Page 1505 of 2321
SPECIAL TOOLS
SDP POWER TRANSFER UNIT
5049-a Seal Puller
5065 Bearing Installer
6514 Bearing Remover
6522 Bearing Remover
7794-a Bearing Remover
C-4171 Handle
C-4171-2 Handle
C-4657 Seal Installer
MD998200 Intaller
21 - 8 POWER TRANSFER UNITRS
POWER TRANSFER UNIT (Continued)
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Page 1506 of 2321

DIFFERENTIAL CARRIER SEAL
REMOVAL
The Power Transfer Unit must be removed from
the vehicle to replace this seal.
(1) Remove P.T.U. from vehicle.
(2) Use a pry bar to remove seal from retainer
plate (Fig. 16). Be careful not to damage seal journal
when removing seal.
INSTALLATION
The Power Transfer Unit must be removed from
the vehicle to replace this seal.
(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.
END COVER BALL BEARING
REMOVAL
The end cover ball bearing can be removed and
installed without removing the Power Transfer Unit
from the vehicle. When replacing the bearing the out-
put seal must be removed to gain access to the bear-
ing.
(1) Raise vehicle on hoist.
(2) Remove right front half shaft from vehicle.
(3) Remove output seal with a hammer and chisel
(Fig. 17).
(4) Remove bearing retaining snap ring (Fig. 18).
MD998334 Seal Installer
MD998346 Bearing Puller
Fig. 16 Transaxle Differential Carrier Seal
1 - TRANSAXLE CASE
2 - DIFFERENTIAL CARRIER SEAL
3 - RETAINER PLATE
Fig. 17 Output Seal Removal
1 - HAMMER
2 - CHISEL
3 - SEAL
4 - POWER TRANSFER UNIT
RSPOWER TRANSFER UNIT21-9
POWER TRANSFER UNIT (Continued)
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Page 1507 of 2321

(5) Use bearing puller MD998346 to remove bear-
ing (Fig. 19).
INSTALLATION
The end cover ball bearing can be removed and
installed without removing the Power Transfer Unit
from the vehicle. When replacing the bearing the out-
put seal must be removed to gain access to the bear-
ing.
CAUTION: When installing bearing, position the
bearing in place by hand square to the bore. Other-
wise, bearing and/or housing damage may occur
upon installation.(1) Use installer MD998200 and driver handle
C-4171 to install bearing (Fig. 20) into the housing.
(2) Install bearing retaining snap ring.
CAUTION: When installing bearing retaining snap
ring, be sure to index the snap ring so that the
snap ring does not cover bearing oil passage.
(3) Install new outer half shaft seal using
MD998334 seal installer (Fig. 21).Do not reuse the
old seal.
(4) Reinstall right front half shaft.
(5) Check and fill fluids as required.
Fig. 18 Bearing Snap Ring
1 - BEARING
2 - SNAP RING PLIERS
3 - BEARING SNAP RING
Fig. 19 Bearing Removal
1 - P.T.U. END COVER
2 - SPECIAL TOOL
MD998346
Fig. 20 Bearing Installation
1 - SPECIAL TOOL MD998200
2 - SPECIAL C-4171
Fig. 21 Installing New Seal
1 - P.T.U. END COVER
2 - HAMMER
3 - SPECIAL TOOL
MD998334
21 - 10 POWER TRANSFER UNITRS
END COVER BALL BEARING (Continued)
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Page 1508 of 2321
END COVER SEAL
REMOVAL
The Power Transfer Unit must be removed from
the vehicle to perform this operation. (Refer to 21 -
TRANSMISSION/TRANSAXLE/POWER TRANSFER
UNIT - REMOVAL)
(1) Remove P.T.U. end cover bolts (Fig. 22).
(2) Gently tap on end cover ears with a hammer to
separate end cover from the case (Fig. 23).
(3) Clean and inspect sealer surfaces.
INSTALLATION
(1) Reinstall cover and tighten bolts to 28 N´m
(250 in. lbs.) in the sequence shown in (Fig. 24).
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.
(2) Reinstall P.T.U. into vehicle.
(3) Check and fill fluids as required.
Fig. 22 P.T.U. End Cover Bolts
1 - POWER TRANSFER UNIT
2 - FILL PLUG
3 - END COVER
4 - OUTPUT SHAFT
Fig. 23 End Cover Removal
1 - END COVER EARS
2 - HAMMER
3 - POWER TRANSFER UNIT
Fig. 24 Bolt Tightening Sequence
RSPOWER TRANSFER UNIT21-11
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Page 1509 of 2321

HALF SHAFT INNER SEAL
REMOVAL
The power transfer unit half shaft inner seal is the
smaller of the two seals located on the inside of the
end cover.
(1) Remove power transfer unit from the vehicle.
(2) Remove end cover bolts (Fig. 25).
(3) Tap on end cover ears to separate cover from
case (Fig. 26).
(4) Drive seal out with a hammer and small chisel
(Fig. 27).
INSTALLATION
The power transfer unit half shaft inner seal is the
smaller of the two seals located on the inside of the
end cover.
(1) Clean and inspect seal area.
(2) Install seal with a 1 1/16 inch socket (Fig. 28).
The seal must be installed with the spring side of the
seal facing end cover ball bearing. The seal will bot-
tom against a machined shoulder in the cover.
(3) Clean sealing surfaces of the end cover and
P.T.U. case. Apply a bead of Moparž Gasket Maker,
Loctite Gasket Eliminator No. 518 or equivalent.
(4) Place end cover onto P.T.U. case and install
bolts. Tighten bolts to 28 N´m (250 in. lbs.) in the
sequence shown in (Fig. 29). Retighten first bolt after
all other bolts are tight.
(5) Reinstall P.T.U. assembly.
(6) Check and fill fluids as required.
Fig. 25 End Cover Bolts
1 - POWER TRANSFER UNIT
2 - FILL PLUG
3 - END COVER
4 - OUTPUT SHAFT
Fig. 26 End Cover Removal
1 - END COVER EARS
2 - HAMMER
3 - POWER TRANSFER UNIT
21 - 12 POWER TRANSFER UNITRS
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INPUT SHAFT COVER SEAL
REMOVAL
The power transfer unit input shaft cover seal is
the larger of the two seals located on the inside of
the end cover. The differential bearing cup must be
removed to service this seal.
(1) Remove P.T.U. end cover bolts (Fig. 30).
(2) Gently tap on end cover ears to separate cover
from case (Fig. 31).
(3) Use special tool No. 6514 and remove the dif-
ferential bearing race located in the end cover (Fig.
32). The race must be removed to gain access to the
seal.
(4) Use special tool No. 7794-A to remove seal (Fig.
33).
Fig. 27 Seal Removal
1 - END COVER
2 - END COVER SEAL
3 - AXLE SHAFT SEAL
Fig. 28 Seal Installation
1 - END COVER
2 - SOCKET
3 - HAMMER
Fig. 29 Bolt Tightening Sequence
RSPOWER TRANSFER UNIT21-13
HALF SHAFT INNER SEAL (Continued)
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Page 1511 of 2321
INSTALLATION
The power transfer unit input shaft cover seal is
the larger of the two seals located on the inside of
the end cover. The differential bearing cup must be
removed to service this seal.
(1) Clean and inspect seal area.
(2) Use special tool No. MD998803 and install seal
(Fig. 34). When installing seal the spring side of the
seal must face toward the special tool.
(3) Reinstall the original bearing race and shim
using special tool No. 6522 (Fig. 35) and (Fig. 36).
Fig. 30 P.T.U. End Cover Bolts
1 - POWER TRANSFER UNIT
2 - FILL PLUG
3 - END COVER
4 - OUTPUT SHAFT
Fig. 31 End Cover Removal
1 - END COVER EARS
2 - HAMMER
3 - POWER TRANSFER UNIT
Fig. 32 Bearing Race Removal
1 - END COVER
2 - SPECIAL TOOL No. 6514
Fig. 33 Seal Removal
1 - END COVER
2 - SPECIAL TOOL 7794±A
3 - SLIDE HAMMER
4 - SOFT JAW VICE
21 - 14 POWER TRANSFER UNITRS
INPUT SHAFT COVER SEAL (Continued)
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Page 1512 of 2321
CAUTION: The original shim must be installed
behind the bearing cup to maintain proper bearing
preload.
(4) Apply Moparž Gasket Maker, Loctite Gasket
Eliminator No. 518 or equivalent to sealing surfaces
of end cover.
(5) Place end cover onto P.T.U. case and install
bolts. Tighten bolts to 28 N´m (250 in. lbs.) in thesequence shown in (Fig. 37). 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. assembly into vehicle.
(7) Check and fill fluids as required.
Fig. 34 Seal Installation
1 - SPECIAL TOOL No. MD998803
2 - HAMMER
3 - END COVER
Fig. 35 Bearing Shim and Race
1 - SHIM
2 - BEARING RACE
3 - END COVER
Fig. 36 Installing Bearing Race
1 - HAMMER
2 - END COVER
3 - SPECIAL TOOL No. 6522
4 - HANDLE 4171
Fig. 37 Bolt Tightening Sequence
RSPOWER TRANSFER UNIT21-15
INPUT SHAFT COVER SEAL (Continued)
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