Pacifica 2006-2008

Transfer Case Removal & Installation

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  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the right halfshaft assembly.
  6.  
  7. Remove the engine cradle crossmember.
  8.  
  9. Remove the driveshaft.
  10.  
  11. Remove the PTU rear mount bracket.
  12.  
  13. Remove the oil pan to transaxle collar.
  14.  
  15. Remove the heat shield. Remove the bracket and brace.
  16.  
  17. Remove the PTU to transaxle upper bolts.
  18.  
  19. Remove the PTU to bracket lower bolts.
  20.  
  21. Carefully remove the assembly from the vehicle.
  22.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Install the PTU lower bracket.
  4.  
  5. Install the PTU to transaxle upper bolts. Tighten to 40 ft. lbs.
  6.  
  7. Install the PTU in position. Tighten the two lower PTU to bracket bolts to 21 ft. lbs.
  8.  
  9. Install the brace and bracket.
  10.  
  11. Install the heat shield.
  12.  
  13. Install the PTU rear mount bracket. Tighten the six bolts to 40 ft. lbs.
  14.  
  15. Install the driveshaft.
  16.  
  17. Install the right halfshaft assembly.
  18.  
  19. Install the engine cradle crossmember.
  20.  
  21. Check and adjust the PTU fluid level. The unit holds 1.7 pints of 75W-90 gear and axle lubricant.
  22.  

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the right halfshaft assembly.
  6.  
  7. Remove the exhaust system.
  8.  
  9. Remove the engine cradle crossmember.
  10.  
  11. Remove the driveshaft.
  12.  
  13. Remove the PTU rear mount bracket.
  14.  
  15. Remove the heat shield. Remove the bracket and brace.
  16.  
  17. Remove the PTU to transaxle upper bolts.
  18.  
  19. Remove the PTU to bracket lower bolts.
  20.  
  21. Carefully remove the assembly from the vehicle.
  22.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Loosen the PTU to transaxle bracket, if not already done.
  4.  
  5. Install a new O-ring onto the PTU. Apply RTV sealant, part number 05010884AA to the O-ring.
    NOTE
    The sequence below should always be followed when installing the PTU.

  6.  
  7. Install the PTU in position. Tighten the two PTU to transaxle adaptor bolts to 30 ft. lbs.
  8.  
  9. Install the heat shield.
  10.  
  11. Install the two PTU to transaxle upper bolts. Tighten to 40 ft. lb.
  12.  
  13. Install the three PTU to transaxle lower bolts. Tighten to 75 ft. lbs.
  14.  
  15. Install the PTU rear mount bracket. Tighten to 40 ft. lbs.
  16.  
  17. Install the driveshaft.
  18.  
  19. Install the right halfshaft assembly.
  20.  
  21. Install the engine cradle crossmember.
  22.  
  23. Install the exhaust system.
  24.  
  25. Check and adjust the PTU fluid level. The unit holds 1.7 pints of 75W-90 gear and axle lubricant.
  26.  

If equipped with AWD, the vehicle will use a Power Transfer Unit assembly (PTU).

 
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