Caliber 2007

Transfer Case Removal & Installation

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NOTE
Dodge refers to the transfer case in this vehicle as the Power Transfer Unit (PTU)

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the engine appearance cover.
  4.  
  5. Remove the air intake assembly.
  6.  
  7. Remove the Power Distribution Center (PDC) from the mounting bracket.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove the front halfshafts. For additional information, refer to following section, -Front Halfshaft, Removal & Installation.-
  12.  
  13. Drain the transfer case fluid and reinstall the drain plug.
  14.  
  15. Remove the driveshaft.
  16.  
  17. Remove the two exhaust flange mounting bolts and disconnect the downstream O 2 sensor to separate the exhaust system.
  18.  
  19. Lower the vehicle.
  20.  
  21. Unplug the upstream O 2 sensor connector.
  22.  
  23. Remove the upstream O 2 sensor from the exhaust manifold.
  24.  
  25. Remove the exhaust manifold top and side heat shields.
  26.  
  27. Remove the exhaust manifold retaining bolts. Slide the exhaust manifold up and to the right, and support the exhaust manifold with a bungee cord or equivalent.
  28.  
  29. Raise and safely support the vehicle.
  30.  
  31. Remove the engine-to-exhaust manifold bracket bolts.
  32.  
  33. Remove the rear engine mount through-bolt.
  34.  
  35. Remove the three front engine mount-to-frame bolts and mount through-bolt.
  36.  
  37. Remove the transfer case mounting bolts.

    Click image to see an enlarged view

    Fig. Location of the upper (1) and lower (2) transfer case mounting bolts.

  38.  
  39. Using a suitable jack, support the engine on the front mount bracket.
  40.  
  41. Raise the front of the engine until the rear mount as dropped.
  42.  
  43. Separate the transfer case from the transaxle. Remove and discard the O-ring.
  44.  
  45. Roll the transfer case forward and down to remove.

    Click image to see an enlarged view

    Fig. Support the engine (3) using a suitable jack (2) by the front mount bracket (1)-Transfer case removal



    Click image to see an enlarged view

    Fig. Raise the front of the engine until the rear mount (1, 2) has dropped-Transfer case removal



    Click image to see an enlarged view

    Fig. Roll the transfer case (1) forward and down to remove-Transfer case removal

  46.  

To install:

  1. Roll the transfer in, moving from front to back.
  2.  
  3. Rest the transfer case on the frame while the engine/transaxle assembly is raised into position.
  4.  
  5. Lower the jack on the front engine mount bracket until the rear mount through-bolt can be installed. Tighten the bolt to 55 ft. lbs. (75 Nm).
  6.  
  7. Install the transaxle crossmember and tighten the bolts to 55 ft. lbs. (75 Nm).
  8.  
  9. Install the front transaxle mount through-bolt and tighten to 55 ft. lbs. (75 Nm).
  10.  
  11. Install a new O-ring between the transfer case and transaxle.
    NOTE
    Coat the O-ring in Vaseline or transaxle assembly grease.



    Click image to see an enlarged view

    Fig. Ensure the O-ring (1) between the transaxle and transfer case (2) is correct installed.

  12.  
  13. Slide the transfer completely into position. Tighten the mounting bolts to 43 ft. lbs. (58 Nm).
  14.  
  15. Lower the vehicle.
  16.  
  17. Install the exhaust manifold.
  18.  
  19. Install the air intake assembly.
  20.  
  21. Install the engine appearance cover.
  22.  
  23. Raise and safely support the vehicle.
  24.  
  25. Reconnect the exhaust system.
  26.  
  27. Install the rear driveshaft.
  28.  
  29. Install the axleshaft.
  30.  
  31. Refill the transfer case with fluid to the correct level.
  32.  
  33. Lower the vehicle.
  34.  
  35. Connect the negative battery cable.
  36.  
  37. Refill the transaxle with fluid to the correct level if necessary.
  38.  
  39. Test drive the vehicle to ensure proper operation and check for leaks.
  40.  

 
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