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Power Transfer Unit (PTU): Installation

  1. NOTE: Install a new compression seal whenever the PTU  is removed from the vehicle.

    Install the new compression seal.

    G07795468
  2. NOTE: It may be necessary to rotate the output shaft flange in either direction to align the splines of the PTU  to the splines of the transaxle.

    Position the PTU  and install the 5 PTU  bolts.

    • Tighten to 90 Nm (66 lb-ft).
  3. Install the 2 front subframe brackets and the 2 new front subframe rearward bolts.
    • Tighten to 200 Nm (148 lb-ft).
      G09142639
  4. Install the 4 new front subframe bracket bolts.
    • Tighten to 55 Nm (41 lb-ft).
      G09142640
  5. Position the steering gear and install the 2 new steering gear bolts.
    • Tighten to 165 Nm (122 lb-ft).
      G09142641
  6. If equipped, Install the RH  turbocharger oil return line. Refer to FUEL CHARGING AND CONTROLS - TURBOCHARGER, 3.5L GTDI .
  7. NOTE: Inspect the O-ring seals and replace as necessary.

    If equipped, install the PTU  coolant tubes and the bolt.

    • Tighten to 25 Nm (18 lb-ft).
      G08616411
  8. If equipped, connect the PTU  cooling system temperature sensor electrical connector.
    G08616410
  9. Position the engine roll restrictor to the transaxle and install the engine roll restrictor bracket and the 2 bolts.
    • Tighten the engine roll restrictor-to-transaxle bolts to 103 Nm (76 lb-ft).
    • Tighten the rear engine roll restrictor bolt to 90 Nm (66 lb-ft).
  10. Position the PTU  support bracket.
    • Install the 3 PTU  support bracket-to-engine bolts.
      • Tighten to 48 Nm (35 lb-ft).
    • Install the 2 PTU  support bracket-to-Power Transfer Unit (PTU) bolts.
      • Tighten to 48 Nm (35 lb-ft).
  11. If equipped, connect the PTU  vent hose.
  12. NOTE: Line up the index marks made during removal.

    Install the 4 driveshaft-to-output flange bolts.

    • Tighten to 70 Nm (52 lb-ft).
  13. Install the RH  catalytic converter. REFER to CATALYTIC CONVERTER - RH, 3.5L GTDI or REFER to CATALYTIC CONVERTER - RH MANIFOLD .
  14. Install the exhaust flexible pipe. Refer to EXHAUST SYSTEM .
  15. Install the RH  halfshaft. REFER to HALFSHAFT - RH, ALL WHEEL DRIVE (AWD) .
  16. NOTE: Vehicle shown in illustration without PTU  cooler. Vehicles with PTU  cooler similar.

    Remove the PTU  fill plug.

    G08651107
  17. Fill the PTU  fluid level even with the bottom of the fill opening.
    G08651109
  18. Apply silicon sealant to the drain plug threads and install the fill plug.
    • Tighten to 20 Nm (177 lb-in).
      G08616322
  19. If equipped with PTU cooling, fill the cooling system. REFER to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  20. Inspect the transmission fluid level and add clean, specified fluid as necessary.
  21. Check and if necessary, adjust the front toe. Refer to SUSPENSION SYSTEM - GENERAL INFORMATION .
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