that sells for $150 is self adjusting like the stock one. the performance one likely is not. i can't even begin to wonder how you'd adjust the hydraulics. if your PT is like mine, there is no bleeder on the master, slave, or the line. that might cause you an expensive headache down the road.

Last edited by rob342; 25 May 2014 at 07:25 am.
Reply With Quote
  #8 (permalink)  
Old 30 May 2014, 09:58 pm
Cool Cruiser
 
Join Date: Jul 2011
Location: somerset,ky
Posts: 223
Default Re: 5 Speed trans removal,, clutch replace info?

thanks for all the info...what years tran will work in a 01 model? 01-01 only? or will 3-4-5-6 fit?
Reply With Quote
  #9 (permalink)  
Old 04 Feb 2016, 02:51 pm
_PTGT03's Avatar
Fanatic Cruiser
 
Join Date: Oct 2015
Location: Abbotsford, British Columbia.
Posts: 759
Default Re: 5 Speed trans removal,, clutch replace info?

im trying to get the 6638a hydraulic line disconnect tool. my entire job is now on hold. snap on will take 7 days to order it in. anybody know an alternate tool that i can use ?
__________________
2003 GT M/T in Onyx Green Pearl on Michelin Pilot Sport AS 3 Plus Tires 205/50ZR17. Dark Slate Gray Interior. OEM cargo net, parcel shelf, slush mats and trunk protector, mud flaps, mopar subwoofer. Platinum edition pedals, Neon SX 2.0 steering wheel with black+grey wrapped leather cover. Generic lowering springs, KYB gas shocks, Valeo solid flywheel conversion and clutch kit. Urethane insert engine mounts. Energy suspension full body urethane bushing kit. Chrysler premium front speakers, Jenson 6x9 rears. Boston Audio 4x55W amp. Panasonic head unit with xtenzi bluetooth. 300W AC power inverter. Escort 360max and Escort Shifter ZR4, dual front+rear dash camera. stage 1 blow off valve and syked tune computer . Boost and oil pressure gauges with Turbo-Timer. Needswings 3" exhaust elbow, Electric valve actuated Y-pipe with catalytic converter. To do: coilovers, 2step controller, quaife diff, Air-Fuel Meter
Reply With Quote
  #10 (permalink)  
Old 04 Feb 2016, 07:55 pm
Veteran Cruiser
 
Join Date: Mar 2012
Location: darien il
Posts: 4,592
Default Re: 5 Speed trans removal,, clutch replace info?

Try making one by cutting the two inner prongs off a salad fork.

IMG_20160204_185811.jpg

^that can't be hard to make


Edit: try just cutting off one middle prong and spreading them as needed.

Last edited by rob342; 04 Feb 2016 at 08:26 pm.
Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Similar Threads
Thread Thread Starter Forum Replies Last Post
Clutch removal Garrett Tech & Performance Forum 10 04 Mar 2014 07:31 pm
tools needed to replace 2003 clutch Anthony1 Tech & Performance Forum 1 12 Jan 2014 10:25 pm
5 speed trans oil? Kjj Tech & Performance Forum 2 29 Sep 2010 03:55 am
Headlight Removal/Replace 2k1PT General PT Cruiser Discussions 7 31 Aug 2008 05:36 pm
GT 5 speed clutch noise or " clutch chatter". boosta General Turbo Discussions 3 11 Aug 2003 08:10 pm


All times are GMT -5. The time now is 12:19 am.




Powered by vBulletin® Version 3.8.2
Copyright ©2000 - 2019, Jelsoft Enterprises Ltd.
LinkBacks Enabled by vBSEO 3.6.0 PL2 © 2011, Crawlability, Inc.
vB.Sponsors