Power Transfer Unit (Service Information): Disassembly: Disassembly

Fig 1: Extension And Pinion Housing Bolts

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1. Remove extension housing bolts.
   Fig 2: Extension Housing O-Ring

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2. Remove the extension housing.
3. Remove the extension housing O-ring.
   Fig 3: Removing Dust Shield From Extension Housing

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4. Using a chisel (2) remove the dust shield (1) from the extension housing (3).
   Fig 4: Extension And Pinion Housing Bolts

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5. Remove the pinion housing bolts.
   Fig 5: Pinion Housing

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6. Remove the pinion housing.
   Fig 6: Pinion Housing Shim

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7. Remove the pinion housing shim.
8. Remove the pinion housing O-ring.
   Fig 7: Pinion Shaft Nut

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   NOTE:

   The pinion nut is a staked type nut.

9. Using a chisel or a grinder, remove the staked depression in the pinion nut.
   Fig 8: Removing Pinion Nut

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10. Remove the output shaft nut, using the Output Shaft Nut Socket (special tool #9921, Wrench, Pinion Nut) and Spline Socket (special tool #9922, Socket, Splined).
    Fig 9: Removing Output Shaft

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11. Press the output shaft from the housing using a press.
    Fig 10: Pinion Shaft Spacer

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12. Remove the output shaft spacer.
    Fig 11: Output Shaft Bearing

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13. Remove the output shaft bearing.
    Fig 12: Removing Small Side Bearing Cup

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14. Remove the output shaft housing small side bearing cup using a brass drift.
    Fig 13: Removing Large Side Bearing Cup

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15. Remove the output shaft housing large side bearing cup using a brass drift.
    Fig 14: Removing Output Shaft Head Bearing

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16. Install Puller (special tool #6444, Puller, Bearing/Gear) and Jaws (special tool #6451, Jaws, Puller) onto output shaft head bearing.
17. Place Puller in a vice and remove the bearing.
    Fig 15: Inspection Cover

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18. Remove the inspection cover bolts (1).
    Fig 16: Removing Inspection Cover

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19. Remove the inspection cover.
    Fig 17: Side Cover Bolts

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20. Remove the side cover bolts (1).
    Fig 18: Removing Side Cover

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21. Remove the side cover from case.
    Fig 19: Carrier Assembly

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22. Remove the carrier assembly.
    Fig 20: Carrier Bearing Cup And Seal

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    NOTE:

    Bearing cup is a slip fit.

23. Remove bearing cup by hand (1) or by using a pick.
    Fig 21: Bearing Cup And Shim

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24. Remove the shim (1) under the bearing cup (3). Measure and record the size of the shim.
    Fig 22: Inner Cover Seal

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25. Remove the inner seal from the PTU cover.
26. Remove the outer seal from the PTU cover.
    Fig 23: Shim Under Bearing Cup

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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.
    Fig 24: Carrier Case Seal

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29. Remove the carrier case seal.
    Fig 25: Ring Gear Bolts

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30. Remove the ring gear bolts.
    Fig 26: Ring Gear

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31. Remove the ring gear.
    Fig 27: Removing Ring Gear Side Bearing

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32. Remove ring gear side bearing using Puller (special tool #C-293-PA, Puller, Press), Inserts (special tool #C-293-37, Block Set, Puller) and Insert (special tool #C-4487-1, Adapter).
    Fig 28: Removing Output Side Bearing

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33. Remove output side bearing using Puller (special tool #C-293-PA, Puller, Press), Inserts (special tool #C-293-37, Block Set, Puller) and Insert (special tool #C-4487-1, Adapter).