M/T - Gear Rattle at Idle
NUMBER: 06-001-05GROUP: Clutch
DATE: February 19, 2005
THIS BULLETIN IS BEING PROVIDED IN ADVANCE. DO NOT ORDER PARTS OR
PERFORM ANY ACTIONS RELATED TO THIS BULLETIN UNTIL THE WEEK OF
MARCH 7, 2005.
SUBJECT:
Transmission Gear Rattle Sound at Idle
OVERVIEW:
This bulletin involves replacing the modular clutch assembly.
MODELS:
2001 - 2005 (PT) PT Cruiser
NOTE:
This bulletin applies to vehicles equipped with a 2.4L engine (sales code EDZ) and a 5 speed manual transmission (sales code DD5) built on or before March 6, 2005 (MDH 0306XX).
SYMPTOM/CONDITION:
The vehicle operator may describe a rattle sound with the transmission in neutral, engine at idle and clutch pedal released.
DIAGNOSIS:
Using a Scan Tool (DRBIII(R)) and the appropriate Diagnostic Procedures, verify all engine systems are functioning as designed. If DTCs are present record them on the repair order and repair as necessary before proceeding further with this bulletin.
Verify the clutch neutral gear sound at idle as follows:
1. Park the vehicle on a flat surface with the parking brake applied.
2. With A/C in the off position, warm up the engine to normal operating temperature (radiator fan should cycle on and off).
3. Place the transmission gear shift in neutral with the engine at idle. Do not touch the clutch pedal. Close all windows.
4. Load the engine by operating (turn on) the following systems at the same time:
a. Turn on the rear window defroster.
b. Turn on the headlamps.
c. Turn on the radio.
d. Turn on the A/C to it's maximum cooling. Wait for the system to stabilize and make sure that the radiator fan is running.
e. Operate the power windows as if you were trying to close the window. With the window already closed, this will generate more load on the engine.
5. Verify the transmission gear sound is audible.
6. Repeat step 4 at least 6 times (if necessary).
If the vehicle operator describes or experiences the Symptom/Condition and the technician can verify the clutch gear sound is audible, perform the Repair Procedure.
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Replace the Modular Clutch Assembly, p/n 04668555AH, and the 4 attaching bolts, p/n 06504383. Refer to the service information available in TechCONNECT, Section 6 - Clutch/Modular Clutch, Removal and Installation procedures.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.