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Power Transfer Unit

Fig 1: SPOOL SHAFT OUTPUT SIDE BEARING
GC0056233Courtesy of CHRYSLER LLC
  1. Install output side spool shaft bearing using Installer C-3095-A.
    Fig 2: SPOOL SHAFT RING GEAR SIDE BEARING
    GC0056234Courtesy of CHRYSLER LLC
  2. Install ring gear side bearing using Installer 8148.
    Fig 3: RING GEAR
    GC0056230Courtesy of CHRYSLER LLC
  3. Install the ring gear.
    Fig 4: RING GEAR BOLTS
    GC0056229Courtesy of CHRYSLER LLC
  4. Install thenew  ring gear Bolts and tighten to 74 N.m (55 ft. lbs.).
    Fig 5: INSTALL CARRIER CASE SEAL
    GC0056235Courtesy of CHRYSLER LLC
  5. Install the carrier case seal using Installer 9851 and Handle C- 4171.
    Fig 6: CARRIER RACE HOUSING SIDE
    GC0056227Courtesy of CHRYSLER LLC
  6. Install the shim (3) under the bearing cup (1) in the case side.
  7. Install the bearing cup by hand.
    Fig 7: INSTALL CARRIER COVER INNER SEAL
    GC0056236Courtesy of CHRYSLER LLC
  8. Install the inner seal into the PTU cover using Installer 9852 and Handle C-4171.
    Fig 8: INSTALL CARRIER COVER OUTER SEAL
    GC0056237Courtesy of CHRYSLER LLC
  9. Install the outer seal into the PTU cover using Installer 9853 and Handle C-4171.
    Fig 9: COVER SIDE CUP AND SHIM
    GC0056225Courtesy of CHRYSLER LLC
  10. Install the shim (1) under the bearing cup (3).
  11. Install bearing cup by hand (3).
    Fig 10: SIDE COVER
    GC0056221Courtesy of CHRYSLER LLC
  12. Install the carrier assembly into the case
  13. Install the side cover
  14. Tighten side cover bolts (1) to 23 N.m (17 ft. lbs.).
    Fig 11: INSTALL PINION HEAD BEARING
    GC0056238Courtesy of CHRYSLER LLC
  15. Install the output shaft head bearing on to the pinion shaft using Installer 9714 and a Press.
    Fig 12: INSTALL PINION HEAD BEARING CUP
    GC0056239Courtesy of CHRYSLER LLC
  16. Install the output shaft head bearing cup using Installer 6061 and Handle C-4171.
    Fig 13: OUTPUT SHAFT TAIL BEARING CUP
    GC0056240Courtesy of CHRYSLER LLC
  17. Install the output shaft tail bearing cup using Installer 9855 and Handle C-4171.
    Fig 14: PINION SHAFT SPACER
    GC0056214Courtesy of CHRYSLER LLC
  18. Install the output shaft spacer onto the output shaft.
    Fig 15: OUT PUT SHAFT TAIL BEARING
    GC0056241Courtesy of CHRYSLER LLC
  19. Install output shaft into output shaft housing.
  20. Install output shaft tail bearing on to out put shaft using Installer L-4411.
    Fig 16: OUT PUT SHAFT NUT
    GC0056211Courtesy of CHRYSLER LLC
    NOTE: The output shaft nut is a staked type nut.
  21. Install the output shaft nut (1) onto the output shaft (2).
    Fig 17: INSTALL PINION NUT
    GC0056242Courtesy of CHRYSLER LLC
  22. Tighten the output shaft nut using Pinion Nut Socket 9921 to 150 N.m (111 ft. lbs.).
  23. Using an inch pound torque wrench check and Pinion Nut Socket 9921 (1) check the rotating torque, it should be 30 in. lbs. Add.002 in. larger shim to increase rotating torque and add.002 in. smaller shim to decrease rotating torque. Repeat until proper turning torque is obtained.
  24. Using a punch stake the output shaft nut.
    Fig 18: PINION HOUSING SHIM
    GC0056210Courtesy of CHRYSLER LLC
  25. Install the pinion housing O-ring (3).
  26. Install the pinion housing shim (1).
    Fig 19: PINION SHAFT SEAL
    GC0056243Courtesy of CHRYSLER LLC
  27. Install the output shaft seal using Installer 9851 and Handle C-4171.
    Fig 20: EXTENSION HOUSING O-RING
    GC0056207Courtesy of CHRYSLER LLC
  28. Install anew  extension housing O-ring.
    Fig 21: PINION HOUSING
    GC0056209Courtesy of CHRYSLER LLC
  29. Install the output shaft housing and bolts onto the carrier housing.
  30. Apply pattern check grease to the ring gear.
    Fig 22: DUST SHIELD ON PTU MK
    GC0056244Courtesy of CHRYSLER LLC
  31. Using a block of wood (2) install the dust shield (3) onto the extension housing (1).
    Fig 23: EXTENSION AND PINION HOUSING BOLTS
    GC0056206Courtesy of CHRYSLER LLC
  32. Install the extension housing and bolts.
  33. Tighten output shaft housing bolts to 38 N.m (28 ft. lbs.).
  34. Tighten the extension housing bolts to 38 N.m (28 ft. lbs.).
    Fig 24: VENT
    GC0056245Courtesy of CHRYSLER LLC
  35. Clean cover and apply MOPAR® axle RTV or equivalent.
  36. Install the vent and bolts, tighten the bolts to 23 N.m (17 ft. lbs.).
    Fig 25: VENT SHIELD
    GC0056246Courtesy of CHRYSLER LLC
  37. Install the vent shield and bolts. Tighten the bolts to 23 N.m (17 ft. lbs.).
    Fig 26: INSPECTION COVER
    GC0056247Courtesy of CHRYSLER LLC
  38. Clean cover and apply MOPAR® axle RTV.
  39. Apply MOPAR® lock & seal adhesive or equivalent to bolts.
  40. Install the inspection cover and bolts. Tighten the bolts to 23 N.m (17 ft. lbs.).
  41. Fill the PTU. See STANDARD PROCEDURE .
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