Chrysler Dodge Caravan 2002 Manual page 1558

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POWER TRANSFER UNIT
31TH AUTOMATIC TRANSAXLE
POWER TRANSFER UNIT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING
SEAL IDENTIFICATION
FLUID LEAK DIAGNOSIS
STANDARD PROCEDURE
STANDARD PROCEDURE - FLUID LEVEL
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STANDARD PROCEDURE - PTU FLUID
CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ADJUSTMENTS
OUTPUT FLANGE SHIM SELECTION
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPECIAL TOOLS
SDP POWER TRANSFER UNIT
DIFFERENTIAL CARRIER SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
END COVER BALL BEARING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
POWER TRANSFER UNIT
DESCRIPTION
The Power Transfer Unit (P.T.U.) is attached to a
modified automatic transaxle case where the right
half shaft extension housing would normally be
located.
The Power Transfer Unit is sealed from the trans-
axle and has its own oil sump. The Unit uses Mopar
TRANSMISSION/TRANSAXLE
TABLE OF CONTENTS
page
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POWER TRANSFER UNIT
TABLE OF CONTENTS
page
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. . . . . . . . . . . . . . . . 4
. . . . . . . 7
. . . . . . . . . . . . 8
TRANSMISSION/TRANSAXLE
41TE AUTOMATIC TRANSAXLE
T850 MANUAL TRANSAXLE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
END COVER SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
HALF SHAFT INNER SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
INPUT SHAFT COVER SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
INPUT SHAFT END SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
INPUT SHAFT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OUTER HALF SHAFT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
REAR COVER O-RING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
SAE 80W-90 Gear and Axle Lubricant (MS-9020) and
holds 1.15 liters (1.22 quarts).
Service of the Power Transfer Unit is limited to:
• Fluid Change
• Seals
• Gaskets
• One ball bearing
• Output flange
If the ring gear and pinion, any tapered roller
bearings, case, covers, or pinion carrier fail the entire
unit must be replaced.
21 - 1
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