Intermediate Shaft Seal and Deflector
Intermediate Shaft Seal and Deflector
Removal
NOTE: The Power Transfer Unit (PTU) may leak different color fluids, red oil leak for automatic transmission fluid and brown/black gear lube for PTU fluid. The PTU seals prevent these types of fluids from leaking. It is important to note which color fluid is leaking to conduct the most appropriate service procedure. This procedure will correct a red oil leak (automatic transmission fluid) from the intermediate shaft seal on the RH side of the PTU. If the leak is red automatic transmission fluid, this indicates that the differential seals in the transaxle are also leaking and need to be replaced along with the intermediate shaft seal. For additional information, refer to Analysis of Leakage. Analysis of Leakage
NOTE: This procedure is to be performed through the RH wheel opening. It is not necessary to remove the exhaust components to complete this repair.
1. Remove the intermediate shaft.
2. NOTE: The following instruction will prevent the Bearing Cup Remover from opening too far which would make removing the intermediate shaft seal deflector difficult.
Place a 16 mm (5/8 in) washer between the components of the Bearing Cup Remover as shown.
3. NOTE: Using a 5-pound or larger slide hammer eases the removal of the seal deflector.
Using the Bearing Cup Remover, the extension from the Halfshaft Remover, and a suitable slide hammer, remove the seal deflector.
- The seal deflector will have been damaged during removal. Remove all foreign material from the PTU before continuing with the repair.
4. Using the Bearing Cup Remover, the extension from the Halfshaft Remover, and a suitable slide hammer, remove the intermediate shaft seal, and if equipped, the alignment washer.
Installation
NOTE: The following illustration shows the correct orientation of the seal components when installed in the vehicle.
1. Place the intermediate shaft seal on the PTU Linkshaft Seal Installer and Driver Handle with the spring side facing away from the tool.
2. Using the PTU Linkshaft Seal Installer and Driver Handle, install the intermediate shaft seal.
3. Place the alignment washer on the PTU Linkshaft Seal Installer and Driver Handle with the beveled edge (white-striped side) facing towards the tool.
4. NOTICE: Do not use force when installing the alignment washer or damage to the washer can occur.
Using the PTU Linkshaft Seal Installer and Driver Handle, install the alignment washer by hand, pushing it in until it bottoms against the seal.
- When installed, the white-striped side should be facing out.
5. NOTICE: Do not overheat (melt) the seal deflector. Monitor the temperature of the deflector with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating. Do not allow the temperature to exceed 100°C (212°F). Overheating will damage the deflector. If the deflector is damaged, a new deflector must be used.
NOTE: Apply a small amount of silicone brake caliper grease and dielectric compound to the inner lip of the deflector where it installs on the tube inside the PTU before heating. This will ease the installation of the deflector.
Position the deflector on the PTU Linkshaft Seal Dust Shield Installer using silicone brake caliper grease and dielectric compound to retain it to the installer. Using a suitable heat gun, heat the deflector to a minimum of 66°C (150°F) and a maximum of 100°C (212°F) by concentrating the heat across the back of the installer while rotating, not directly on the deflector itself.
- As an alternative method to heating the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry off the deflector and install.
6. Install the seal deflector immediately after heating using the PTU Linkshaft Seal Dust Shield Installer and Driver Handle.
7. Make sure the deflector is completely seated all the way around and there are no cracks on the face or inner diameter white-colored tab. The deflector is correctly installed when the face of the deflector is recessed 3-5 mm (0.12-0.20 in) into the pocket all the way around.
8. NOTE: Some residual fluid will collect between the seal and deflector during this repair. This is a normal condition and should not be misinterpreted as a leak after the repair is complete.
Using brake parts cleaner, thoroughly clean the deflector and intermediate shaft area of any residual fluid that may have accumulated during the repair.
9. Install the intermediate shaft.
10. Top off the transmission fluid as necessary.