Power Transfer Unit System - GKN 761

• Specifications
  • Fastener Specifications
    • Single Use Non-Threaded Fasteners/Components
    • Reusable Threaded Fastener Tightening Specifications
  • Approximate Fluid Capacities
  • Adhesives, Fluids, Lubricants, and Sealers
• Visual Identification
  • Power Transfer Unit Case Disassembled View
    • Power Transfer Unit Components
    • Power Transfer Unit Mounting
    • Power Transfer Unit Seal View
    • Power Transfer Unit Vent Hose Assembly
• Diagnostic Information and Procedures
  • Symptoms - Power Transfer Unit Case
    • Strategy Based Diagnostics
    • Visual/Physical Inspection
    • Intermittent
    • Symptom List
  • Noisy in Drive
  • Noisy When Coasting
  • Intermittent Noise
  • Constant Noise
  • Ratcheting Noise During All-Wheel Drive (AWD) Engagement
  • Power Transfer Unit Case Leak Diagnosis
• Repair Instructions - On Vehicle
  • Power Transfer Unit Case Fluid Replacement
    • Removal Procedure
    • Installation Procedure
  • Drain Plug Replacement
    • Removal Procedure
    • Installation Procedure
  • Fill Plug Replacement
    • Removal Procedure
    • Installation Procedure
  • Power Transfer Unit Vent Replacement
    • Removal Procedure
    • Installation Procedure
  • Intermediate Drive Shaft Replacement
    • Single Use Fasteners and Components
  • Power Transfer Unit Intermediate Drive Shaft Seal Replacement
    • Single Use Fasteners and Components
  • Output Shaft Seal Replacement
    • Single Use Fasteners and Components
    • Removal Procedure
    • Installation Procedure
  • Intermediate Drive Shaft Bearing Replacement
    • Single Use Fasteners and Components
  • Power Transfer Unit Shift Actuator Replacement
  • Transfer Case Bracket Replacement
    • Removal Procedure
    • Installation Procedure
  • Power Transfer Unit Interface O-Ring Seal Replacement
    • Removal Procedure
    • Installation Procedure
  • Power Transfer Unit Case Replacement
    • Removal Procedure
    • Installation Procedure
• Repair Instructions - Off Vehicle
  • Power Transfer Unit Case Disassemble
    • Single Use Fasteners and Components
    • Power Transfer Unit Case Holding Fixture Installation, Oil Fill Plug, Oil Drain Plug, and Vent Hose Connector Removal
    • Power Transfer Unit Shift Actuator Removal
    • Power Transfer Unit Intermediate Drive Shaft Components Removal
    • Power Transfer Unit Worm Gear Removal
    • Power Transfer Unit Extension Housing Removal
    • Power Transfer Unit Rear Output Shaft Housing Removal
    • Power Transfer Unit Input Shaft Assembly Removal
    • Power Transfer Unit Idler Shaft and Input Disconnect Shaft Removal
    • Power Transfer Unit Input Shaft Seal - Cover Removal
    • Power Transfer Unit Input Shaft Seal - Case Removal
  • Power Transfer Unit Case Cleaning and Inspection
    • Power Transfer Unit Case Housing Cleaning and Inspection
    • Power Transfer Unit Cover Housing Cleaning and Inspection
    • Power Transfer Unit Case Extension Housing Cleaning and Inspection
    • Power Transfer Unit Rear Output Shaft Housing Cleaning and Inspection
    • Power Transfer Unit Input Shaft Cleaning and Inspection
    • Power Transfer Unit Input Disconnect Shaft Cleaning and Inspection
    • Power Transfer Unit Idler Shaft Cleaning and Inspection
    • Power Transfer Unit Intermediate Drive Shaft Cleaning and Inspection
    • Power Transfer Unit Shift Components Cleaning and Inspection
  • Power Transfer Unit Case Assemble
    • Single Use Fasteners and Components
    • Power Transfer Unit Input Shaft Seal - Case Installation
    • Power Transfer Unit Input Shaft Seal - Cover Installation
    • Power Transfer Unit Idler Shaft and Input Disconnect Shaft Installation
    • Power Transfer Unit Rear Output Shaft Housing Installation
    • Power Transfer Unit Input Shaft Assembly Installation
    • Power Transfer Unit Extension Housing Installation
    • Power Transfer Unit Worm Gear Installation
    • Power Transfer Unit Intermediate Drive Shaft Components Installation
    • Power Transfer Unit Shift Actuator Installation
    • Power Transfer Unit Case Holding Fixture Removal, Oil Fill Plug, Oil Drain Plug, and Vent Hose Connector Installation
• Description and Operation
  • Power Transfer Unit Case Identification
    • Notes
    • Transfer Case Primary Identification Label
  • Power Transfer Unit Case Description and Operation
    • Driver Mode Control
    • General Description
    • External Components
    • Internal Components
    • Shift Components and Function
    • Service All Wheel Drive
    • All Wheel Drive Off
    • Power Transfer Case Actuator Motor
    • Power Transfer Case Actuator Motor Rotational Position Sensor
    • Rear Differential Clutch Control Module
• Special Tools and Equipment
  • Special Tools