Power Take-Off Unit (PTU) Stub Shaft

POWER TAKE-OFF UNIT (PTU) STUB SHAFT

^ TOOLS REQUIRED
- J43828 Ball Stud Separator
- J44015 Tie Rod End-to-Knuckle Tool
- J44017 Shaft Remover
- J45341 Drive Axle Remover
- SA91100 Tie Rod Separator
- SA91112T Seal Protector
- SA9133T Slide Hammer
- SA9173G Slide Hammer

REMOVAL





1. Remove axle shaft hub nut. Discard used nut.

CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON THE HOIST. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS, ON THE HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE OPPOSITE FROM WHICH COMPONENTS ARE BEING REMOVED.

2. Hoist vehicle.
3. Remove right side wheel and tire.

NOTICE: Hold ball stud from turning while removing nut. The boot can be damaged if the ball stud rotates. Discard used nut.





4. Remove right side tie rod-outer to knuckle.

NOTICE: Do not use wedge type tool to separate joint. Damage may occur to seal.





5. Separate tie rod from knuckle using Tie Rod Separator SA9ll00C (or equivalent).





6. Remove right side lower control arm ball using. Discard used pin.





7. Disengage ball stud from knuckle using Ball Stud Separator J43828 (or equivalent).

IMPORTANT: Do not allow stud to rotate. Secure link stud with wrench to remove nut.





8. Remove right side lower stabilizer bar link.

NOTICE: Do not hammer directly on end of axle. Damage may occur to axle.

9. Disengage right side axle shaft from knuckle. Use a wood block and hammer if difficulty is encountered.

NOTICE: Use caution to prevent damage to the seal protector (slinger).

IMPORTANT: Stub shaft may disengage from PTU. Separate from axle if this happens.





10. Disengage axle from PTU using Drive Axle Remover J45341 and Slide Hammer SA9173G.
11. Remove axle.

IMPORTANT: Remove retainer ring from stub shaft for tool installation. Discard used ring.

IMPORTANT: Use proper container for fluid loss when the stub shaft is removed. Plug PTU to minimize fluid loss.





12. Disengage PTU stub shaft from PTU using Shaft Remover 144017 and Slide Hammer SA9133T.

INSTALLATION





1. Install new C-clips on stub shaft.





2. Install axle seal protector into seal. Remove protector after stub shaft splines pass the seal using Seal Protector SA91l12T.

NOTICE: When inserting stub shaft be sure not to damage seal. Align splines and use wood block to hammer shaft into seated position. Verify shaft is fully seated by hand-pull check.

3. Install stub shaft to PTU.

NOTICE: Use care to prevent damage to the slinger (seal protector) when installing axles.

IMPORTANT: Verify axle shaft is fully seated by hand-pull check.





4. Install right hand axle shaft onto PTU stub shaft.

IMPORTANT: When installing fill plug use teflon sealant.





5. Check fluid fill.
6. Remove fluid fill plug and fill until fluid is just below the bottom of the fill hole.
Versatrak Fluid: 500 ml. (16.9 oz.)
7. Install fill plug and tighten.
Torque:
Fill Plug: 15 Nm (11 ft. lbs.)

NOTICE: Use care not to damage boots or seals.





8. Insert knuckle onto axle shaft, ensure splines are fully engaged.





9. Install lower control arm ball stud to knuckle.

IMPORTANT: Align the slots to the front lower control arm ball stud nut with a cotter pin hole by tightening the nut. Do not loosen the nut in order to align the holes for the cotter pin.

10. Install lower control arm ball stud to knuckle nut and tighten.
Torque:
Lower Control Arm Ball Stud-to-Knuckle Nut: 10 Nm (89 inch lbs.) + 150°

IMPORTANT: Align the slots to the front lower control arm ball stud nut with a cotter pin hole by tightening the nut. Do not loosen the nut to align holes.

IMPORTANT: Ensure that the cotter pin ends do not contact the ABS wheel speed sensor harness or drive axle.

11. Install new cotter pin.

IMPORTANT: Install new nut and secure link stud with wrench.





12. Install stabilizer link to stabilizer bar and tighten.
Torque:
Stabilizer Link-to-Stabilizer Bar: 65 Nm (48 ft. lbs.)

NOTICE: Hold ball from turning while tightening nut to prevent boot damage.





13. Install outer tie rod end into knuckle using Tie Rod End-to-Knuckle Tool J44015 (or equivalent).
Torque:
Tie Rod End-to-Knuckle Tool: 40 Nm (30 ft. lbs.)





14. Remove tie rod end-to-knuckle tool and install new nut and tighten.
Torque:
Tie Rod End Nut: 50 Nm (37 ft. lbs.)





15. Install wheel and tire.
16. Install wheel nuts and tighten in a criss-cross pattern.
Torque:
Wheel Nuts: 125 Nm (92 ft. lbs.)
17. Install new nut to the axle shaft and tighten.
Torque:
Front Axle-to-Knuckle Nut: 205 Nm (151 ft. lbs.)
18. Lower vehicle.
19. Check alignment and align as necessary.
20. Check and fill transmission oil level.