Transfer Case - Power Transfer Unit (PTU) - Removal

Power Transfer Unit (PTU) - 3.5L GTDI









1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.

2. NOTE: Use a steering wheel holding device (such as Hunter(R) 28-75-1 or equivalent).

Using a suitable holding device, hold the steering wheel in the straight-ahead position.





3. Remove the 4 retainers and the underbody shield.





4. Remove the RH halfshaft. For additional information, refer to Drive Axles, Bearings and Joints.

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

6. NOTE: To maintain the initial driveshaft balance, index-mark the driveshaft flange and the output flange.

Remove the 4 driveshaft-to-output flange bolts, then disconnect the driveshaft from the output flange. Position the driveshaft aside.





7. 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.

Remove the steering shaft bolt and disconnect the steering column shaft from the steering gear.
- Discard the bolt.





8. Remove the bolt and disconnect the 2 Electronic Power Assist Steering (EPAS) electrical connectors (1 shown) and the wiring retainer (not shown).





9. Remove the 3 bolts and the RH turbocharger lower bracket.





10. Remove the 3 bolts and the Power Transfer Unit (PTU) support bracket.

11. Position the rear engine roll restrictor aside in the following sequence.

1. Remove the 2 engine roll restrictor-to-transaxle bolts.

2. Loosen the engine roll restrictor-to-frame bolt and pivot the roll restrictor downward.





12. Remove the front engine roll restrictor bolt and position the engine roll restrictor aside.

13. Position a jackstand under the rear of the subframe.





14. NOTE: RH shown, LH similar.

Remove the subframe bracket-to-body bolts.





15. NOTE: RH shown, LH similar.

Remove the subframe rear bolts and the subframe brackets.

- Discard the bolts.





16. Position a jackstand under the front roll restrictor bracket and raise the engine far enough to allow the PTU to be removed.





17. NOTE: Position a drain pan under the vehicle.

Remove the 5 PTU bolts. Pull the PTU outward to separate it from the transaxle. Rotate the output flange upward, then turn it and remove the
PTU from the vehicle.

18. Using a small screwdriver, remove and discard the compression seal.