Transfer Case - Power Transfer Unit (PTU)

Output Shaft Seal

Special Tool(s):

Output Shaft Seal And Flange - Exploded View:

Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Remove the exhaust flexible pipe. For additional information, refer to Exhaust System.

3. 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 and position it aside.
^ Using mechanic's wire, support the driveshaft.

4. NOTE: Rotational torque of the PTU 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.





5. Using the special tool, hold the output pinion flange and remove and discard the pinion nut.





6. NOTE: Index-mark the output pinion flange to the pinion shaft.

Using the special tool, remove the output pinion flange.





7. Remove and discard the output shaft seal deflector.
8. Remove and discard the output shaft seal.
9. Remove and discard the collapsible spacer.

Installation
1. Install the new collapsible spacer.
2. Using the special tool, install the output shaft seal.





3. Using the special tool, install the output shaft seal deflector.





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

Install the output pinion flange.

5. CAUTION: 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 you exceed 0.3 Nm (3 lb-in), then the collapsible spacer will be damaged and a new collapsible spacer will be required.

Using the special tool to hold the output pinion flange, install and tighten the new pinion flange nut.





6. Position the driveshaft using the index-mark and install the 4 driveshaft-to-PTU output flange bolts.
^ Tighten to 70 Nm (52 lb-ft).
7. Install the exhaust flexible pipe. For additional information, refer to Exhaust System.