Chrysler Caravan/Voyager/Town and Country 1996-1999

Power Transfer Unit Assembly

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3



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Fig. Fig. 1: Remove the cradle plate to access the power transfer unit



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Fig. Fig. 2: Rear PTU mounting bracket detail

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the front wheels.
  4.  
  5. Remove the right front halfshaft and plug the seal hole.
  6.  
  7. Matchmark the front driveshaft flange and remove the driveshaft from the Power Transfer Unit (PTU). Suspend the driveshaft with wire.
  8.  
  9. Remove the cradle plate.
  10.  
  11. Remove the PTU mounting bracket bolts at the rear of the unit.
  12.  
  13. Remove the right outboard support bracket near the right halfshaft.
  14.  
  15. Remove the mounting bolts and the PTU from the vehicle.
  16.  



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Fig. Fig. 3: Lower mounting bracket detail for the PTU

To install:
  1. Position the PTU on the transaxle and install the mounting bolts. Tighten the bolts to 30 ft. lbs. (41 Nm).
  2.  
  3. Install the right outboard support bracket. Tighten the bolts to 37 ft. lbs. (50 Nm).
  4.  
  5. Install the rear mounting bracket. Tighten the bolts to 37 ft. lbs. (50 Nm).
  6.  
  7. Install the cradle plate. Tighten the bolts to 38 ft. lbs. (51 Nm).
  8.  
  9. Align the matchmark and install the driveshaft.
  10.  
  11. Install the right front halfshaft.
  12.  
  13. Install the front wheels and lower the vehicle to the floor.
  14.  

 
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