Power Transfer Unit (Service Information): Removal: Removal

Fig 1: Air Cleaner Assembly

Courtesy of CHRYSLER LLC

1. Disconnect negative battery cable (2).
2. Remove the engine trim cover.
3. Remove air cleaner assembly (1).
4. Remove Power Distribution Center (PDC) from bracket.
5. Raise the vehicle on the hoist.
6. Remove front halfshafts. Refer to Removal .
   Fig 2: PTU Drain - Fill Plugs

   Courtesy of CHRYSLER LLC
7. Remove drain plug (2) at PTU and allow fluid to drain.
8. Reinstall drain plug.
   Fig 3: Mark Prop Shaft

   Courtesy of CHRYSLER LLC
9. Mark (2) prop shaft and differential (3) for proper installation.
10. Remove the rear prop shaft. Refer to Removal .
    Fig 4: Exhaust To Maniverter Bolts

    Courtesy of CHRYSLER LLC
11. Remove the two exhaust to maniverter (exhaust manifold with catalytic converter) bolts (1).
12. Unplug the downstream O2 sensor connector.
13. Remove the exhaust system. Refer to MUFFLER, Exhaust, Removal .
14. Lower the vehicle on the hoist.
15. Unplug the upstream O2 sensor connector.
    Fig 5: Use O2 Sensor Tool - 8439

    Courtesy of CHRYSLER LLC
16. Remove upstream O2 sensor from the maniverter (exhaust manifold with catalytic converter) using O2s (Oxygen Sensor) Remover/Installer (special tool #8439, O2 Sensor Wrench) (2).
    Fig 6: Maniverter Heat Shield And Bolts

    Courtesy of CHRYSLER LLC
17. Remove the four maniverter heat shield bolts (1).
    Fig 7: Maniverter Side Heat Shield

    Courtesy of CHRYSLER LLC
18. Remove the two retaining bolts (2) and one nut (1) from the maniverter side heat shield (3).
    Fig 8: Support Maniverter

    Courtesy of CHRYSLER LLC
19. Remove the seven maniverter to head retaining bolts.
20. Slide the maniverter up and to the right, support the maniverter (1) with the help of a bungie cord.
    Fig 9: Maniverter To Block Support Bracket

    Courtesy of CHRYSLER LLC
21. Raise the vehicle on the hoist.
22. Remove the four (1) engine to maniverter bracket bolts.
    Fig 10: Rear Engine Mount

    Courtesy of CHRYSLER LLC
23. Remove the rear engine mount through bolt (2).
24. Remove the three front engine mount to frame bolts and the mount through bolt.
    Fig 11: PTU Mounting Bolts

    Courtesy of CHRYSLER LLC
25. Remove the PTU mounting bolts (1, 2).
    Fig 12: Jack AT Trans Mount

    Courtesy of CHRYSLER LLC
26. Install a screw jack (2) on front engine mount bracket (1).
    Fig 13: Rear Mount No Bolts

    Courtesy of CHRYSLER LLC
27. Raise the front of the engine until the rear mount has dropped (1, 2).
28. Separate the PTU from the transaxle.
29. Remove and discard old O-ring between Transmission and PTU.
    Fig 14: Remove - Install PTU

    Courtesy of CHRYSLER LLC
30. Roll the PTU (1) forward and down to remove.