Manual reparacion Jeep Compass - Patriot Limited 2007-2009_Transfer case

2009 TRANSFER CASE
Power Transfer Unit - Compass & Patriot
STANDARD PROCEDURE
DRAIN AND FILL
Fig. 1: DRAIN AND FILL PLUGS
Courtesy of CHRYSLER LLC
1. If fluid level is low or fluid change is required fill with MOPAR® MS9020 SAE 80W90 Gear Lube until
to bottom of fill plug.
2. Tighten fill plug (1) to 32 N.m (24 ft.lbs.).
3. Tighten drain plug (2) to 32 N.m (24 ft.lbs.).
REMOVAL
REMOVAL
2009 Jeep Patriot Limited
2009 TRANSFER CASE Power Transfer Unit - Compass & Patriot
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Saturday, September 08, 2012 2:16:38 PM Page 1 © 2006 Mitchell Repair Information Company, LLC.
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Fig. 2: AIR CLEANER ASSEMBLY
1. Disconnect negative battery cable (2).
2. Remove the engine trim cover.
3. Remove air cleaner assembly (1).
4. Remove Power Distribution Center (PDC) from bracket.
5. Raise the vehicle on the hoist.
6. Remove front halfshafts. Refer to Differential and Driveline/Half Shaft - Removal .
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Fig. 3: PTU DRAIN - FILL PLUGS
7. Remove drain plug (2) at PTU and allow fluid to drain.
8. Reinstall drain plug.
Fig. 4: MARK PROP SHAFT
9. Mark (2) prop shaft and differential (3) for proper installation.
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10. Remove the rear prop shaft. Refer to Differential and Driveline/Propeller Shaft - Removal .
Fig. 5: EXHAUST TO MANIVERTER BOLTS
11. Remove the two exhaust to maniverter (exhaust manifold with catalytic converter) bolts (1).
12. Unplug the downstream O2 sensor connector.
13. Remove the exhaust system. Refer to Exhaust System/MUFFLER, Exhaust - Removal .
14. Lower the vehicle on the hoist.
15. Unplug the upstream O2 sensor connector.
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Fig. 6: USE O2 SENSOR TOOL - 8439
16. Remove upstream O2 sensor from the maniverter (exhaust manifold with catalytic converter) using O2s
(Oxygen Sensor) Remover/Installer 8439 (2).
Fig. 7: MANIVERTER HEAT SHIELD AND BOLTS
17. Remove the four maniverter heat shield bolts (1).
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Fig. 8: MANIVERTER SIDE HEAT SHIELD
18. Remove the two retaining bolts (2) and one nut (1) from the maniverter side heat shield (3).
Fig. 9: SUPPORT MANIVERTER
19. Remove the seven maniverter to head retaining bolts.
20. Slide the maniverter up and to the right, support the maniverter (1) with the help of a bungie cord.
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Fig. 10: MANIVERTER TO BLOCK SUPPORT BRACKET
22. Remove the four (1) engine to maniverter bracket bolts.
Fig. 11: REAR ENGINE MOUNT
23. Remove the rear engine mount through bolt (2).
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24. Remove the three front engine mount to frame bolts and the mount through bolt.
Fig. 12: PTU MOUNTING BOLTS
25. Remove the PTU mounting bolts (1, 2).
Fig. 13: JACK AT TRANS MOUNT
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26. Install a screw jack (2) on front engine mount bracket (1).
Fig. 14: REAR MOUNT PTU BOLTS
27. Raise the front of the engine until the rear mount has dropped (1, 2).
28. Separate the PTU from the transaxle.
29. Remove and discard old O-ring between Transmission and PTU.
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Fig. 15: REMOVE - INSTALL PTU
30. Roll the PTU (1) forward and down to remove.
DISASSEMBLY
DISASSEMBLY
Fig. 16: EXTENSION AND PINION HOUSING BOLT
1. Remove extension housing bolts.
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Fig. 17: EXTENSION HOUSING O-RING
2. Remove the extension housing.
3. Remove the extension housing O-ring.
Fig. 18: DUST SHIELD OFF PTU
4. Using a chisel (2) remove the dust shield (1) from the extension housing (3).
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5. Remove the pinion housing bolts.
Fig. 20: PINION HOUSING
6. Remove the pinion housing.
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Fig. 21: PINION HOUSING SHIM
7. Remove the pinion housing shim.
8. Remove the pinion housing O-ring.
Fig. 22: PINION SHAFT NUT
NOTE: The pinion nut is a staked type nut.
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9. Using a chisel or a grinder, remove the staked depression in the pinion nut.
Fig. 23: REMOVE PINION NUT
10. Remove the output shaft nut, using the Output Shaft Nut Socket 9921 and Spline Socket 9922.
Fig. 24: PRESS PINION
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11. Press the output shaft from the housing using a press.
Fig. 25: PINION SHAFT SPACER
12. Remove the output shaft spacer.
Fig. 26: PINION SHAFT BEARING.
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13. Remove the output shaft bearing.
Fig. 27: REMOVE SMALL SIDE BEARING CUP PINION HOUSING
14. Remove the output shaft housing small side bearing cup using a brass drift.
Fig. 28: REMOVE LARGE SIDE BEARING CUP PINION HOUSING
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15. Remove the output shaft housing large side bearing cup using a brass drift.
Fig. 29: PULL PINION HEAD BEARING
16. Install Puller 6444 and Jaws 6451 onto output shaft head bearing.
17. Place Puller in a vice and remove the bearing.
Fig. 30: INSPECTION COVER
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18. Remove the inspection cover bolts (1).
Fig. 31: REMOVE INSPECTION COVER
19. Remove the inspection cover.
Fig. 32: SIDE COVER
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20. Remove the side cover bolts (1).
Fig. 33: REMOVE SIDE COVER.
21. Remove the side cover from case.
Fig. 34: CARRIER
22. Remove the carrier assembly.
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Fig. 35: CARRIER BEARING CUP AND SEAL.
23. Remove bearing cup by hand (1) or by using a pick.
Fig. 36: COVER SIDE CUP AND SHIM
24. Remove the shim (1) under the bearing cup (3). Measure and record the size of the shim.
NOTE: Bearing cup is a slip fit.
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Fig. 37: INNER COVER SEAL
25. Remove the inner seal from the PTU cover.
26. Remove the outer seal from the PTU cover.
Fig. 38: CARRIER RACE HOUSING SIDE
27. Remove bearing cup by hand (1) or by using a pick.
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28. Remove the shim (3) under the bearing cup (1). Measure and record the size of the shim.
Fig. 39: CARRIER CASE SEAL.
29. Remove the carrier case seal.
Fig. 40: RING GEAR BOLTS
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30. Remove the ring gear bolts.
Fig. 41: RING GEAR
31. Remove the ring gear.
Fig. 42: REMOVE DIFFERENTIAL SIDE BEARING
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32. Remove ring gear side bearing using Puller C-293-PA, Inserts C-293-37 and Insert C-4487-1.
Fig. 43: REMOVE OUTPUT SIDE BEARING
33. Remove output side bearing using Puller C-293-PA, Inserts C-293-37 and Insert C-4487-1.
ASSEMBLY
ASSEMBLY
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Fig. 44: SPOOL SHAFT OUTPUT SIDE BEARING
1. Install output side spool shaft bearing using Installer C-3095-A.
Fig. 45: SPOOL SHAFT RING GEAR SIDE BEARING
2. Install ring gear side bearing using Installer 8148.
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Fig. 46: RING GEAR
3. Install the ring gear.
Fig. 47: RING GEAR BOLTS
4. Install the new ring gear bolts and tighten to 74 N.m (55 ft. lbs.).
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Fig. 48: INSTALL CARRIER CASE SEAL
5. Install the carrier case seal using Installer 9851 and Handle C- 4171.
Fig. 49: CARRIER RACE HOUSING SIDE
6. Install the shim (3) under the bearing cup (1) in the case side.
7. Install the bearing cup by hand.
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Fig. 50: INSTALL CARRIER COVER INNER SEAL
8. Install the inner seal into the PTU cover using Installer 9852 and Handle C-4171.
Fig. 51: INSTALL CARRIER COVER OUTER SEAL
9. Install the outer seal into the PTU cover using Installer 9853 and Handle C-4171.
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Fig. 52: COVER SIDE CUP AND SHIM
10. Install the shim (1) under the bearing cup (3).
11. Install bearing cup by hand (3).
Fig. 53: SIDE COVER
12. Install the carrier assembly into the case
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13. Install the side cover
14. Tighten side cover bolts (1) to 23 N.m (17 ft. lbs.).
Fig. 54: INSTALL PINION HEAD BEARING
15. Install the output shaft head bearing on to the pinion shaft using Installer 9714 and a Press.
Fig. 55: INSTALL PINION HEAD BEARING CUP
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16. Install the output shaft head bearing cup using Installer 6061 and Handle C-4171.
Fig. 56: OUTPUT SHAFT TAIL BEARING CUP
17. Install the output shaft tail bearing cup using Installer 9855 and Handle C-4171.
Fig. 57: PINION SHAFT SPACER
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18. Install the output shaft spacer onto the output shaft.
Fig. 58: OUTPUT SHAFT TAIL BEARING
19. Install output shaft into output shaft housing.
20. Install output shaft tail bearing on to out put shaft using Installer L-4411.
Fig. 59: OUTPUT SHAFT NUT
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21. Install the output shaft nut (1) onto the output shaft (2).
Fig. 60: INSTALL PINION NUT
22. Tighten the output shaft nut using Pinion Nut Socket 9921 to 150 N.m (111 ft. lbs.).
23. Using an inch pound torque wrench check and Pinion Nut Socket 9921 (1) check the rotating torque, it
should be 30 in. lbs. Add 0.002 in. larger shim to increase rotating torque and add 0.002 in. smaller shim
to decrease rotating torque. Repeat until proper turning torque is obtained.
24. Using a punch stake the output shaft nut.
NOTE: The output shaft nut is a staked type nut.
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Fig. 61: PINION HOUSING SHIM
25. Install the pinion housing O-ring (3).
26. Install the pinion housing shim (1).
Fig. 62: PINION SHAFT SEAL
27. Install the output shaft seal using Installer 9851 and Handle C-4171.
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Fig. 63: EXTENSION HOUSING O-RING
28. Install a new extension housing O-ring.
Fig. 64: PINION HOUSING
29. Install the output shaft housing and bolts onto the carrier housing.
30. Apply pattern check grease to the ring gear.
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Fig. 65: DUST SHIELD ON PTU
31. Using a block of wood (2) install the dust shield (3) onto the extension housing (1).
32. Install the extension housing and bolts.
33. Tighten output shaft housing bolts to 38 N.m (28 ft. lbs.).
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34. Tighten the extension housing bolts to 38 N.m (28 ft. lbs.).
Fig. 67: VENT
35. Clean cover and apply MOPAR® axle RTV or equivalent.
36. Install the vent and bolts, tighten the bolts to 23 N.m (17 ft. lbs.).
Fig. 68: VENT SHIELD
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37. Install the vent shield and bolts. tighten the bolts to 23 N.m (17 ft. lbs.).
Fig. 69: INSPECTION COVER
38. Clean cover and apply MOPAR® axle RTV.
39. Apply MOPAR® lock AND seal adhesive or equivalent to bolts.
40. Install the inspection cover and bolts. tighten the bolts to 23 N.m (17 ft. lbs.).
41. Fill the PTU. See Transmission and Transfer Case/Power Transfer Unit - Standard Procedure.
INSTALLATION
INSTALLATION
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Fig. 70: REMOVE - INSTALL PTU
1. Roll the PTU in, moving from front to back (1) .
Fig. 71: PTU INSTALL
2. Rest the PTU (1) on the frame (3) while the engine and transaxle (2) are raised back into position.
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Fig. 72: JACK AT TRANS MOUNT
3. Lower screw jack (2) until rear mount through bolt can be installed.
Fig. 73: REAR ENGINE MOUNT
4. Install rear mount through bolt (2) and tighten bolt to 75 Nm (55 ft. lbs.).
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Fig. 74: FRONT ENGINE MOUNT
5. Install the transmission crossmember and bolts, (2) tighten to 75 Nm (55 ft. lbs.).
6. Install the through bolt at the front transmission mount (1) and tighten to 75 Nm (55 ft. lbs.).
Fig. 75: PTU O-RING
NOTE: STICKING THE O-RING WITH VASELINE OR TRANS ASSEMBLY GREASE
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7. Insure that the O-ring (1) between the PTU and transaxle is in place.
Fig. 76: PTU MOUNTING BOLTS
8. Slide the PTU into place.
9. Install and tighten the PTU mounting bolts (1,2) to 58 N.m (43ft. lbs.).
10. Lower the hoist.
11. Install the maniverter. Refer to Exhaust System/CONVERTER, Catalytic - Installation .
IS RECOMMENDED.
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Fig. 77: AIR CLEANER ASSEMBLY
12. Install the air box (1).
13. Install engine trim cover.
15. Install the exhaust system. Refer to Exhaust System/MUFFLER, Exhaust - Installation .
16. Install the Prop shaft. Refer to Differential and Driveline/Propeller Shaft - Installation .
17. Install the axle shafts. Refer to Differential and Driveline/Half Shaft - Installation .
18. Fill PTU. See Transmission and Transfer Case/Power Transfer Unit - Standard Procedure.
19. Lower hoist.
20. Connect battery cables (2).
21. Top off the fluids. See Transmission and Transfer Case/Power Transfer Unit - Standard Procedure.
SPECIFICATIONS
TORQUE
TORQUE
DESCRIPTION N.m Ft. Lbs. In. Lbs.
Plug, Fill 32 24 -
Plug, Drain 32 24 -
Bolts, Inspection cover 23 17 -
Bolts, Vent Shield 23 17 -
Bolts, Vent 23 17 -
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SPECIAL TOOLS
SPECIAL TOOLS
Fig. 78: TRAK-LOK AXLE TOOL - C-4487
Fig. 79: INSTALLER, CUP - 6061
Bolts, Output Shaft
Housing
38 28 -
Bolts, extension housing 38 28 -
Nut, Output Shaft 150 111 -
Bolts, Carrier Assembly
Side Cover
23 17 -
Bolts, Ring Gear 74 55 -
Bolt and Nut, Rear
Mount Through
75 55 -
Bolts, Transmission
Crossmember
75 55 -
Bolt and Nut,
Transmission
Crossmember through
75 55 -
Bolts, PTU Mounting 58 43 -
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Fig. 80: PULLER, BEARING/GEAR - 6444
Fig. 81: JAWS, PULLER - 6451
Fig. 82: CUP - 8148
Fig. 83: O2 SENSOR WRENCH - 8439
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Fig. 84: INSTALLER, BEARING - 9714
Fig. 85: INSTALLER, SEAL - 9715
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Fig. 86: SPLINED SOCKET - 9742
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Fig. 90: INSTALLER, BEARING CUP - 9855
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Fig. 91: WRENCH, PINION NUT - 9921
Fig. 92: SOCKET, SPLINED - 9922
Fig. 93: PULLER, PRESS - C-293-PA
Fig. 94: BLOCK SET, PULLER - C-293-37
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Fig. 95: INSTALLER, BEARING - C-3095-A
Fig. 96: DRIVER HANDLE, UNIVERSAL - C-4171
Fig. 97: INSTALLER, BEARING - L-4411
SEAL, DIFFERENTIAL CARRIER
REMOVAL
REMOVAL
1. Remove PTU from transaxle. See Transmission and Transfer Case/Power Transfer Unit - Removal.
2. Use a screw mounted in a slide hammer to remove seal. Be careful not to damage seal journal when
removing seal.
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INSTALLATION
INSTALLATION
Fig. 98: INSTALL CARRIER CASE SEAL
1. Install the carrier case seal using Installer 9851 and Handle C-4171.
2. Install the PTU. See Transmission and Transfer Case/Power Transfer Unit - Installation.
SEAL, OUTPUT FLANGE
REMOVAL
REMOVAL
1. Remove the propeller shaft. Refer to Differential and Driveline/Propeller Shaft - Removal .
2. Using a screwdriver remove the output seal.
INSTALLATION
INSTALLATION
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Fig. 99: PINION SHAFT SEAL
1. Install the output shaft seal using Installer 9851 and Handle C-4171.
2. Install the propeller shaft. Refer to Differential and Driveline/Propeller Shaft - Installation .
SEALS, END COVER
REMOVAL
REMOVAL
Fig. 100: SIDE COVER
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1. Remove the right halfshaft. Refer to Differential and Driveline/Half Shaft - Removal .
2. Remove the side cover bolts.
3. Remove the side cover.
Fig. 101: INNER COVER SEAL
4. Using a drift remove both inner and outer seals.
INSTALLATION
INSTALLATION
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Fig. 102: INSTALL CARRIER COVER INNER SEAL
1. Install the inner seal into the PTU cover using Installer 9852 and Handle C-4171.
Fig. 103: INSTALL CARRIER COVER OUTER SEAL
2. Install the outer seal into the PTU cover using Installer 9853 and Handle C-4171.
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Fig. 104: SIDE COVER
3. Install the side cover.
4. Tighten side cover bolts (1) to 23 N.m (17 ft. lbs.).
5. Install the right halfshaft. Refer to Differential and Driveline/Half Shaft - Installation .
SHIELD, EXTENSION HOUSING DUST
REMOVAL
REMOVAL
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1. Remove the propeller shaft. Refer to Differential and Driveline/Propeller Shaft - Removal .
2. Remove the extension housing bolts (1).
3. Remove the extension housing.
4. Remove the extension housing O-ring and inspect.
Fig. 106: DUST SHIELD OFF PTU
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5. Using a chisel (2) remove the dust shield (1) from the extension housing (3).
INSTALLATION
INSTALLATION
Fig. 107: DUST SHIELD ON PTU
1. Using a block of wood (2) install the dust shield (3) onto the extension housing (1).
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Fig. 108: EXTENSION AND PINION HOUSING BOLTS
2. Install the extension housing and bolts.
3. Tighten the extension housing bolts to 38 N.m (28 ft. lbs.).
4. Install the propeller shaft. Refer to Differential and Driveline/Propeller Shaft - Installation .
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