Transfer Case: Service and Repair

Power Transfer Unit (PTU)





NOTE: 3.5L with Aisin AW21 transaxle shown, 3.0L with 6F35 transaxle similar.









Vehicles equipped with Aisin AW21 transaxle

1. NOTICE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is removed from the vehicle. Failure to replace the compression seal may allow debris to enter the area around the transaxle seal and cause the transaxle seal to fail.

Using a suitable tool, install the new compression seal.






All vehicles

2. Position the Power Transfer Unit (PTU) to the transaxle. Install the 5 PTU (Power Transfer Unit) -to-transaxle bolts.
- Tighten to 90 Nm (66 lb-ft).






3. Position the PTU (Power Transfer Unit) support bracket into place and install the 5 PTU (Power Transfer Unit) support bracket bolts.
1. Tighten the bolts to the PTU (Power Transfer Unit) to 48 Nm (35 lb-ft).

2. Tighten the bolts to the engine to 48 Nm (35 lb-ft).






4. Position the driveshaft and install 4 new driveshaft-to-PTU (Power Transfer Unit) flange bolts.
- Tighten to 70 Nm (52 lb-ft).






3.0L vehicles

5. Install the intermediate shaft.

All vehicles

6. Install the RH catalytic converter.

7. Fill the transaxle and/or PTU (Power Transfer Unit) as necessary.