Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 99
Remove P.T.U. remote vent from left engine
mount.
Remove P.T.U. assembly from vehicle.
To Install, Reverse Removal Procedure.
POWER TRANSFER UNIT END COVER—RESEAL
The Power Transfer Unit must be removed from the
vehicle to perform this operation. Refer to Power
Transfer Unit Removal in this section for procedures.
(1) Remove P.T.U. end cover bolts (Fig. 13).
(2) Gently tap on end cover ears with a hammer to
separate end cover from the case (Fig. 14).
(3) Clean and inspect sealer surfaces.
(4) Apply Mopar
t Gasket Maker, Loctite Gasket
Eliminator No.518 or equivalent to sealing surfaces.
(5) Reinstall cover and tighten bolts to 28 N
Im (250
in. lbs.) in the sequence shown in figure 15. Retighten
first bolt after all others are tight.
CAUTION: When end cover is installed be careful not
to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. into vehicle.
(7) Check and fill fluids as required.
Fig. 11 Remove Distance Sensor from P.T.U.
Fig. 12 Remove P.T.U. Mounting Bolts (4)
Fig. 13 P.T.U. End Cover Bolts
Fig. 14 End Cover Removal
.
TRANSAXLE
21 - 145
POWER TRANSFER UNIT INPUT SHAFT SEAL
The Power Transfer Unit must be removed from the
vehicle to service this seal. Refer to Power Transfer
Unit Removal in this section for procedures.
REMOVAL
(1) Remove P.T.U. end cover bolts (Fig. 1).
(2) Gently tap on end cover ears to separate cover
from case (Fig. 2).
(3) Remove ring gear oil slinger (Fig. 3).
(4) Remove input shaft and ring gear from case (Fig.
4).
(5) Use Special Tool No. 7794-A (seal puller) to
remove seal (Fig. 5).
INSTALLATION
(1) Clean and inspect seal area.
(2) Lay housing on bench and install new seal with
seal driver C-4657 and handle C-4171 (Fig. 6). The seal
must be installed with the spring side facing to-
Fig. 15 Bolt Tightening Sequence
Fig. 1 P.T.U. End Cover Bolts
Fig. 2 End Cover Removal
Fig. 3 Oil Trough
21 - 146
TRANSAXLE
.
wards the ring gear. Drive the seal in until it bottoms
against the case shoulder.
(3) Install input shaft.
(4) Install oil trough.
(5) Apply Mopar
t Gasket Maker, Loctite Gasket
Eliminator No. 518 or equivalent to sealing surfaces of
end cover and reinstall. Tighten bolts to 28 N
Im (250
in. lbs.)
CAUTION: When end cover is installed be careful not
to damage the P.T.U. Input Shaft Cover Seal.
(6) Reinstall P.T.U. assembly into vehicle.
(7) Check and fill fluids as required.
TRANSAXLE DIFFERENTIAL CARRIER SEAL
The Power Transfer Unit must be removed from the
vehicle to replace this seal.
REMOVAL
(1) Remove P.T.U. from vehicle.
(2) Use a pry bar to remove seal from retainer plate
(Fig. 7). Be careful not to damage seal journal when
removing seal.
INSTALLATION
(1) Using a large socket, carefully install new seal.
The spring side of the seal must face the transaxle
differential.
(2) Reinstall the P.T.U. into the vehicle.
(3) Check and fill fluids as required.
Fig. 7 Transaxle Differential Carrier Seal
Fig. 4 Input Shaft and Ring Gear Removal
Fig. 5 Seal Removal
Fig. 6 Seal Installation
.
TRANSAXLE
21 - 147
POWER TRANSFER UNIT REAR COVER O-RING
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove rear cover retaining bolts (Fig. 1).
(3) Index rear cover to the case for later reassembly
(Fig. 2).
(4) Pull rear cover out of the P.T.U. case (Fig. 3).
(5) Remove rear cover O-Ring (Fig. 4).
(6) To Install, Reverse Removal Procedure.
POWER TRANSFER UNIT OUTPUT SEAL
The power transfer unit must be removed from the
vehicle to replace this seal.
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove propeller shaft.
(3) Remove rear cover retaining bolts (Fig. 5).
(4) Index rear cover to the case for later reassembly
(Fig. 6).
(5) Pull rear cover out of the P.T.U. case (Fig. 7).
(6) Remove output flange nut (Fig. 8).
(7) Index the pinion to the flange (Fig. 9).
(8) Using a hydraulic press, press off output flange
from pinion.
Fig. 1 Rear Cover Bolts
Fig. 2 Mark Rear Cover
Fig. 3 Rear Cover Removal
Fig. 4 O-Ring Removal
Fig. 5 Rear Cover Bolts
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TRANSAXLE
.
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