Intermediate Shaft Seal and Deflector: Installation
NOTE:
The following illustration shows the correct orientation of the seal components when installed in the vehicle.
| Item | Description |
|---|---|
| 1 | Intermediate shaft seal (part of 7275 kit) - retains red transmission fluid used in the transaxle |
| 2 | Alignment washer (part of 7275 kit) - supports and centers the intermediate shaft in the seal |
| 3 | Seal deflector (part of 7275 kit) - keeps dust/dirt away from the intermediate shaft seal and PTU input shaft seal |
| 4 | Seal protector (part of 7275 kit) - protects intermediate shaft seal from damage by the intermediate shaft splines during installation. Must be removed before shaft is fully installed |
- Place the intermediate shaft seal on the PTU Linkshaft Seal Installer and Driver Handle with the spring side facing away from the tool.
- Using the PTU Linkshaft Seal Installer and Driver Handle, install the intermediate shaft seal.
- Place the alignment washer on the PTU Linkshaft Seal Installer and Driver Handle.
- Using the PTU Linkshaft Seal Installer and Driver Handle, install the alignment washer by hand, pushing it in until it bottoms against the seal.
- Position the deflector on the PTU Linkshaft Seal Dust Shield Installer using silicone brake caliper grease and dielectric compound to retain it to the installer. Using a suitable heat gun, heat the back of the tool to a minimum of 71°C (160°F) and a maximum of 93°C (200°F) by concentrating the heat across the back of the installer while rotating the tool. Once the optimum temperature is achieved on the tool, move the heat gun to the front of the tool and heat the inside of the deflector where it snaps onto the PTU shaft until the temperature of the deflector is a minimum of 93°C (200°F) to a maximum of 100°C (212°F).
- As an alternative method to heating the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry off the deflector and install.
- Using a 5-pound or larger dead blow hammer, install the seal deflector immediately after heating using the PTU Linkshaft Seal Dust Shield Installer and Driver Handle.
- Make sure the deflector is completely seated all the way around and there are no cracks on the face. The deflector is correctly installed when the face of the deflector is recessed 3-5 mm (0.118-0.196 in) into the pocket all the way around.
- Once the deflector is fully seated, insert the seal protector into the PTU deflector inside diameter.
- Apply a thin coat of silicone brake caliper grease and dielectric compound to the intermediate shaft seal journal.
- Partially install the intermediate and halfshaft assembly through the PTU deflector until the splines have cleared the seal protector.
- Pull the seal protector out of the deflector and off of the intermediate and halfshaft assembly.
- Fully install the intermediate and halfshaft assembly and the 2 nuts.
- Tighten to 25 Nm (18 lb-ft).
- Using brake parts cleaner, thoroughly clean the deflector and intermediate shaft area of any residual fluid that may have accumulated during the repair.
- Position the halfshaft and ball joint into the wheel knuckle. Install the new ball joint nut.
- Tighten to 150 Nm (111 lb-ft).
- Install the RH brake disc. Refer to FRONT DISC BRAKE .
- Apply the brake to keep the halfshaft from rotating. Using the previously removed wheel hub nut, seat the halfshaft into the front wheel hub.
- Tighten to 350 Nm (258 lb-ft).
- Remove and discard the wheel hub nut.
- Apply the brake to keep the halfshaft from rotating and install a new wheel hub nut.
- Tighten to 350 Nm (258 lb-ft).
- Install the RH front wheel and tire. Refer to WHEELS AND TIRES .
- Check the transmission fluid level and add clean transmission fluid as necessary.
NOTE:
Do not use force when installing the alignment washer or damage to the washer can occur.
NOTE:
Do not overheat (melt) the seal deflector. Monitor the temperature of the deflector with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating. Do not allow the temperature to exceed 100°C (212°F). Overheating will damage the deflector. If the deflector is damaged, a new deflector must be used.
NOTE:
Apply a small amount of silicone brake caliper grease and dielectric compound to the inner lip of the deflector where it installs on the tube inside the PTU before heating. This will ease the installation of the deflector.
NOTE:
A slight effort may be required to fully seat the intermediate and halfshaft assembly as it passes through the alignment washer.
NOTE:
A significant amount of residual fluid will collect between the seal and deflector during this repair. This is a normal condition and should not be misinterpreted as a leak after the repair is complete.
NOTE:
Do not tighten the halfshaft nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.
NOTE:
The wheel hub nut contains a one-time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur.