Power Transfer Unit: Removal & Installation Dodge Journey I

REMOVAL

1. Remove right halfshaft assembly. Refer to «Differential and Driveline/Half Shaft - Removal»(ref-353569-S23433654932010011200000) .
2. Using suitable screwdriver (1), remove outer halfshaft seal (2).

INSTALLATION

1. Install outer halfshaft seal using Handle C-4171 and Installer 6536-A.
2. Install right halfshaft assembly. Refer to «Differential and Driveline/Half Shaft - Installation»(ref-353569-S33188263152010011200000) .

Note. The Power Transfer Unit must be removed from the vehicle to replace this O-ring.

1. Remove PTU from transaxle. See «Removal»(ref-353620-S28539122802010011200000) .
2. Remove the O-ring.

1. Install a new O-ring (1).
2. Install the PTU to the transaxle. See «Installation»(ref-353620-S05433498112010011200000) .
3. Check PTU fluid level. See «Standard Procedure»(ref-353620-S33661856492010011200000) .

Scheme 24

1. Remove power transfer unit. See «Removal»(ref-353620-S28539122802010011200000) .
2. Using drill and suitable bit (2), drill hole in input shaft seal (1) to facilitate removal with slide hammer. Use care not to damage the shaft sealing surface.
3. Using slide hammer and suitable screw, remove input shaft seal.

Scheme 25

1. Using Handle C4171 (1) and Installer L-4429-3 (2), install input shaft seal.
2. Install Power Transfer Unit. See «Installation»(ref-353620-S05433498112010011200000) .

Scheme 26

Scheme 27

1. Remove propeller shaft. Refer to «Differential and Driveline/Propeller Shaft - Removal»(ref-353569-S30582861682010011200000) .
2. Using Spanner Wrench 6958 (1) and suitable ratchet and socket, remove output flange nut 1 - PULLER 1026 2 - OUTPUT FLANGE
3. Install Puller 1026 (1) and remove PTU output flange (2).
4. Using suitable screwdriver, remove seal and discard.

Scheme 28

Scheme 29

1. Using Installer 9684 (1) and Handle C-4171 (2), install new PTU output flange seal . 1 - HANDLE C-4171 2 - INSTALLER 9321 3 - OUTPUT FLANGE
2. Using Installer 9321 (2) and Handle C-4171 ,(1) install output flange (3). Lightly tap on flange until sufficient threads are exposed to start flange nut by hand. 1 - SPANNER WRENCH 6958
3. Using Spanner Wrench 6958 (1), install and torque output flange nut to 102 N.m (75 ft. lbs.) torque.
4. Install propeller shaft. Refer to «Differential and Driveline/Propeller Shaft - Installation»(ref-353569-S22009109082010011200000) .