Power Transfer Unit (Service Information): Assembly: Assembly

Fig 1: Installing Output Side Spool Shaft Bearing

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1. Install output side spool shaft bearing using Installer (special tool #C-3095-A, Installer, Bearing).
   Fig 2: Installing Ring Gear Side Bearing

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2. Install ring gear side bearing using Installer (special tool #8148, Cup).
   Fig 3: Ring Gear

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3. Install the ring gear.
   Fig 4: Ring Gear Bolts

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4. Install the new  ring gear bolts and tighten to 74 N.m (55 ft. lbs.).
   Fig 5: Installing Carrier Case Seal

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5. Install the carrier case seal using Installer (special tool #9851, Installer, Seal) and Handle (special tool #C-4171, Driver Handle, Universal).
   Fig 6: Shim Under Bearing Cup

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6. Install the shim (3) under the bearing cup (1) in the case side.
7. Install the bearing cup by hand.
   Fig 7: Installing Carrier Cover Inner Seal

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8. Install the inner seal into the PTU cover using Installer (special tool #9852, Installer, Seal) and Handle (special tool #C-4171, Driver Handle, Universal).
   Fig 8: Installing Carrier Cover Outer Seal

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9. Install the outer seal into the PTU cover using Installer (special tool #9853, Installer, Seal) and Handle (special tool #C-4171, Driver Handle, Universal).
   Fig 9: Bearing Cup And Shim

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10. Install the shim (1) under the bearing cup (3).
11. Install bearing cup by hand (3).
    Fig 10: Side Cover Bolts

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12. Install the carrier assembly into the case
13. Install the side cover
14. Tighten side cover bolts (1) to 23 N.m (17 ft. lbs.).
    Fig 11: Installing Output Shaft Head Bearing

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15. Install the output shaft head bearing on to the pinion shaft using Installer (special tool #9714, Installer, Bearing) and a Press.
    Fig 12: Installing Output Shaft Head Bearing Cup

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16. Install the output shaft head bearing cup using Installer (special tool #6061, Installer, Cup) and Handle (special tool #C-4171, Driver Handle, Universal).
    Fig 13: Installing Output Shaft Tail Bearing Cup

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17. Install the output shaft tail bearing cup using Installer (special tool #9855, Installer, Bearing Cup) and Handle (special tool #C-4171, Driver Handle, Universal).
    Fig 14: Pinion Shaft Spacer

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18. Install the output shaft spacer onto the output shaft.
    Fig 15: Installing Output Shaft Tail Bearing

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19. Install output shaft into output shaft housing.
20. Install output shaft tail bearing on to out put shaft using Installer (special tool #L-4411, Installer, Bearing).
    Fig 16: Pinion Shaft Nut

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    NOTE:

    The output shaft nut is a staked type nut.

21. Install the output shaft nut (1) onto the output shaft (2).
    Fig 17: Installing Pinion Nut

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22. Tighten the output shaft nut using Pinion Nut Socket (special tool #9921, Wrench, Pinion Nut) to 150 N.m (111 ft. lbs.).
23. Using an inch pound torque wrench check and Pinion Nut Socket (special tool #9921, Wrench, Pinion Nut) (1) check the rotating torque, it should be 30 in. lbs. Add 0.002 in. larger shim to increase rotating torque and add 0.002 in. smaller shim to decrease rotating torque. Repeat until proper turning torque is obtained.
24. Using a punch stake the output shaft nut.
    Fig 18: Pinion Housing Shim

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25. Install the pinion housing O-ring (3).
26. Install the pinion housing shim (1).
    Fig 19: Pinion Shaft Seal

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27. Install the output shaft seal using Installer (special tool #9851, Installer, Seal) and Handle (special tool #C-4171, Driver Handle, Universal).
    Fig 20: Extension Housing O-Ring

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28. Install a new  extension housing O-ring.
    Fig 21: Pinion Housing

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29. Install the output shaft housing and bolts onto the carrier housing.
30. Apply pattern check grease to the ring gear.
    Fig 22: Installing Dust Shield

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31. Using a block of wood (2) install the dust shield (3) onto the extension housing (1).
    Fig 23: Extension And Pinion Housing Bolts

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32. Install the extension housing and bolts.
33. Tighten output shaft housing bolts to 38 N.m (28 ft. lbs.).
34. Tighten the extension housing bolts to 38 N.m (28 ft. lbs.).
    Fig 24: Vent

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35. Clean cover and apply MOPAR® axle RTV or equivalent.
36. Install the vent and bolts, tighten the bolts to 23 N.m (17 ft. lbs.).
    Fig 25: Vent Shield

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37. Install the vent shield and bolts. tighten the bolts to 23 N.m (17 ft. lbs.).
    Fig 26: Inspection Cover

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38. Clean cover and apply MOPAR® axle RTV.
39. Apply MOPAR® lock AND seal adhesive or equivalent to bolts.
40. Install the inspection cover and bolts. tighten the bolts to 23 N.m (17 ft. lbs.).
41. Fill the PTU. Refer to STANDARD PROCEDURE .