Transfer Case - Power Transfer Unit (PTU) - Installation

Power Transfer Unit (PTU)









1. NOTE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is removed from the vehicle.

Using a suitable tool, install the new compression seal.





2. NOTE: A new PTU intermediate shaft seal must be installed whenever the intermediate shaft or PTU is removed from the vehicle.

Using a suitable pry bar, move the engine forward. Install a block of wood to hold the engine in the forward position. Install the PTU with the output flange facing the passenger side, filler plug facing upward. Rotate the PTU to the transaxle. Install the 5 PTU-to-transaxle bolts.
- Tighten to 90 Nm (66 lb-ft).





3. Position the PTU support bracket into place and hand-tighten the 5 PTU support bracket bolts.

1. Tighten the bolts to the transaxle to 70 Nm (52 lb-ft).

2. Tighten the bolts to the engine to 70 Nm (52 lb-ft).





4. Install the roll restrictor-to-transmission bracket and the 3 roll restrictor bracket-to-transmission bolts.
- Tighten to 90 Nm (66 lb-ft).





5. Install the roll restrictor through bolt and the 2 roll restrictor bracket bolts.
- Tighten to 90 Nm (66 lb-ft).





6. Install the roll restrictor through bolt
- Tighten to 103 Nm (76 lb-ft).





7. Install the roll restrictor shield and the 2 roll restrictor nuts.
- Tighten to 11 Nm (97 lb-in).





8. Install the exhaust flexible pipe and RH catalytic converter.

9. Install the intermediate shaft.

10. Line up the index marks on the driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts.
- Tighten to 70 Nm (52 lb-ft).





11. Fill the PTU, if necessary. For additional information, refer to Power Transfer Unit (PTU) Draining and Filling Procedures.

12. Install the LH and RH wheel and tire.