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Power Transfer Unit: Overview Jeep Compass I

Transfer Case 80 illustrations ~1471 words

Scheme 1

Scheme 1: POWER TRANSFER UNIT
Scheme 1: POWER TRANSFER UNIT
  1. If fluid level is low or fluid change is required fill with MOPAR® MS9020 SAE 80W90 Gear Lube until to bottom of fill plug.
  2. Tighten fill plug (1) to 32 N.m (24 ft. lbs.).
  3. Tighten drain plug (2) to 32 N.m (24 ft. lbs.).

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Scheme 2: POWER TRANSFER UNIT
Scheme 2: POWER TRANSFER UNIT

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  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. Refer to «REMOVAL»(ref-304331-S17395270962008110700000) .
  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 shaft. Refer to «REMOVAL»(ref-304331-S08676079522008110700000) .
  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 system. Refer to «REMOVAL»(ref-304333-S16434975412008110700000) .
  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 bungee 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 six PTU mounting bolts (2), three on the bottom and three on the top.
  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.

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Scheme 16: POWER TRANSFER UNIT
Scheme 16: POWER TRANSFER UNIT

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Scheme 42
  1. Remove extension housing bolts.
  2. Remove the extension housing.
  3. Remove the extension housing O-ring.
  4. Using a chisel (2) remove the dust shield (1) from the extension housing (3).
  5. Remove the pinion housing bolts.
  6. Remove the pinion housing.
  7. Remove the pinion housing shim.
  8. Remove the pinion housing O-ring. NOTE: The pinion nut is a staked type nut.
  9. Using a chisel or a grinder, remove the staked depression in the pinion nut.
  10. Remove the output shaft nut, using the Output Shaft Nut Socket 9921 and Spline Socket 9922.
  11. Press the output shaft from the housing using a press.
  12. Remove the output shaft spacer.
  13. Remove the output shaft bearing.
  14. Remove the output shaft housing small side bearing cup using a brass drift.
  15. Remove the output shaft housing large side bearing cup using a brass drift.
  16. Install Puller 6444 and Jaws 6451 onto output shaft head bearing.
  17. Place Puller in a vice and remove the bearing.
  18. Remove the inspection cover bolts (1).
  19. Remove the inspection cover.
  20. Remove the side cover bolts (1).
  21. Remove the side cover from case.
  22. Remove the carrier assembly. NOTE: Bearing cup is a slip fit.
  23. Remove bearing cup by hand (1) or by using a pick.
  24. Remove the shim (1) under the bearing cup (3). Measure and record the size of the shim.
  25. Remove the inner seal from the PTU cover.
  26. Remove the outer seal from the PTU cover.
  27. Remove bearing cup by hand (1) or by using a pick.
  28. Remove the shim (3) under the bearing cup (1). Measure and record the size of the shim.
  29. Remove the carrier case seal.
  30. Remove the ring gear bolts.
  31. Remove the ring gear.
  32. Remove ring gear side bearing using Puller C-293-PA, Inserts C-293-37 and Insert C-4487-1.
  33. Remove output side bearing using Puller C-293-PA, Inserts C-293-37 and Insert C-4487-1.

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Scheme 43: POWER TRANSFER UNIT
Scheme 43: POWER TRANSFER UNIT

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  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 N.m (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 N.m (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 N.m (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 .002 in. larger shim to increase rotating torque and add .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 a new 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 N.m (28 ft. lbs.).
  34. Tighten the extension housing bolts to 38 N.m (28 ft. lbs.).
  35. Clean cover and apply MOPAR® axle RTV or equivalent.
  36. Install the vent and bolts, tighten the bolts to 23 N.m (17 ft. lbs.).
  37. Install the vent shield and bolts. tighten the bolts to 23 N.m (17 ft. lbs.).
  38. Clean cover and apply MOPAR® axle RTV.
  39. Apply MOPAR® lock & seal adhesive or equivalent to bolts.
  40. Install the inspection cover and bolts. tighten the bolts to 23 N.m (17 ft. lbs.).
  41. Fill the PTU. See «STANDARD PROCEDURE»(ref-304399-S08970440812008110700000) .

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  1. Roll the PTU in, moving from front to back (1). see scheme 70
  2. Rest the PTU (1) on the frame (3) while the engine and transaxle (2) are raised back into position. (Scheme 58)
  3. Lower screw jack (2) until rear mount through bolt can be installed. see scheme 72
  4. Install rear mount through bolt (2) and tighten bolt to 75 Nm (55 ft. lbs.). see scheme 73
  5. Install the transmission crossmember and bolts, (2) tighten to 75 Nm (55 ft. lbs.). (Scheme 59)
  6. Install the through bolt at the front transmission mount (1) and tighten to 75 Nm (55 ft. lbs.). NOTE: STICKING THE O-RING WITH VASELINE OR TRANS ASSEMBLY GREASE IS RECOMMENDED.
  7. Insure that the O-ring (1) between the PTU and transaxle is in place. (Scheme 60)
  8. Slide the PTU into place.
  9. Install and tighten the six PTU mounting bolts (2), three on the bottom and three on the top to 58 N.m (43 ft. lbs.).
  10. Lower the hoist.
  11. Install the maniverter. Refer to «INSTALLATION»(ref-304333-S39802385142008110700000).
  12. Install the air box (1).
  13. Install engine trim cover.
  14. Raise the vehicle on the hoist.
  15. Install the exhaust system. Refer to «INSTALLATION»(ref-304333-S38988080702008110700000).
  16. Install the propeller shaft. Refer to «INSTALLATION»(ref-304331-S06435970062008110700000).
  17. Install the axle shafts. Refer to «INSTALLATION»(ref-304331-S24431726682008110700000).
  18. Fill PTU. See «STANDARD PROCEDURE»(ref-304399-S08970440812008110700000).
  19. Lower hoist.
  20. Connect battery cables (2).
  21. Top off the fluids. See «STANDARD PROCEDURE»(ref-304399-S08970440812008110700000).
DESCRIPTIONN.mFt. Lbs.In. Lbs.
Plug, Fill3224
Plug, Drain3224
Bolts, Inspection cover2317
Bolts, Vent Shield2317
Bolts, Vent2317
Bolts, Output Shaft Housing3828
Bolts, extension housing3828
Nut, Output Shaft150111
Bolts, Carrier Assembly Side Cover2317
Bolts, Ring Gear7455
Bolt and Nut, Rear Mount Through7555
Bolts, Transmission Crossmember7555
Bolt and Nut, Transmission Crossmember through7555
Bolts, PTU Mounting5843

TORQUE SPECIFICATIONS

Scheme 61

Scheme 61: POWER TRANSFER UNIT
Scheme 61: POWER TRANSFER UNIT

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