July 1: So it begins. Don't worry, this is not in the correct legal jurisdiction!

Section 652 (Power Transfer Unit (Service Information) - MK): Disassembly

WARNING: This page is about a different car, the 2017 Jeep Patriot and 2017 Jeep Compass. However, it is still accessible from the selected car via links, so may be relevant.

GC0084387

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Remove extension housing bolts.

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Remove the extension housing.
Remove the extension housing O-ring.

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Using a chisel (2) remove the dust shield (1) from the extension housing (3).

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Remove the pinion housing bolts.

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Remove the pinion housing.

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Remove the pinion housing shim.
Remove the pinion housing O-ring.

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NOTE:
The pinion nut is a staked type nut.
Using a chisel or a grinder, remove the staked depression in the pinion nut.

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Remove the output shaft nut, using the Output Shaft Nut Socket (special tool #9921, Wrench, Pinion Nut) and Spline Socket (special tool #9922, Socket, Splined).

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Press the output shaft from the housing using a press.

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Remove the output shaft spacer.

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Remove the output shaft bearing.

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Remove the output shaft housing small side bearing cup using a brass drift.

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Remove the output shaft housing large side bearing cup using a brass drift.

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Install Puller (special tool #6444, Puller, Bearing/Gear) and Jaws (special tool #6451, Jaws, Puller) onto output shaft head bearing.
Place Puller in a vice and remove the bearing.

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Remove the inspection cover bolts (1).

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Remove the inspection cover.

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Remove the side cover bolts (1).

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Remove the side cover from case.

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Remove the carrier assembly.

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NOTE:
Bearing cup is a slip fit.
Remove bearing cup by hand (1) or by using a pick.

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Remove the shim (1) under the bearing cup (3). Measure and record the size of the shim.

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Remove the inner seal from the PTU cover.
Remove the outer seal from the PTU cover.

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Remove bearing cup by hand (1) or by using a pick.
Remove the shim (3) under the bearing cup (1). Measure and record the size of the shim.

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Remove the carrier case seal.

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Remove the ring gear bolts.

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Remove the ring gear.

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Remove ring gear side bearing using Puller (special tool #C-293-PA, Puller, Press), Inserts (special tool #C-293-37, Block Set, Puller) and Insert (special tool #C-4487-1, Adapter).

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Remove output side bearing using Puller (special tool #C-293-PA, Puller, Press), Inserts (special tool #C-293-37, Block Set, Puller) and Insert (special tool #C-4487-1, Adapter).