Power Transfer Unit - Removal

REMOVAL





1. Disconnect negative battery cable (2).
2. Remove the engine trim cover.
3. Remove air cleaner assembly (1).
4. Remove Power Distribution Center (PDC) from bracket.
5. Raise the vehicle on the hoist.
6. Remove front halfshafts Half Shaft - Removal.





7. Remove drain plug (2) at PTU and allow fluid to drain.
8. Reinstall drain plug.





9. Mark (2) prop shaft and differential (3) for proper installation.
10. Remove the rear prop shaftRemoval.





11. Remove the two exhaust to maniverter (exhaust manifold with catalytic converter) bolts (1).
12. Unplug the downstream O2 sensor connector.
13. Remove the exhaust systemRemoval.
14. Lower the vehicle on the hoist.
15. Unplug the upstream O2 sensor connector.





16. Remove upstream O2 sensor from the maniverter (exhaust manifold with catalytic converter) using O2s (Oxygen Sensor) Remover/Installer 8439 (2).





17. Remove the four maniverter heat shield bolts (1).





18. Remove the two retaining bolts (2) and one nut (1) from the maniverter side heat shield (3).





19. Remove the seven maniverter to head retaining bolts.
20. Slide the maniverter up and to the right, support the maniverter (1) with the help of a bungie cord.





21. Raise the vehicle on the hoist.
22. Remove the four (1) engine to maniverter bracket bolts.





23. Remove the rear engine mount through bolt (2).
24. Remove the three front engine mount to frame bolts and the mount through bolt.





25. Remove the PTU mounting bolts (1, 2).





26. Install a screw jack (2) on front engine mount bracket (1).





27. Raise the front of the engine until the rear mount has dropped (1, 2).
28. Separate the PTU from the transaxle.
29. Remove and discard old O-ring between Transmission and PTU.





30. Roll the PTU (1) forward and down to remove.