Page 1497 of 3229
Publi s hed: 11-May-2011
Transfer Case - Power Transfer UnitTD4 2.2L Diesel, Vehicles With: M66
6-Speed Manual Transmission AWD
Removal and Inst all ati on
Removal
Rais e t he vehicle on a li ft .
1.
Remove t he dri ves haft .
Refer t o: Dri ves haft - Vehicles W it hout : Dies el Part icul ate Fi lt er (DPF) (205-01 Driveshaft, Removal and Ins tal lati on).
2.
Remove t he cat alyti c convert er.
Refer t o: Cat alyt ic Converter - Vehicles W it hout : Di es el Part iculate Fil ter (DPF) (309-00B Exhaus t Syst em - TD4 2.2L Di es el, Removal
and Inst all at ion).
3.
Remove t he lower engi ne s tabil izer bar.
Refer t o: Engi ne Lower Support Ins ulat or (303-01A Engine - I6 3.2L
Petrol, Removal and Ins tall ati on).
4.
Remove t he RH halfs haft.
Refer t o: Front Halfs haft RH (205-04 Front Dri ve Halfs haft s , Removal
and Inst all at ion).
5. 6.
Page 1498 of 3229
T orque:
25 Nm 7.
T orque:
10 Nm 8.
T orque:
65 Nm 9.
Page 1499 of 3229
10.
11.
NOTE: Thi s s tep requires the ai d of anot her
t echnician.
T orque: 60 Nm 11.
T orque:
10 Nm 12.
Installation
Page 1500 of 3229
1. CAUTION: Make s ure that the component is
clean, free of forei gn mat erial and l ubricant .
• NOTE: Apply t he requi red quanti ty of greas e t he
correct s peci fi cat ion.
For fl ui d s peci fi cat ion, refer t o t he s peci fi cat ion's
s ect ion.
1.
To i nst all , revers e t he removal procedure.
2.
Page 1501 of 3229
Publi s hed: 11-May-2011
Transfer Case - Transfer Case Connecting Sleeve Seals
Removal and Inst all ati on
Special T ool(s)
100-012Sl ide Hammer
303-538Remover/Ins t al ler, Cranks haft Oi l Seal
307-594Inst all er, Seal
308-615Remover, Seals
Removal
1. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he power t rans fer unit .
Refer t o: Power Trans fer Uni t - TD4 2.2L Di esel , Vehi cl es W i th: M666-Speed Manual Transmis si on AW D (308-07B Transfer Cas e,Removal and Ins tall ati on).
2.
Page 1502 of 3229
3.
CAUTIONS: Make s ure that t he area around the component i s
clean and free of foreign materi al. Take extra care not t o damage t he mati ng faces .
Speci al Tool (s ): 303-538 ,
308-615 ,
100-012 3.
Installation 1. CAUTION: Take ext ra care not t o damage the
s eal.
Speci al Tool (s ): 307-594 1.
Inst all t he power t rans fer unit .
Refer t o: Power Trans fer Uni t - TD4 2.2L Di esel , Vehi cl es W i th: M66 6-Speed Manual Transmis si on AW D (308-07B Transfer Cas e,
Removal and Ins tall ati on).
2.
Page 1503 of 3229
Publi s hed: 11-May-2011
Transfer Case - Transfer Case Rear Seal
Removal and Inst all ati on
Special T ool(s)
100-012Sl ide Hammer
205-053Ret ai ner, Drive Flange
205-871Inst all er, Trans fer Cas e Rear Seal
308-615Remover, Seals
308-617Dept h Dri ll , Seal Remover
Removal
1. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he dri ves haft .
Refer t o: Dri ves haft - Vehicles W it hout : Dies el Part icul ate Fi lt er(DPF) (205-01 Driveshaft, Removal and Ins tal lati on).Refer t o: Dri ves haft - Vehicles W it h: Dies el Parti cul at e Fi lt er (DPF)(205-01 Dri ves haft , Removal and Inst all ati on).
2.
Page 1504 of 3229
3. CAUTION: Make s ure that a new bol t is
i ns t alled.
• NOTE: Pos it ion clot h t o col lect fl uid s pil lage.
Speci al Tool (s ): 205-053 T orque:
48 Nm 3.
Speci al Tool (s ):
308-617 4.
5.
CAUTIONS: Make s ure that t he area around the component i s
clean and free of foreign materi al. Take extra care not t o damage t he mati ng faces .
Speci al Tool (s ): 308-615 ,
100-012 5.
Installation