Output Shaft Seal

Output Shaft Seal





Output Shaft Seal and Flange










Removal

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist.

All vehicles except Gasoline Turbocharged Direct Injection (GTDI)

2. Remove the 2 exhaust Y-pipe-to-muffler and tail pipe flange nuts.
- Discard the nuts and gasket.


3. NOTICE: The resonator must be supported to prevent damage to the flexible pipe.

Using a length of mechanic's wire, support the resonator.


GTDI (Gasoline Turbocharged Direct Injection) vehicles

4. Remove the 4 LH and RH exhaust flexible pipes-to-underbody catalytic converter nuts.
- Discard the nuts and gasket.


All vehicles

5. NOTE: Index-mark both the driveshaft flanges for installation.
Remove the 4 driveshaft-to-Power Transfer Unit (PTU) output flange bolts. Disconnect the driveshaft from the PTU (Power Transfer Unit) and position it aside.

- Using mechanic's wire, support the driveshaft.


6. NOTE: Rotational torque of the PTU (Power Transfer Unit) rear output shaft flange must be measured and recorded using a Nm (lb-in) torque wrench for correct pinion bearing preload when reassembled. This will be the torque-to-turn measurement.
Using a suitable torque wrench, measure and record the rotational torque of the PTU (Power Transfer Unit) output shaft.






7. Using the Drive Pinion Flange Holding Fixture, hold the output pinion flange. Remove and discard the pinion nut.





8. NOTE: Index-mark the output pinion flange to the pinion shaft.
Using the Output Flange Remover, remove the output pinion flange.






9. Remove and discard the output shaft seal.

10. Remove and discard the collapsible spacer.

Installation

All vehicles

1. Install the new collapsible spacer.

2. Using the PTU (Power Transfer Unit) Drive Gear Outer Oil Seal Installer, install the output shaft seal.





3. NOTE: Install the output pinion flange to engage the spline as previously marked.
Install the output pinion flange.


4. NOTICE: Refer to the rotational torque previously recorded with the Nm (lb-in) torque wrench. Tighten the pinion nut in small increments until it is within 0.3 Nm (3 lb-in) of the reference measurement. If 0.3 Nm (3 lb-in) is exceeded, then the collapsible spacer will be damaged and a new collapsible spacer will be required.

Using the Drive Pinion Flange Holding Fixture to hold the output pinion flange, install and tighten the new pinion flange nut.






5. Using the index mark, position the driveshaft and install the 4 driveshaft-to-PTU (Power Transfer Unit) output flange bolts.
- Tighten to 70 Nm (52 lb-ft).


GTDI (Gasoline Turbocharged Direct Injection) vehicles

6. Install the new LH and RH exhaust flexible pipe-to-underbody catalytic converter gaskets and nuts.
- Tighten to 40 Nm (30 lb-ft).


All vehicles except GTDI (Gasoline Turbocharged Direct Injection)

7. Install the new exhaust Y-pipe-to-muffler and tail pipe flange gasket and nuts.
- Tighten to 40 Nm (30 lb-ft).


All vehicles

8. Fill the PTU (Power Transfer Unit) as necessary. For additional information, refer to Power Transfer Unit (PTU) Draining and Filling .