Removal — Power Transfer Unit

Special Service Tools / General Equipment

1. 1
   Remove the front subframe.
   Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
2. 2
   Drain the PTU.
   Refer to: Power Transfer Unit Fluid Drain and Fill (308-07D).
3. 3
   Remove the intermediate shaft.
   Refer to: Intermediate Shaft (205-04 Front Drive Half Shafts, Removal and Installation).
4. 4
   1. Loosen the catalytic converter to muffler and exhaust pipe nut and separate them.

   2. Position and support the muffler and exhaust pipe aside.

   

5. 5
   Remove the catalytic converter bracket nuts and the catalytic converter bracket.

   

6. 6
   Remove and discard the driveshaft bolts to the PTU and the retaining straps.
   Torque: 26 lb-ft (35 N·m)

   

7. 7
   
   Separate the driveshaft from the PTU flange.
   

   1. Mark the driveshaft and PTU flange with an alignment mark.

   2. NOTICE: Do not remove the driveshaft from the PTU flange by pulling on the driveshaft tube. This may damage the CV joint.

      Using common equipment, separate the driveshaft from the PTU flange.
      Use common equipment: hammer
      Use common equipment: copper hammer.

   3. Position and support the driveshaft aside.

   

8. 8
   1. 1. Remove the engine appearance cover nut.

   2. 2. Place your hand under the engine appearance cover at each grommet and pull straight up to release each grommet from the stud.

   3. 3. After all grommets are removed from the studs, remove the engine appearance cover.

   

9. 9
   Disconnect and set aside the PTU vent hose.

   

10. 10
    Remove the breather hose clip.

    

11. 11
    If equipped, disconnect the PTU temperature sensor electrical connector. Disconnect the engine connectors and clips.

    

12. 12
    If equipped, disconnect the clip and set aside the wiring harness.

    

13. 13
    Remove the PTU support bracket bolts and the PTU support bracket.

    

14. 14
    Secure the flexible exhaust pipe.

    

15. 15
    • Disconnect the HO2S sensor connector and the wiring harness clip.

    • Disconnect the catalyst monitor sensor connector and the wiring harness clips.

    

16. 16
    Remove the EGR cooler inlet pipe.
    Refer to: Exhaust Gas Recirculation (EGR) Cooler Inlet Pipe (303-08C Engine Emission Control, Removal and Installation).
17. 17
    Remove the bolts and the heat shield.

    

18. 18
    Remove and discard the exhaust manifold nuts.

    

19. 19
    Set the catalytic converter aside.

    

20. 20
    Remove the PTU bolts.

    

21. 21

    NOTICE: This is a tight fit, use care to avoid damaging the transmission and PTU mating surfaces.

    Remove the PTU bolts and the PTU.

    

22. 22
    Remove and discard the PTU-to-transmission gasket.

    

23. 23
    Remove and discard the gasket.

    

24. 24
    Remove the PTU heat shield bolts and the PTU heat shield.
    Torque: 89 lb-in (10 N·m)

    

25. 25
    If equipped, remove the PTU temperature sensor wiring harness bracket.