Power Transfer Unit Case Disassemble

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NOTE:
Always secure with the pivot pin after rotating.

NOTE:
The power transfer unit can be rotated 360 degrees to facilitate repair.

Mount the power transfer unit case (3) to the DT-36842 Transaxle Holding Fixture (2) and then mount them to the DT-3289-20 Holding Fixture (1).
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NOTE:
The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.

Power Transfer Unit Fill Plug (1) - Remove and DISCARD

NOTE:

The plug and seal are only available as an assembly. Install a NEW plug with seal during assembly.

Power Transfer Unit Drain Plug (2) - Remove and DISCARD

NOTE:

Remove the vent hose connector only if replacement is required.

Power Transfer Unit Vent Hose Connector (3) - Remove and DISCARD
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Power Transfer Unit Half Shaft Retainer Clip (1) - Remove and DISCARD
Power Transfer Unit Half Shaft Seal (2) - Remove and DISCARD

NOTE:

Push the OD flange of the seal to remove from extension housing and shaft.

Power Transfer Unit Intermediate Drive Shaft to Input Shaft Seal (3) - Remove and DISCARD
Power Transfer Unit Intermediate Drive Shaft Retainer (4) - Remove
Power Transfer Unit Intermediate Drive Shaft (5) - Remove
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CAUTION:
Do not nick, scratch or damage the sealing surface. The sealing surface is a machined surface. Damage to the machined surface can cause leakage.

Power Transfer Unit Intermediate Drive Shaft Bearing Retaining Ring (1) - Remove

NOTE:

Use a press to remove the bearing from the power transfer unit intermediate drive shaft.

Power Transfer Unit Intermediate Drive Shaft Bearing (2) - Remove
Power Transfer Unit Intermediate Drive Shaft Bearing Retaining Ring (3) - Remove
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Power Transfer Unit Propeller Shaft Retainer (1) - Remove and DISCARD
Power Transfer Unit Propeller Shaft Seal (2) - Remove and DISCARD

NOTE:

Use a screwdriver to remove the seal from the housing. Remove the inner part of the seal first and then the outer part of the seal. Use care to prevent damage to the housing seal bore or shaft sealing surface. The seal is to be removed in two pieces.

Power Transfer Unit Output Shaft Seal (3) - Remove and DISCARD
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Power Transfer Unit Shift Actuator Bolt (1) - Remove [4x]
Power Transfer Unit Shift Actuator (2) - Remove
Power Transfer Unit Shift Actuator Seal (3) - Remove and DISCARD
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Power Transfer Unit Cover Housing Bolt (1) - Remove and DISCARD [10x]
Power Transfer Unit Cover Housing (2) - Remove
Power Transfer Unit Cover Housing Seal (3) - Remove and DISCARD
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Power Transfer Unit Input Shaft (1) - Remove
Power Transfer Unit Idler Shaft (2) - Remove

NOTE:

The orientation of the tube for assembly. The end of the tube with the knurled OD area is to be facing the extension housing.

Power Transfer Unit Idler Shaft Tube (3) - Remove
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Install the DT-45124-9 Puller Legs (2) to the DT-45124 Removal Bridge (1).
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Using the DT-26941 Bushing and Bearing Remover (4) and DT-45124 Removal Bridge (5), remove and discard the front power transfer unit input shaft seal (1).
Power Transfer Unit Idler Gear Shaft Tube O-ring (2) - Remove and DISCARD

NOTE:

Remove as required.

Power Transfer Unit Locating Pin (3) - Remove [2x]
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Power Transfer Unit Face Seal (1) - Remove and DISCARD
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Power Transfer Unit Idler Gear Shaft Tube O-ring (1) - Remove and DISCARD
Using the DT-26941 Bushing and Bearing Remover (4) and DT-45124 Removal Bridge (3) remove and discard the rear power transfer unit input shaft seal (2).