Power Transfer Unit - Disassembly

DISASSEMBLY

Special Tools:














1. Remove extension housing bolts.





2. Remove the extension housing.
3. Remove the extension housing O-ring.





4. Using a chisel (2) remove the dust shield (1) from the extension housing (3).





5. Remove the pinion housing bolts.





6. Remove the pinion housing.





7. Remove the pinion housing shim.
8. Remove the pinion housing O-ring.






NOTE: The pinion nut is a staked type nut.

9. Using a chisel or a grinder, remove the staked depression in the pinion nut.





10. Remove the output shaft nut, using the Output Shaft Nut Socket and Spline Socket.





11. Press the output shaft from the housing using a press.





12. Remove the output shaft spacer.





13. Remove the output shaft bearing.





14. Remove the output shaft housing small side bearing cup using a brass drift.





15. Remove the output shaft housing large side bearing cup using a brass drift.





16. Install Puller and Jaws onto output shaft head bearing.
17. Place Puller in a vice and remove the bearing.





18. Remove the inspection cover bolts (1).





19. Remove the inspection cover.





20. Remove the side cover bolts (1).





21. Remove the side cover from case.





22. Remove the carrier assembly.





NOTE: Bearing cup is a slip fit.

23. Remove bearing cup by hand (1) or by using a pick.





24. Remove the shim (1) under the bearing cup (3). Measure and record the size of the shim.





25. Remove the inner seal from the PTU cover.
26. Remove the outer seal from the PTU cover.





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.





29. Remove the carrier case seal.





30. Remove the ring gear bolts.





31. Remove the ring gear.





32. Remove ring gear side bearing using Puller , Inserts and Insert.





33. Remove output side bearing using Puller , Inserts and Insert.