Power Transfer Unit Case Replacement (M3D, M3H Transmission with LTG Engine)

Removal Procedure

  1. Remove the right wheel drive shaft. Front Wheel Drive Half Shaft Replacement - Right Side
  2. Remove the exhaust front pipe. Exhaust Front Pipe Replacement
  3. Remove the power transfer unit heat shield. Power Transfer Unit Heat Shield Replacement
  4. Remove the front wheelhouse liner - right side. Front Wheelhouse Liner Replacement - Right Side

    5. Object ID: 4587266
  5. Remove the power transfer unit to transmission brace bolts (1).

    6. Object ID: 4574300
  6. Disconnect the transfer case vent hose (1) from the power transfer unit case (2).
  7. Disconnect the two piece propeller shaft from the power transfer unit case. Two-Piece Propeller Shaft Replacement

    8. Object ID: 4574313
  8. Disconnect the electrical connectors (1, 2), then remove the wiring harness retainers (3) from the power transfer unit.
  9. Position the wiring harness (4) out of the way,

    10. Object ID: 4891622
  10. Remove the transmission mount strut bracket bolts (1, 2). Transmission Mount Strut Bracket Replacement
  11. Support the power transfer unit case (2) with a suitable jack, and secure with suitable straps.

    12. Object ID: 4574324
  12. Remove the remaining power transfer unit case-to-transmission bolts (1).
  13. Separate the transfer case (2) from the transmission and remove the power transfer unit case.

    14. Object ID: 4574042
  14. Remove and DISCARD the power transfer unit case-to-transmission O-ring.

Installation Procedure


    Object ID: 4574042
  1. Clean the contact surfaces between the power transfer unit case and the transmission.
  2. Install a NEW power transfer unit case-to-transmission O-ring (1).

    3. Object ID: 4574324

    Caution: Use care when installing the transfer case assembly to avoid contact with the pinion spline. Contact with the pinion spline may cause damage to the transfer case assembly.

  3. Support the power transfer unit case with a suitable jack, and secure with suitable straps.
  4. Raise and align the power transfer unit case in the correct position in relation to the transmission.
  5. Install the power transfer unit case (2) to the transmission.

    6. Caution: Refer to Fastener Caution.

  6. Install the power transfer unit case-to-transmission bolts (1) and tighten to 100 N·m (74 lb ft).
  7. Remove the suitable jack and straps.

    8. Object ID: 4891622
  8. Install the transmission mount strut bracket bolts (1, 2). Transmission Mount Strut Bracket Replacement

    9. Object ID: 4574313
  9. Connect the electrical connectors (1, 2), then install the wiring harness retainers (3) To the power transfer unit.
  10. Connect the two piece propeller shaft to the power transfer unit case. Two-Piece Propeller Shaft Replacement

    11. Object ID: 4574300
  11. Connect the transfer case vent hose (1) to the power transfer unit case (2).

    12. Object ID: 4587266
  12. Install the power transfer unit to transmission brace bolts (1) and tighten to 22 N·m (16 lb ft).
  13. Install the front wheelhouse liner - right side. Front Wheelhouse Liner Replacement - Right Side
  14. Install the power transfer unit heat shield. Power Transfer Unit Heat Shield Replacement
  15. Install the right wheel drive shaft. Front Wheel Drive Half Shaft Replacement - Right Side
  16. Install the exhaust front pipe. Exhaust Front Pipe Replacement
  17. Check transmission fluid level. Transmission Fluid Drain and Fill