Output Shaft Seal

Special Tool(s)

	Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)
	Installer, PTO Drive Gear Outer Oil Seal 308-430
	Remover, Output Flange 307-523

Removal

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02 .

All vehicles except 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 vehicles

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

All vehicles

5. Index-mark the driveshaft.
   Marker. Discard the specified component. Follow local disposal regulations.

6. 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.

   General equipment: Torque wrench.

7. Special Tool(s): Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A).
   Discard the specified component. Follow local disposal regulations.

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

   Marker.
   Special Tool(s): Remover, Output Flange 307-523.

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. Special Tool(s): Installer, PTO Drive Gear Outer Oil Seal 308-430.

3. Visual check.
   Align the index-mark made during removal.

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.

   New nut.
   Special Tool(s): Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A).

5. NOTE: Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal.

   • Tighten to 70 Nm (52 lb-ft).

GTDI 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

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 as necessary. Refer to Power Transfer Unit (PTU) Draining and Filling .