2003 CHRYSLER CARAVAN Service Manual

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Page 1457 of 2177

CHRYSLER CARAVAN 2003 Service Manual (4) Remove bearing retaining snap ring (Fig. 18). (5) Use bearing puller MD998346 to remove bear- ing (Fig. 19). INSTALLATION The end cover ball bearing can be removed and installed without removing t

Page 1458 of 2177

CHRYSLER CARAVAN 2003 Service Manual 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 co

Page 1459 of 2177

CHRYSLER CARAVAN 2003 Service Manual 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)

Page 1460 of 2177

CHRYSLER CARAVAN 2003 Service Manual (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

Page 1461 of 2177

CHRYSLER CARAVAN 2003 Service Manual 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

Page 1462 of 2177

CHRYSLER CARAVAN 2003 Service Manual (3) Reinstall the original bearing race and shim using special tool No. 6522 (Fig. 35) and (Fig. 36). CAUTION: The original shim must be installed behind the bearing cup to maintain proper bearing pre

Page 1463 of 2177

CHRYSLER CARAVAN 2003 Service Manual (3) Tap on end cover ears to separate end cover from case (Fig. 39). (4) Pry out seal with a pry bar (Fig. 40).INSTALLATION The input shaft end seal is located on the end of the input shaft. (1) Clean

Page 1464 of 2177

CHRYSLER CARAVAN 2003 Service Manual INPUT SHAFT SEAL REMOVAL The Power Transfer Unit must be removed from the vehicle to service this seal. Refer to Power Trans- fer Unit Removal in this section for procedures. (1) Remove P.T.U. end cov
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