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Power Take Off Unit - Disassembly And Assembly: Disassembly

WARNING: This page is about a different car, the 2005 Mazda Tribute. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION:
  • Discard all seals after removing them.
    CAUTION:
    • Rotational torque of the power take off rear output shaft flange must be measured and recorded using an in-lb torque wrench for correct pinion bearing preload when reassembled.
    Fig 1: Holding Power Take Off Rear Output Shaft Flange Using Special Tool
    G03725329Courtesy of MAZDA MOTORS CORP.
  1. Using the special tool to hold the power take off rear output shaft flange, remove the nut.
    2. CAUTION:
    • Mark the power take off rear output shaft flange relative to the pinion spline.
    Fig 2: Removing Power Take Off Rear Output Shaft Flange
    G03725330Courtesy of MAZDA MOTORS CORP.
  2. Using the special tool, remove the power take off rear output shaft flange.
  3. Remove the power take off rear output shaft flange dust shield.
  4. Remove the power take off rear output shaft flange oil seal.
  5. Using the special tools, remove the power take off driven gear seal.
    Fig 3: Removing Power Take Off Driven Gear Seal
    G03725331Courtesy of MAZDA MOTORS CORP.
    6. CAUTION:
    • The power take off cover is located to the case using 2 hollow dowels. Remove the cover squarely from the dowels to avoid cracking the cover bosses.
    Fig 4: Removing Bolts And Power Take Off Cover And Gears
    G03725332Courtesy of MAZDA MOTORS CORP.
  6. Remove the 12 bolts and the power take off cover and gears.
  7. Remove the gears.
    1. Remove the drive gear.
      • Remove the drive gear using a slight rotation to prevent damaging the power take off inner half shaft seal.
      2. NOTE:
      • Remove the idle gear and the driven gear as an assembly.
    2. Remove the idle gear.
    3. Remove the driven gear.
    Fig 5: Removing Gears
    G03725333Courtesy of MAZDA MOTORS CORP.
  8. Remove the power take off inner halfshaft seal
  9. Clean the mating surfaces.
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