Power Transfer Unit (PTU) 3.5L GTDI: Installation

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

Install the new PTU compression seal.

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Remove the PTU bolts and the PTU.
1. With the help of a assistant to rotate the engine, install the PTU.
2. Install the transmission side PTU bolts.
  - Tighten to 90 Nm (66 lb-ft).
3. Install the intermediate shaft side PTU bolts.
  - Tighten to 90 Nm (66 lb-ft).
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Fill the PTU, If necessary. Power Transfer Unit (PTU) Draining and Filling .
NOTE: The PTU vent hose should be replaced whenever a new PTU is installed.

Connect the PTU vent hose.

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NOTE: Inspect the O-ring seals and replace as necessary.

If equipped, install the PTU coolant tubes and the bolt.
- Tighten to 25 Nm (18 lb-ft).
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If equipped, connect the PTU cooling system temperature sensor electrical connector.

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NOTE: RH shown, LH similar.

Install the front subframe support bracket and the front subframe support brackets bolts.
- Tighten to 55 Nm (41 lb-ft).
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NOTE: RH shown, LH similar.

Install the new rear bolts of the front subframe.
- Tighten to 150 Nm (111 lb-ft).
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Position the front roll restrictor and tighten the front roll restrictor through bolt. Install the front roll restrictor bracket bolts.
- Tighten the roll restrictor bracket bolts to 90 Nm (66 lb-ft).
- Tighten the roll restrictor through bolt to 103 Nm (76 lb-ft).
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Position the roll restrictor aside and tighten the roll restrictor through bolt. Install the rear roll restrictor bracket and the rear roll restrictor bracket bolts.
- Tighten the roll restrictor bracket bolts to 90 Nm (66 lb-ft).
- Tighten the roll restrictor through bolt to 103 Nm (76 lb-ft).
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Install the PTU support bracket and the PTU support bracket bolts.
- Tighten to 48 Nm (35 lb-ft).
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Install the RH turbocharger lower bracket and the RH turbocharger lower bracket bolts.
- Tighten the 2 bolts to 48 Nm (35 lb-ft).
- Tighten the bolt to 19 Nm (168 lb-in).
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Position back the LH exhaust flexible pipe. Install the new LH exhaust flexible pipe-to-underbody catalytic converter nuts.
- Alternately tighten the nuts to 40 Nm (30 lb-ft).
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Connect the steering gear harness and install the steering gear harness push pin.

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Install the steering gear harness bolt.
- Tighten to 9 Nm (80 lb-in).
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Remove the steering gear shield retainer and position the steering gear shield aside.
- Tighten to 9 Nm (80 lb-in).
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NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. Refer to Supplemental Restraint System .

Connect the steering shaft and install the new steering coupler through bolt.
- Tighten to 20 Nm (177 lb-in).
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Line up the index marks and install the new driveshaft bolts.
- Tighten to 70 Nm (52 lb-ft).
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Install the RH catalytic converter. Refer to Exhaust System .
NOTE: A new PTU intermediate shaft seal must be installed whenever the intermediate shaft or PTU is removed from the vehicle. Refer to Intermediate Shaft Seal and Deflector .

Install the intermediate shaft. Refer to Front Drive Halfshafts .
If equipped, install the retainers and the underbody shield.

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If equipped with PTU cooling, fill the cooling system. Refer to Engine Cooling .