One Speed PTU Assembly

Clean the Power Transfer Unit (PTU) components using a suitable solvent. Blow the components dry using regulated 344 kPa (50 psi) shop air. Inspect all sealing surfaces for excessive wear or scratches the may cause damage to new seals. If damage is evident replace the PTU assembly.

Fig 1: Installing Outer Seal In Input Gear

Courtesy of CHRYSLER GROUP, LLC

1. If a manual transmission equipped vehicle, using tool (special tool #10517, Installer, Seal) (1), with the long side (4) toward the seal (2), install the outer seal (2) in the input gear (3) with the tension spring facing outward. The shoulder on the tool will stop against the input shaft (3) roller bearing.
2. For both automatic and manual transmission equipped vehicle, using tool (special tool #10517, Installer, Seal) (1), with the short side (4) toward the seal (2), install the inner seal (2) in the input gear (3) with the tension spring facing the tool. The shoulder on the tool will stop against the input shaft (3) roller bearing.
   Fig 2: Installing Outer Seal Into Housing

   Courtesy of CHRYSLER GROUP, LLC
3. If a manual transmission equipped vehicle, using tool (special tool #10515, Installer, Seal) and (special tool #C-4171, Driver Handle, Universal), with the long side (2) toward the seal (1), install the outer seal (1) in the housing (4) with the tension spring facing outward. The shoulder on the tool will stop against the top of the bore in the housing (4).
4. For both automatic and manual transmission equipped vehicle, using tool (special tool #10515, Installer, Seal) and (special tool #C-4171, Driver Handle, Universal), with the short side (2) toward the seal (1), install the inner seal (1) in the housing (4) with the tension spring facing the tool. The shoulder on the tool will stop against the top of the bore in the housing (4).
   Fig 3: Removing/Installing Input Shaft & Bearing At PTU Housing

   Courtesy of CHRYSLER GROUP, LLC
5. Install the input shaft (1) and bearing into the PTU housing.
   Fig 4: Locating Dog Clutch Sleeve

   Courtesy of CHRYSLER GROUP, LLC
6. Install the dog clutch sleeve (1) onto the input shaft
   Fig 5: Ensuring Proper Orientation Of Tapered Splines On Dog Clutch Sleeve

   Courtesy of CHRYSLER GROUP, LLC
   NOTE:

   Ensure that the dog clutch sleeve is oriented so that the tapered splines (1) are facing the input gear (towards the interior of the case).

   Fig 6: Removing/Installing Input Gear & Output Ring Gear At PTU Housing

   Courtesy of CHRYSLER GROUP, LLC
7. In unison, install the input gear (1) and output ring gear (2) into the PTU housing.
   Fig 7: PTU Housing & Gasket

   Courtesy of CHRYSLER GROUP, LLC
8. Install the gasket (1) into the groove in the PTU housing (2).
   Fig 8: Separating/Installing Right Housing At PTU Housing

   Courtesy of CHRYSLER GROUP, LLC
9. If necessary, install the bearing cups and shims into their proper bores of the right PTU housing. Use a light grease to retain the cups in their bores.
10. Place the right housing (1) onto the PTU housing (2).
    Fig 9: Locating PTU Housing Bolts

    Courtesy of CHRYSLER GROUP, LLC
11. Install the bolts (1) to hold the PTU housing halves together. Refer to SPECIFICATIONS .
12. Lubricate the intermediate shaft splines.
13. Install the PTU in the vehicle.
14. Fill the PTU to the proper lever with Mopar® 75W-90 fluid.
15. Road test the vehicle to verify the repair.