Transfer Case - Power Transfer Unit (PTU) - Installation

Power Transfer Unit (PTU) - 3.5L GTDI













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. Position the PTU and install the 5 bolts.
- Tighten to 90 Nm (66 lb-ft).

3. Lower the engine and remove the jackstand from the front of the roll restrictor.

4. Using the jackstand, raise the subframe into the installed position.

5. NOTE: RH shown, LH similar.

Position the subframe brackets and loosely install the 4 bolts.





6. NOTE: RH shown, LH similar.

Install the 2 subframe rear bolts.

- Tighten to 150 Nm (111 lb-ft).





7. NOTE: RH shown, LH similar.

Tighten the 4 subframe bracket-to-body bolts to 55 Nm (41 lb-ft).





8. Remove the jackstand from the subframe.

9. Position the front engine roll restrictor to the bracket and install the bolt.
- Tighten the front engine roll restrictor bolt to 90 Nm (66 lb-ft).





10. Position the rear engine roll restrictor to the transaxle and install the 3 bolts.
- Tighten the engine roll restrictor-to-transaxle bolts to 103 Nm (76 lb-ft).

- Tighten the rear engine roll restrictor bolt to 90 Nm (66 lb-ft).

11. Position the PTU support bracket in place and install the 3 bolts.
- Tighten to 48 Nm (35 lb-ft).

12. Install the RH turbocharger lower bracket and the 3 bolts.

1. Tighten the bolt to 19 Nm (168 lb-in).

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





13. Connect the 2 Electronic Power Assist Steering (EPAS) electrical connectors (1 shown) and attach the wiring retainer (not shown) and install the bolt.
- Tighten to 9 Nm (80 lb-in).





14. NOTICE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to Restraint Systems.

Install the steering intermediate shaft onto the steering gear and install a new bolt.
- Tighten to 20 Nm (177 lb-in).





15. NOTE: Align the index marks made during removal.

Install the 4 driveshaft-to-output flange bolts.

- Tighten to 70 Nm (52 lb-ft).





16. Install the RH catalytic converter. For additional information, refer to Exhaust System &/or Catalytic Converter.

17. Install the RH front halfshaft. For additional information, refer to Drive Axles, Bearings and Joints.

18. Install the underbody shield and the 4 retainers.





19. Remove the locking device from the steering wheel.





20. Inspect the transmission fluid level and add clean, specified fluid as necessary.