Power Take-Off Unit (PTU) Installation
POWER TAKE-OFF UNIT (PTU) INSTALLATION^ TOOLS REQUIRED
- J44015 Tie Rod Installer
- SA91112T Axle Seal Protector
IMPORTANT: Lubricate seal with transmission fluid prior to PTU installation.
1. Inspect transmission output shaft seal, replace if damaged.
2. Install PTU to transmission. Ensure PTU is fully engaged. Hand start PTU to transmission bolts. Do not tighten.
3. Install PTU brace. Hand start all (6) bolts.
4. Tighten PTU to transmission bolts.
Torque:
PTU-to-Transmission Bolts: 60 Nm (44 ft. lbs.)
5. Tighten PTU brace to engine bolts.
Torque:
PTU Brace-to Engine Bolts: 60 Nm (44 ft. lbs.)
6. Tighten PTU brace to PTU bolts.
Torque:
PTU Brace-to-PTU Bolts: 60 Nm (44 ft. lbs.)
7. Hand start all powertrain mount to PTU bolts and tighten.
IMPORTANT: Use index mark for reassembly.
8. Hand start propshaft center bearing bolts.
9. Ensure all PTU flange and propshaft coupling area is clean. Insert coupling into PTU flange.
IMPORTANT: Apply Permatex Threadlocker - Blue to bolt threads.
10. Hand start all propshaft coupling bolts and tighten.
Torque:
Propshaft Coupling Bolts: 25 Nm (19 ft. lbs.)
11. Tighten center bearing bolts
Torque:
Center Bearing Support Bolts: 25 Nm (19 ft. lbs.)
12. Install new C-clips on stub shaft.
13. Install Axle Seal Protector SA91112T into seal. Remove protector after stub shaft splines pass the seal.
NOTICE: Use care when inserting stub shaft as not to damage seal. Align splines and using wood block hammer shaft into seated position. Verify shaft is fully seated by hand pull check.
14. Install stub shaft to PTU. Ensure shaft is fully seated.
15. Position steering gear mounts to cradle. Hand start both bolts and tighten.
Torque:
Steering Gear Mounts to-Cradle Bolts: 110 Nm (81 ft. lbs.)
16. Position I-shaft onto steering pinion shaft. Install new I-shaft bolt and tighten.
Torque:
I-Shaft-to-Steering Pinion Shaft Bolt: 34 Nm (25 ft. lbs.)
17. Install PTU vent hose.
IMPORTANT: Use Sealant G/M 12345493 or equivalent on fill plug.
18. Check PTU fluid fill. Remove fluid fill plug. Fill until fluid is just below the bottom of the fill hole.
PTU Fluid: 500 ml. (17 oz.)
Torque:
Fill Plug: 15 Nm (11 ft. lbs.)
IMPORTANT: Verify axle shaft is fully seated by hand pull check.
19. Install right hand axle shaft onto PTU stub shaft.
NOTICE: Use care not to damage boots or seals.
20. Insert outer end of axle into knuckle.
21. Install lower control arm ball stud to knuckle.
IMPORTANT: Ensure that the cotter pin ends do not contact the ABS wheel speed sensor harness or drive axle.
22. Install nut and new cotter pin.
Torque:
Lower Control Arm Ball Stud-to-Knuckle Nut: 10 Nm (89 inch lbs.) + 150°
IMPORTANT: Install new nut and secure link stud with wrench.
23. Install stabilizer link to stabilizer bar.
Torque:
Stabilizer Link-to-Stabilizer Bar: 65 Nm (48 ft. lbs.)
NOTICE: Hold ball from turning while tightening nut to prevent boot damage.
24. Install outer tie rod end into knuckle. Install Tie Rod Installer J44015 (or equivalent) and tighten.
Torque:
Tie Rod End-to-Knuckle Tool: 40 Nm (30 ft. lbs.)
25. Remove J44015. Install new nut and tighten.
Torque:
Tie Rod End-to-Knuckle Nut: 50 Nm (37 ft. lbs.)
26. Install wheel and tire.
27. Install wheel nuts and tighten in a crisscross pattern.
Torque:
Wheel Nuts: 125 Nm (92 ft. lbs.)
28. Install new front axle to knuckle nut and tighten.
Torque:
Front Axle-to-Knuckle Nut: 205 Nm (151 ft. lbs.)
29. Lower vehicle.
30. Start engine and observe idle shape. Compare to pre-removal condition, if excessive: perform powertrain balance procedure - operation #1.
31. Check transmission oil level and fill as required.
32. Check alignment and align as necessary.