Intermediate Shaft Seal and Deflector

Special Tool(s)

	Handle, Driver (32 in) 205-907
	Installer, PTU Linkshaft Seal 205-883
	Installer, Front Axle Bushing 205-346
	Remover, Halfshaft 205-241
	Remover, Transfer Case Bearing Cup 308-125 (T87P-7120-D)
	Slide Hammer Master Set 100-D112

Removal

NOTE: For high resolution:  Click here to view a video version of this procedure.

NOTE: For low resolution:  Click here to view a video version of this procedure.

NOTE: The PTU may leak different color fluids, red fluid 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 determine the most appropriate service procedure. This procedure will correct a red fluid leak (automatic transmission fluid) from the intermediate shaft seal on the RH side of the PTU . Refer to Analysis of Leakage under Power Transfer Unit (PTU) .

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

2. Remove the RH front wheel and tire. Refer to Section 204-04 .

3. Remove the RH brake disc. Refer to Section 206-03 .

4. Remove the RH intermediate shaft. Refer to Section 205-04 .

5. NOTE: The following instruction will prevent the Remover, Transfer Case Bearing Cup 308-125 (T87P-7120-D) from opening too far which would make removing the intermediate shaft seal deflector difficult.

   Special Tool(s): Remover, Transfer Case Bearing Cup 308-125 (T87P-7120-D).
   Place a 16 mm (5/8 in) washer between the components as shown.

NOTICE: Failure to utilize the recommended tools may result in serious damage to the PTU .

6. Special Tool(s): Remover, Transfer Case Bearing Cup 308-125 (T87P-7120-D), handle from Remover, Halfshaft 205-241, Slide Hammer Master Set 100-D112.

7. Special Tool(s): Remover, Transfer Case Bearing Cup 308-125 (T87P-7120-D), handle from Remover, Halfshaft 205-241, Slide Hammer Master Set 100-D112.
   • The seal deflector will be damaged during removal. Remove all foreign material from the PTU before continuing with the repair.

8. Special Tool(s): Remover, Transfer Case Bearing Cup 308-125 (T87P-7120-D), handle from Remover, Halfshaft 205-241, Slide Hammer Master Set 100-D112.
   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. Special Tool(s): Installer, PTU Linkshaft Seal 205-883, Handle, Driver 812.8 mm (32 in) 205-907.

2. Special Tool(s): Installer, PTU Linkshaft Seal 205-883, Handle, Driver 812.8 mm (32 in) 205-907.

3. Special Tool(s): Installer, PTU Linkshaft Seal 205-883, Handle, Driver 812.8 mm (32 in) 205-907.

4. NOTICE: Do not use force when installing the alignment washer or damage to the washer can occur.

   Special Tool(s): Installer, PTU Linkshaft Seal 205-883, Handle, Driver 812.8 mm (32 in) 205-907.

5. NOTICE: Do not overheat (melt) the seal deflector. Monitor the temperature of the deflector with a 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.

   Hot air gun.
   Special Tool(s): Installer, Front Axle Bushing 205-346, Handle, Driver 812.8 mm (32 in) 205-907.
   Position the deflector on the Installer, Front Axle Bushing 205-346 using silicone brake caliper grease and dielectric compound to retain it to the Installer, Front Axle Bushing 205-346. Using a hot air gun, heat the back of the tool to a minimum of 71°C (160°F) and a maximum of 93°C (200°F) by concentrating the heat across the back of the installer while rotating the tool. Once the optimum temperature is achieved on the tool, move the heat gun to the front of the tool and heat the inside of the deflector where it snaps onto the PTU shaft until the temperature of the deflector is a minimum of 93°C (200°F) to a maximum of 100°C (212°F).
   • 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. General Equipment: 5-Pound Dead Blow Hammer
   Special tool(s): Installer, Front Axle Bushing 205-346, Handle, Driver 812.8 mm (32 in) 205-907.
   Install the seal deflector immediately after heating.

7. Make sure the deflector is completely seated all the way around and there are no cracks on the face. 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: A significant amount of 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 metal 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 RH intermediate shaft. Refer to Section 205-04 .

10. Install the RH brake disc. Refer to Section 206-03 .

11. Install the RH front wheel and tire. Refer to Section 204-04 .

12. Fill the transmission as necessary. Refer to Section 307-01 .