Power Transfer Unit

WARNING: This page is about a different variant/trim than selected.

Fig 1: Extension And Pinion Housing Bolts

GC0056206

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Remove extension housing bolts.

Fig 2: Extension Housing O-Ring
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Remove the extension housing.
Remove the extension housing O-ring.

Fig 3: Removing Dust Shield From Extension Housing
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Using a chisel (2) remove the dust shield (1) from the extension housing (3).

Fig 4: Extension And Pinion Housing Bolts
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Remove the pinion housing bolts.

Fig 5: Pinion Housing
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Remove the pinion housing.

Fig 6: Pinion Housing Shim
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Remove the pinion housing shim.
Remove the pinion housing O-ring.

Fig 7: Pinion Shaft Nut
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NOTE: The pinion nut is a staked type nut.
Using a chisel or a grinder, remove the staked depression in the pinion nut.

Fig 8: Remove Pinion Nut
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Remove the output shaft nut, using the Output Shaft Nut Socket 9921 and Spline Socket 9922.

Fig 9: Press Pinion
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Press the output shaft from the housing using a press.

Fig 10: Pinion Shaft Spacer
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Remove the output shaft spacer.

Fig 11: Pinion Shaft Bearing.
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Remove the output shaft bearing.

Fig 12: Remove Small Side Bearing Cup
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Remove the output shaft housing small side bearing cup using a brass drift.

Fig 13: Remove Large Side Bearing Cup
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Remove the output shaft housing large side bearing cup using a brass drift.

Fig 14: Pull Pinion Head Bearing
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Install Puller 6444 and Jaws 6451 onto output shaft head bearing.
Place Puller in a vice and remove the bearing.

Fig 15: Inspection Cover
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Remove the inspection cover bolts (1).

Fig 16: Remove Inspection Cover
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Remove the inspection cover.

Fig 17: Side Cover
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Remove the side cover bolts (1).

Fig 18: Remove Side Cover
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Remove the side cover from case.

Fig 19: Carrier Assembly
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Remove the carrier assembly.

Fig 20: Carrier Bearing Cup And Seal
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NOTE: Bearing cup is a slip fit.
Remove bearing cup by hand (1) or by using a pick.

Fig 21: Cover Side Cup And Shim
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Remove the shim (1) under the bearing cup (3). Measure and record the size of the shim.

Fig 22: Inner Cover Seal
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Remove the inner seal from the PTU cover.
Remove the outer seal from the PTU cover.

Fig 23: Carrier Race Housing Side
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Remove bearing cup by hand (1) or by using a pick.
Remove the shim (3) under the bearing cup (1). Measure and record the size of the shim.

Fig 24: Carrier Case Seal
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Remove the carrier case seal.

Fig 25: Ring Gear Bolts
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Remove the ring gear bolts.

Fig 26: Ring Gear
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Remove the ring gear.

Fig 27: Removing Ring Gear Side Bearing
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Remove ring gear side bearing using Puller C-293-PA, Inserts C-293-37 and Insert C-4487-1.

Fig 28: Remove Output Side Bearing
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Remove output side bearing using Puller C-293-PA, Inserts C-293-37 and Insert C-4487-1.