Intermediate Shaft Seal and Deflector
Intermediate Shaft Seal and Deflector
Removal
NOTE: For High Resolution:
NOTE: For Low Resolution:
NOTE: The Power Transfer Unit (PTU) may leak different color fluids, red oil leak for automatic transmission fluid and brown/black gear lube for PTU fluid. The PTU seals prevent these types of fluids from leaking. It is important to note which color fluid is leaking to determine the most appropriate service procedure. This procedure will correct a red oil leak (automatic transmission fluid) from the intermediate shaft seal on the RH side of the PTU. If the leak is red automatic transmission fluid, this indicates that the differential seals in the transaxle are also leaking and need to be replaced along with the intermediate shaft seal. Refer to Automatic Transmission/Transaxle &/or Transmission Control Systems (3.5L with Aisin AWF21 transaxle only) to replace the differential seals before replacing the intermediate shaft seal. For additional information, refer to Analysis of Leakage. Analysis Of Leakage
NOTE: This procedure is to be performed through the RH wheel opening. It is not necessary to remove the exhaust components to complete this repair.
1. Remove the intermediate shaft. For additional information, refer to Drive Axles, Bearings and Joints.
2. NOTE: The following instruction will prevent the Bearing Cup Remover from opening too far which would make removing the intermediate shaft seal deflector difficult.
Place a 16 mm (5/8 in) washer between the components of the Bearing Cup Remover as shown.
NOTICE: Failure to utilize the recommended tools may result in serious damage to the Power Transfer Unit (PTU).
3. Assemble the special tools as indicated in the following table and illustration:
4. NOTE: Using a 5-pound or larger slide hammer eases the removal of the seal deflector.
Using the Bearing Cup Remover, the extension from the Halfshaft Remover and a suitable slide hammer, remove the seal deflector.
- The seal deflector will have been damaged during removal. Remove all foreign material from the PTU before continuing with the repair.
5. Using the Bearing Cup Remover, the extension from the Halfshaft Remover and a suitable slide hammer, remove the intermediate shaft seal, and if equipped, the alignment washer.
Installation
NOTE: The following illustration shows the correct orientation of the seal components when installed in the vehicle.
1. Place the intermediate shaft seal on the PTU Linkshaft Seal Installer and Driver Handle with the spring side facing away from the tool.
2. Using the PTU Linkshaft Seal Installer and Driver Handle, install the intermediate shaft seal.
3. Place the alignment washer on the PTU Linkshaft Seal Installer and Driver Handle with the beveled edge (white-striped side) facing towards the tool.
4. NOTICE: Do not use force when installing the alignment washer or damage to the washer can occur.
Using the PTU Linkshaft Seal Installer and Driver Handle, install the alignment washer by hand, pushing it in until it bottoms against the seal.
- When installed, the white-striped side should be facing out.
5. NOTICE: Do not overheat (melt) the seal deflector. Monitor the temperature of the deflector with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating. Do not allow the temperature to exceed 100°C (212°F). Overheating will damage the deflector. If the deflector is damaged, a new deflector must be used.
NOTE: Apply a small amount of silicone brake caliper grease and dielectric compound to the inner lip of the deflector where it installs on the tube inside the PTU before heating. This will ease the installation of the deflector.
Position the deflector on the PTU Linkshaft Seal Dust Shield Installer using silicone brake caliper grease and dielectric compound to retain it to the installer. Using a suitable heat gun, heat the deflector to a minimum of 71°C (160°F) and a maximum of 93°C (200°F) by concentrating the heat across the back of the installer while rotating the tool. Once the optimum temperature is achieved on the tool, move the heat gun to the front of the tool and heat the inside of the deflector where it snaps onto the PTU shaft until the temperature of the deflector is a minimum of
100°C (212°F).
- As an alternative method to heating the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry off the deflector and install.
6. Using a 5-pound or larger dead blow hammer, install the seal deflector immediately after heating using the PTU Linkshaft Seal Dust Shield Installer and Driver Handle.
7. Make sure the deflector is completely seated all the way around and there are no cracks on the face. The deflector is correctly installed when the face of the deflector is recessed 3-5 mm (0.12-0.20 in) into the pocket all the way around.
8. Once the deflector is fully seated, insert the seal protector into the PTU deflector ID.
9. Apply a thin coat of silicone brake caliper grease and dielectric compound to the intermediate shaft seal journal.
10. NOTE: A slight effort may be required to fully seat the intermediate and halfshaft assembly as it passes through the alignment washer.
Partially install the intermediate and halfshaft assembly through the PTU deflector until the splines have cleared the seal protector. Pull the seal protector out of the deflector and off of the intermediate shaft. Complete the installation of the intermediate and halfshaft assembly.
11. Fully install the intermediate and halfshaft assembly and the 2 bolts.
- Tighten to 40 Nm (30 lb-ft).
12. NOTE: A significant amount of residual fluid will collect between the seal and deflector during this repair. This is a normal condition and should not be misinterpreted as a leak after the repair is complete.
Using metal brake parts cleaner, thoroughly clean the deflector and intermediate shaft area of any residual fluid that may have accumulated during the repair.
13. Top off the transmission fluid as necessary.