Section 3 (Power Transfer Unit): Installation: Installation

Fig 1: REMOVE - INSTALL PTU

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1. Roll the PTU in, moving from front to back (1) .
   Fig 2: PTU INSTALL

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2. Rest the PTU (1) on the frame (3) while the engine and transaxle (2) are raised back into position.
   Fig 3: JACK AT TRANS MOUNT

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3. Lower screw jack (2) until rear mount through bolt can be installed.
   Fig 4: REAR ENGINE MOUNT

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4. Install rear mount through bolt (2) and tighten bolt to 75 Nm (55 ft. lbs.).
   Fig 5: FRONT ENGINE MOUNT

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5. Install the transmission crossmember and bolts, (2) tighten to 75 Nm (55 ft. lbs.).
6. Install the through bolt at the front transmission mount (1) and tighten to 75 Nm (55 ft. lbs.).
   Fig 6: PTU O-RING

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   NOTE: STICKING THE O-RING WITH VASELINE OR TRANS ASSEMBLY GREASE IS RECOMMENDED.
7. Insure that the O-ring (1) between the PTU and transaxle is in place.
   Fig 7: PTU MOUNTING BOLTS

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8. Slide the PTU into place.
9. Install and tighten the PTU mounting bolts (1,2) to 58 N.m (43ft. lbs.).
10. Lower the hoist.
11. Install the maniverter. Refer to Exhaust System/CONVERTER, Catalytic - Installation .
    Fig 8: AIR CLEANER ASSEMBLY

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12. Install the air box (1).
13. Install engine trim cover.
14. Raise the vehicle on the hoist.
15. Install the exhaust system. Refer to Exhaust System/MUFFLER, Exhaust - Installation .
16. Install the Prop shaft. Refer to Differential and Driveline/Propeller Shaft - Installation .
17. Install the axle shafts. Refer to Differential and Driveline/Half Shaft - Installation .
18. Fill PTU. See Transmission and Transfer Case/Power Transfer Unit - Standard Procedure .
19. Lower hoist.
20. Connect battery cables (2).
21. Top off the fluids. See Transmission and Transfer Case/Power Transfer Unit - Standard Procedure .