Power Transfer Unit (PTU) - With 8F30: Notes

REMOVAL 

1. Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable.
2. Raise and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
3. Remove the belly pan. Refer to BELLY PAN, REMOVAL AND INSTALLATION .
4. Remove the right front halfshaft. Refer to AXLE SHAFTS, DRIVE SHAFTS AND HALF SHAFTS, REMOVAL AND INSTALLATION .
5. Remove the rear driveshaft. Refer to REAR DRIVESHAFT, REMOVAL AND INSTALLATION .
6. Visually inspect the end of the quill shaft through the weep hole in the PTU. There should be a 3mm gap of empty space between the end of the shaft and the edge of the hole if the quill shaft is pushed in completely. If there is no empty space the quill shaft has become disengaged from the transmission and should be replaced before installing or replacing the PTU.

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   1 - Weep Hole

   2 - Quill Shaft

7. Remove the front exhaust pipe to catalytic converter nuts and disengage the exhaust pipe from the catalytic converter.

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   1 - Front Exhaust Pipe to Catalytic Converter

   2 - Exhaust Pipe Isolator to Crossmember Bolt

   3 - Exhaust Pipe Upper Isolator to Crossmember Bolt

   4 - Resonator to Front Exhaust Pipe Clamp

8. Loosen the resonator to front exhaust pipe clamp.
9. Remove the exhaust pipe isolator to crossmember bolt.
10. Remove the exhaust pipe upper isolator to crossmember bolt.
11. Position the exhaust pipe aside.
12. Disconnect the wire harness connector from the PTU actuator.
13. Remove the vacuum pump.
14. Remove the PTU bracket.

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    1 - Power Transfer Unit (PTU) to Transmission Bolts

    2 - PTU Bracket To Engine Block Bolts

    3 - PTU Bracket To PTU Bolts

    4 - PTU Bracket To Engine Oil Pan Bolt

    5 - PTU Oil Fill Plug

15. Remove the PTU vent tube.
16. Loosen the PTU bolts to allow the PTU to slightly pivot.
17. Remove the engine mount bolt and move the engine forward approximately one inch.

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    1 - Engine Mount Bracket Bolts

    2 - Engine Mount Bolt

    3 - Engine Mount Bracket

18. Completely remove the PTU bolts and remove the PTU from the vehicle.
19. Remove and DISCARD  the PTU O-ring.

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    1 - PTU O-ring

20. If required, remove the PTU actuator bolts and remove the PTU actuator.

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    1a - PTU Actuator Bolts

    1b - PTU Actuator

INSTALLATION 

During installation, torque the fasteners to the specifications in the torque table(s) below.

Follow the removal procedure in reverse for general reassembly of the components on the vehicle. The steps listed below are calling out specific procedures that should be followed during installation.

• Install a NEW  PTU O-ring.
• Inspect the end of the quill shaft through the weep hole in the PTU. There should be a 3mm gap of empty space between the end of the shaft and the edge of the hole if the quill shaft is pushed in completely. Failure to install the quill shaft completely will lead to a transmission fluid leak from the PTU weep hole.

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  1 - Weep Hole

  2 - Quill Shaft

• Verify that the PTU and transmission are filled to the specified fluid level. Refer to TRANSMISSION OIL DRAIN AND FILL and FLUID FILL  .
• When installing a NEW  (PTU), connect the diagnostic scan tool, enter "miscellaneous functions" of the DriveTrain Control Module (DTCM) and run the self-learning procedure for the PTU.

TORQUE SPECIFICATIONS