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Power Transfer Unit

WARNING: This page is about a different variant/trim than selected.
Fig 1: EXTENSION AND PINION HOUSING BOLTS
GC0056206Courtesy of CHRYSLER LLC
  1. Remove extension housing bolts.
    Fig 2: EXTENSION HOUSING O-RING
    GC0056207Courtesy of CHRYSLER LLC
  2. Remove the extension housing.
  3. Remove the extension housing O-ring.
    Fig 3: DUST SHIELD OFF PTU MK
    GC0056208Courtesy of CHRYSLER LLC
  4. Using a chisel (2) remove the dust shield (1) from the extension housing (3).
    Fig 4: EXTENSION AND PINION HOUSING BOLTS
    GC0056206Courtesy of CHRYSLER LLC
  5. Remove the pinion housing bolts.
    Fig 5: PINION HOUSING
    GC0056209Courtesy of CHRYSLER LLC
  6. Remove the pinion housing.
    Fig 6: PINION HOUSING SHIM
    GC0056210Courtesy of CHRYSLER LLC
  7. Remove the pinion housing shim.
  8. Remove the pinion housing O-ring.
    Fig 7: PINION SHAFT NUT
    GC0056211Courtesy of CHRYSLER LLC
    NOTE: The pinion nut is a staked type nut.
  9. Using a chisel or a grinder, remove the staked depression in the pinion nut.
    Fig 8: REMOVE PINION NUT
    GC0056212Courtesy of CHRYSLER LLC
  10. Remove the output shaft nut, using the Output Shaft Nut Socket 9921 and Spline Socket 9922.
    Fig 9: PRESS PINION
    GC0056213Courtesy of CHRYSLER LLC
  11. Press the output shaft from the housing using a press.
    Fig 10: PINION SHAFT SPACER
    GC0056214Courtesy of CHRYSLER LLC
  12. Remove the output shaft spacer.
    Fig 11: PINION SHAFT BEARING.
    GC0056215Courtesy of CHRYSLER LLC
  13. Remove the output shaft bearing.
    Fig 12: REMOVE SMALL SIDE BEARING CUP
    GC0056216Courtesy of CHRYSLER LLC
  14. Remove the output shaft housing small side bearing cup using a brass drift.
    Fig 13: REMOVE LARGE SIDE BEARING CUP
    GC0056217Courtesy of CHRYSLER LLC
  15. Remove the output shaft housing large side bearing cup using a brass drift.
    Fig 14: PULL PINION HEAD BEARING
    GC0056218Courtesy of CHRYSLER LLC
  16. Install Puller 6444 and Jaws 6451 onto output shaft head bearing.
  17. Place Puller in a vice and remove the bearing.
    Fig 15: INSPECTION COVER
    GC0056219Courtesy of CHRYSLER LLC
  18. Remove the inspection cover bolts (1).
    Fig 16: REMOVE INSPECTION COVER
    GC0056220Courtesy of CHRYSLER LLC
  19. Remove the inspection cover.
    Fig 17: SIDE COVER
    GC0056221Courtesy of CHRYSLER LLC
  20. Remove the side cover bolts (1).
    Fig 18: REMOVE SIDE COVER.
    GC0056222Courtesy of CHRYSLER LLC
  21. Remove the side cover from case.
    Fig 19: CARRIER
    GC0056223Courtesy of CHRYSLER LLC
  22. Remove the carrier assembly.
    Fig 20: CARRIER BEARING CUP AND SEAL.
    GC0056224Courtesy of CHRYSLER LLC
    NOTE: Bearing cup is a slip fit.
  23. Remove bearing cup by hand (1) or by using a pick.
    Fig 21: COVER SIDE CUP AND SHIM
    GC0056225Courtesy of CHRYSLER LLC
  24. Remove the shim (1) under the bearing cup (3). Measure and record the size of the shim.
    Fig 22: INNER COVER SEAL
    GC0056226Courtesy of CHRYSLER LLC
  25. Remove the inner seal from the PTU cover.
  26. Remove the outer seal from the PTU cover.
    Fig 23: CARRIER RACE HOUSING SIDE
    GC0056227Courtesy of CHRYSLER LLC
  27. Remove bearing cup by hand (1) or by using a pick.
  28. Remove the shim (3) under the bearing cup (1). Measure and record the size of the shim.
    Fig 24: CARRIER CASE SEAL.
    GC0056228Courtesy of CHRYSLER LLC
  29. Remove the carrier case seal.
    Fig 25: RING GEAR BOLTS
    GC0056229Courtesy of CHRYSLER LLC
  30. Remove the ring gear bolts.
    Fig 26: RING GEAR
    GC0056230Courtesy of CHRYSLER LLC
  31. Remove the ring gear.
    Fig 27: REMOVE DIFF SIDE BEARING
    GC0056231Courtesy of CHRYSLER LLC
  32. Remove ring gear side bearing using Puller C-293-PA, Inserts C-293-37 and Insert C-4487-1.
    Fig 28: REMOVE OUTPUT SIDE BEARING
    GC0056232Courtesy of CHRYSLER LLC
  33. Remove output side bearing using Puller C-293-PA, Inserts C-293-37 and Insert C-4487-1.
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