PTU Disassembly

NOTE:

The Power Transfer Unit (PTU) is serviced as an assembly when mechanical failure is evident. If the PTU is leaking fluid, the lip seals can be replaced.

NOTE:

One speed shown in illustration, two speed similar.

Remove the PTU from the vehicle. Refer to REMOVAL .
Place the PTU on a suitable, clean and stable work surface.

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NOTE:
The PTU can be drained by turning it upside down, once the shift actuator is removed.
Remove and DISCARD the shift actuator mounting fasteners (2) and remove the PTU shift actuator (1).

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Using a suitable pair of snap ring pliers (1), remove and DISCARD the inner (3) and outer (2) snap rings from the output shaft case bore.

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Using a suitable punch and hammer, drive the output shaft (1) and bearing out of the axle (2) together.
NOTE:
Shaft shown in illustration without the case half for clarity.

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Using a suitable drift punch, drive the seal (1) out of the case half.

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Remove the fasteners (1) holding the PTU housing halves together.

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Using a suitable pry bar, pry the two halves of the PTU housing apart using the pry points (1) provided.

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NOTE:
When separating the housing, bearings and preload shims may dislodge. Make note of bearing cup and shim location for proper reassembly.
Carefully separate the right housing (1) from the PTU housing (2).

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Remove the gasket (1) from the groove in the PTU housing (2).

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Pull the input gear (1) and output ring gear (2) from the PTU housing together.

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NOTE:
Note the orientation of the tapered splines in the dog clutch sleeve for reassembly.
Remove the dog clutch sleeve (1) from the input shaft.

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Remove the input shaft (1) and bearing from the PTU housing.

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Using a suitable screwdriver:
- Remove the single seal from the PTU housing (1) if the PTU is from an automatic transmission equipped vehicle.
- Remove both the inner and outer input shaft seals from the PTU housing (1) if the PTU is from a manual transmission equipped vehicle.
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NOTE:
When equipped with a manual transmission, the input shaft contains two opposing seals. The inner lip seal keeps PTU fluid from entering the transmission. The outer lip seal keeps transmission fluid from entering the PTU when equipped with a manual transmission. There is a weep hole in the cavity between the two seals. When equipped with an automatic transmission, there is only the input shaft which only contains the outer seal.
Using a suitable screw driver;
- Remove the single seal from the inside the input shaft (1) if the PTU is from an automatic transmission equipped vehicle.
- Remove both the inner and outer input shaft seals from the inside the input shaft (1) if the PTU is from a manual transmission equipped vehicle.