Two Speed PTU Installation
If the actuator was inoperative and was not in the 2WD mode before it was removed, the shift forks can be aligned by placing a large plastic loom tie between the shift fork and the actuator housing to position the fork closer to the center of the actuator. Do not attempt to join the ends of the loop tie around the shift mechanism. The loom tie will serve as a shim and can be pulled out after the actuator is in position on the Power Transfer Unit (PTU).
If installing a new actuator, there are two locating dowels that may have stayed in the case, remove them from the case as the dowels will come installed in the new actuator.
- Using a clean lint free cloth, wipe the sealing surfaces clean.NOTE:
Do not use solvent to clean the PTU components.
- Install a NEW
gasket (2) in the groove in the sealing surface of the shaft actuator (1).
- While carefully guiding the shift forks (3 and 4) in the PTU housing, align the grooves in the shift forks (3 and 4) to the rails on the shift sleeves (5 and 6).
- Push the actuator (2) downward until the sealing surfaces mate and the locating dowels line up with the PTU (1).
- If a loom tie was used as a shim, pull the loom tie out from under the actuator.NOTE:
Do not reuse the actuator mounting screws.
- Install NEW
fasteners (2) to hold the shift actuator to the PTU housing and tighten to the proper torque specification. Refer to TORQUE SPECIFICATIONS
.NOTE:
Prior to fully installing the PTU in vehicle, use the scan tool to actuate the actuator to all positions to verify the shift forks properly engaged the hubs in the PTU. It may be necessary to manually manipulate the output shafts to allow the actuator to engage in all positions.
- Install the PTU in the vehicle. Refer to INSTALLATION .
- Fill the PTU to the proper level with the specified fluid. Refer to STANDARD PROCEDURE .
- Road test the vehicle to verify the repair.