Power Transfer Unit (PTU) — 3.5L GTDI

Removal

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

2. General equipment: Steering wheel holder.

4. If equipped with PTU cooling, drain the cooling system. Refer to Section 303-03 .

5. Remove the intermediate shaft. Refer to Section 205-04 .

6. Remove the RH catalytic converter. Refer to Section 309-00 .

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

8. 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. Refer to Section 501-20B .

   Discard the specified component. Follow local disposal regulations.

15. General equipment: Jackstand.

16. NOTE: RH shown, LH similar.

    Discard the specified component. Follow local disposal regulations.

17. NOTE: RH shown, LH similar.

19. General equipment: Jackstand.

20. If equipped with PTU cooling system.

21. If equipped with PTU cooling system.

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

Installation

1. New compression seal.

2. • Tighten to 90 Nm (66 lb-ft).

3. NOTE: Inspect the O-ring seals and replace as necessary.

   If equipped, install the PTU coolant tubes and the bolt.
   • Tighten to 25 Nm (18 lb-ft).

4. If equipped, connect the PTU cooling system temperature sensor electrical connector.

5. NOTE: RH shown, LH similar.

   Tighten to 55 Nm (41 lb-ft).

6. NOTE: RH shown, LH similar.

   • Tighten to 150 Nm (111 lb-ft).

7. • Tighten the roll restrictor bracket bolts to 90 Nm (66 lb-ft).
   • Tighten the roll restrictor through bolt to 103 Nm (76 lb-ft).

8. • Tighten the roll restrictor bracket bolts to 90 Nm (66 lb-ft).
   • Tighten the roll restrictor through bolt to 103 Nm (76 lb-ft).

9. • Tighten the 2 bolts to 70 Nm (52 lb-ft).
   • Tighten the bolt to 48 Nm (35 lb-ft).

10. • Tighten the 2 bolts to 48 Nm (35 lb-ft).
    • Tighten the bolt to 19 Nm (168 lb-in).

12. Tighten to 9 Nm (80 lb-in).

13. Tighten to 9 Nm (80 lb-in).

14. 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. Refer to Section 501-20B .

    • Tighten to 20 Nm (177 lb-in).

15. Line up the index marks. Visual check.
    • Tighten to 70 Nm (52 lb-ft).

16. Install the RH catalytic converter. Refer to Section 309-00 .

17. NOTE: A new PTU intermediate shaft seal must be installed whenever the intermediate shaft or PTU is removed from the vehicle. Refer to Intermediate Shaft Seal and Deflector .

    Install the intermediate shaft. Refer to Section 205-04 .

18. Clean the specified component with the specified material.

19. Fill the PTU , if necessary. The fluid must be even with the bottom of the fill opening.

20. • Tighten to 20 Nm (177 lb-in).

22. If equipped with PTU cooling, fill the cooling system. Refer to Section 303-03 .