Intermediate Shaft - All Wheel Drive (AWD)

See TSB 09-25-7 Dec. 09
Intermediate Shaft - All Wheel Drive (AWD)

Special Tool(s):

Special Tool






Removal

CAUTION: The intermediate shaft seal in the power transfer unit (PTU) must be replaced whenever the intermediate shaft is removed. Seals and Gaskets

1. Remove the right halfshaft assembly. Axle Shaft Assembly
2. Remove the 2 intermediate shaft support bracket bolts and the intermediate shaft.






3. Remove and discard the circlip from the outboard end of the intermediate shaft.

Installation






1. Install a new 30 mm (1.181 inch) circlip on the outboard end of the intermediate shaft.
2. Install a new intermediate shaft seal in the power transfer unit (PTU). Seals and Gaskets






3. Position the special tool over the halfshaft oil seal.
4. Position the intermediate shaft in the transaxle and engage the intermediate shaft splines with the transaxle side gears. Make sure the circlip is locked in the gear.
5. Install the 2 intermediate shaft support bracket bolts.
^ Tighten to 40 Nm (30 lb-ft).
6. Install the right halfshaft. Axle Shaft Assembly