Installation

Power Transfer Unit (PTU)





Power Transfer Unit (PTU) - Exploded View

Power Transfer Unit (PTU) - Exploded View (Part 1):

Power Transfer Unit (PTU) - Exploded View (Part 2):

1. CAUTION: The seal deflector will be damaged during removal. Be careful not to damage the cover seal directly behind the seal deflector.

Using a heat gun, warm the seal deflector. Using a lady foot line-up bar, remove the seal deflector.
2. Using the special tools, remove the intermediate shaft seal.
^ Clean the area around the seal deflector and seal.





3. Use a suitable socket to install the halfshaft seal. The socket should be 39.5 mm (1.55 inch) to 40.5 mm (1.59 inch) in diameter. Using tape, index-mark the socket at 18 mm (0.7 inch).





4. Make sure the seal is centered in the bore, install a new intermediate shaft seal.





5. CAUTION: Do not overheat (melt) the seal deflector. Overheating will damage the deflector. If the deflector is damaged, a new one must be used.

Using a suitable heat gun, heat the new seal deflector. Concentrate the heat across the back of the deflector near the white colored tabs. Install the seal deflector immediately after heating. An audible snap should be heard.
^ If necessary, use special tools 308-430 and 308-431 to seat the seal deflector. Make sure the deflector is fully seated and there are no cracks on the face or inner diameter white-colored tab.
^ An alternate method to heat the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry off deflector and install.
^ Make sure the deflector is completely seated all the way around. It is correctly installed when the face of the deflector is recessed into the pocket.





6. Install a new input shaft seal, if removed.
7. Position the power transfer unit (PTU) in place and install the 5 PTU bolts.
^ Tighten to 90 Nm (66 lb-ft).





8. Position the PTU support bracket in place and install the 3 PTU support bracket-to-engine bolts.
^ Tighten to 70 Nm (52 lb-ft).





9. Install the 2 PTU support bracket-to-transaxle bolts.
^ Tighten to 70 Nm (52 lb-ft).





10. Position the engine roll restrictor to the transaxle and install the 2 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. NOTE: Line up the index marks made during removal.

Install the 4 driveshaft-to-output flange bolts. Tighten the bolts in a star-pattern.
^ Tighten to 70 Nm (52 lb-ft).
12. Install the RH catalytic converter.
13. Install the RH front halfshaft.