Input Shaft Seal

Special Tool(s)

	Handle 205-153 (T80T-4000-W)
	Holding Fixture, Transmission 307-003 (T57L-500-B)
	Installer, Parking Brake Bearing 206-040 (T88T-2598-F)
	Remover/Installer, PTU Input Shaft Seal 308-777 (includes 308-777/1, 308-777/2, 308-777/3, 308-777/4 and 308-777/5)

Removal

1. Remove the PTU . Refer to Power Transfer Unit (PTU) — 3.5L or Power Transfer Unit (PTU) — 3.5L GTDI .

2. Special Tool(s): Holding Fixture, Transmission 307-003 (T57L-500-B).

3. Discard the specified component. Follow local disposal regulations.

NOTICE: Do not press the seals lower than specified. Excessive force will damage the bearing below the seals.

NOTE: Both seals will need to be pressed lower into the PTU input shaft opening to break the seals outer sealant loose from the PTU .

NOTE: There is approximately a 5 mm (0.196 in) air gap between both seals and approximately 1 mm (0.039 in) air gap between the inner seal and the bearing race.

4. Special Tool(s): Installer, Parking Brake Bearing 206-040 (T88T-2598-F).

5. Special Tool(s): Remover/Installer, PTU Input Shaft Seal 308-777/1.

6. Special Tool(s): Remover/Installer, PTU Input Shaft Seal 308-777/1, Remover/Installer, PTU Input Shaft Seal 308-777/2.
   Press the Remover/Installer, PTU Input Shaft Seal 308-777/2 (punch) downward until the shoulder of the Remover/Installer, PTU Input Shaft Seal 308-777/2 (punch) touches the Remover/Installer, PTU Input Shaft Seal 308-777/1.

7. NOTE: Do not overtighten the Remover/Installer, PTU Input Shaft Seal 308-777/3 (screws). Turn the Remover/Installer, PTU Input Shaft Seal 308-777/3 (screws) until they are seated into the Remover/Installer, PTU Input Shaft Seal 308-777/1 holes.

   Special Tool(s): Remover/Installer, PTU Input Shaft Seal 308-777/1, Remover/Installer, PTU Input Shaft Seal 308-777/3 (screws).

8. Special Tool(s): Remover/Installer, PTU Input Shaft Seal 308-777/1, Remover/Installer, PTU Input Shaft Seal 308-777/2.
   Press the Remover/Installer, PTU Input Shaft Seal 308-777/2 (punch) downward until the shoulder of the Remover/Installer, PTU Input Shaft Seal 308-777/2 (punch) touches the Remover/Installer, PTU Input Shaft Seal 308-777/1.

9. NOTE: Do not overtighten the Remover/Installer, PTU Input Shaft Seal 308-777/3 (screws). Turn the Remover/Installer, PTU Input Shaft Seal 308-777/3 (screws) until they are seated into the Remover/Installer, PTU Input Shaft Seal 308-777/1 holes.

   Special Tool(s): Remover/Installer, PTU Input Shaft Seal 308-777/1, Remover/Installer, PTU Input Shaft Seal 308-777/3 (screws).

10. Special Tool(s): Slide Hammer 100-001 (T50T-100-A), Remover/Installer, PTU Input Shaft Seal 308-777/1.
    Discard the specified component. Follow local disposal regulations.

11. Drain the PTU .
    • Position the PTU output flange upward and tilt the PTU approximately 30 degrees toward the LH seal bore to allow the fluid to drain from the PTU input shaft opening.

Installation

1. Clean the specified component with the special material. Visual check.

2. Visual check.
   Special Tool(s): Remover/Installer, PTU Input Shaft Seal 308-777/4, Handle 205-153 (T80T-4000-W).

3. Visual check.
   Special Tool(s): Remover/Installer, PTU Input Shaft Seal 308-777/5, Handle 205-153 (T80T-4000-W).

4. New compression seal.

5. Install the PTU . Refer to Power Transfer Unit (PTU) — 3.5L or Power Transfer Unit (PTU) — 3.5L GTDI .

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