Power Transfer Unit - Assembly

ASSEMBLY





1. Install output side spool shaft bearing using Installer C-3095-A.





2. Install ring gear side bearing using Installer 8148.





3. Install the ring gear.





4. Install the new ring gear bolts and tighten to 74 Nm (55 ft. lbs.).





5. Install the carrier case seal using Installer 9851 and Handle C- 4171.





6. Install the shim (3) under the bearing cup (1) in the case side.
7. Install the bearing cup by hand.





8. Install the inner seal into the PTU cover using Installer 9852 and Handle C-4171.





9. Install the outer seal into the PTU cover using Installer 9853 and Handle C-4171.





10. Install the shim (1) under the bearing cup (3).
11. Install bearing cup by hand (3).





12. Install the carrier assembly into the case
13. Install the side cover
14. Tighten side cover bolts (1) to 23 Nm (17 ft. lbs.).





15. Install the output shaft head bearing on to the pinion shaft using Installer 9714 and a Press.





16. Install the output shaft head bearing cup using Installer 6061 and Handle C-4171.





17. Install the output shaft tail bearing cup using Installer 9855 and Handle C-4171.





18. Install the output shaft spacer onto the output shaft.





19. Install output shaft into output shaft housing.
20. Install output shaft tail bearing on to out put shaft using Installer L-4411.






NOTE: The output shaft nut is a staked type nut.

21. Install the output shaft nut (1) onto the output shaft (2).





22. Tighten the output shaft nut using Pinion Nut Socket 9921 to 150 Nm (111 ft. lbs.).
23. Using an inch pound torque wrench check and Pinion Nut Socket 9921 (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.





25. Install the pinion housing O-ring (3).
26. Install the pinion housing shim (1).





27. Install the output shaft seal using Installer 9851 and Handle C-4171.





28. Install anew extension housing O-ring.





29. Install the output shaft housing and bolts onto the carrier housing.
30. Apply pattern check grease to the ring gear.





31. Using a block of wood (2) install the dust shield (3) onto the extension housing (1).





32. Install the extension housing and bolts.
33. Tighten output shaft housing bolts to 38 Nm (28 ft. lbs.).
34. Tighten the extension housing bolts to 38 Nm (28 ft. lbs.).





35. Clean cover and apply MOPAR(R) axle RTV or equivalent.
36. Install the vent and bolts, tighten the bolts to 23 Nm (17 ft. lbs.).





37. Install the vent shield and bolts. tighten the bolts to 23 Nm (17 ft. lbs.).





38. Clean cover and apply MOPAR(R) axle RTV.
39. Apply MOPAR(R) lock AND seal adhesive or equivalent to bolts.
40. Install the inspection cover and bolts. tighten the bolts to 23 Nm (17 ft. lbs.).
41. Fill the PTU Procedures.