2007 Chrysler Sebring

2007 TRANSFER CASE Power Transfer Unit - Sebring

2007 TRANSFER CASE

Power Transfer Unit - Sebring

POWER TRANSFER UNIT

STANDARD PROCEDURE

STANDARD PROCEDURE - PTU FLUID DRAIN/FILL

1. Raise vehicle on hoist.

2. Remove PTU drain plug. Drain fluid into suitable container.
3. Install drain plug and torque to 35 N.m (26 ft. lbs.).
4. Remove PTU fill plug.
5. Remove the maniverter. Refer to appropriate Engine SERVICE
INFORMATION article.
6. Remove the heat shield at the PTU
7. Fill PTU with.8L (1.7 Pints.) of Mopar® 75W-90 Gear and Axle Lubricant.
8. Install fill plug and torque to 35 N.m (26 ft. lbs.).
9. Install the heat shield (see INSTALLATION of PTU).
10. Install the maniverter. Refer to appropriate Engine SERVICE INFORMATION
article.
11. Lower vehicle.
REMOVAL

POWER TRANSFER UNIT

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 1: Rear Transmission Bracket To Transmission Bolts

Courtesy of CHRYSLER LLC

1. Remove the rear transmission bracket to transmission bolts.

2. Remove crossmember. Refer to REMOVAL .
3. Remove right halfshaft assembly. Refer to REMOVAL .
4. Remove the exhaust and rear maniverter from engine. Refer to REMOVAL .
5. Remove propeller shaft assembly. Refer to REMOVAL .

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 2: HEAT SHIELD BOLTS AND CLIPS

Courtesy of CHRYSLER LLC

6. Remove the one upper bolts (1) and clips (2) at the heat shield (3).

Fig. 3: LOWER HEAT SHIELD BOLT

Courtesy of CHRYSLER LLC
7. Remove the lower heat shield bolt (2) and remove the heat shield (1).

Fig. 4: Removing/Installing Power Transfer Unit

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Courtesy of CHRYSLER LLC

8. Remove PTU-to-bracket lower bolts (2).
9. Roll engine and transmission forward.
10. Remove PTU (1) from vehicle.
INSTALLATION

POWER TRANSFER UNIT

Fig. 5: O-Ring At PTU

Courtesy of CHRYSLER LLC
1. Install new O-ring onto PTU.
2. Apply RTV, 05010884AA, to the PTU O-ring.

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 6: Removing/Installing Power Transfer Unit

Courtesy of CHRYSLER LLC

NOTE: The sequence below should always be followed when

installing the PTU

3. Install PTU into position.

4. Install PTU-to-transmission adapter bolts (2) and tighten to 22 N.m (30 ft.
lbs.).
5. Check and adjust PTU Fluid level. The PTU holds.8L (1.7 Pints.) of Mopar®
75W-90 Gear and Axle Lubricant.

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 7: HEAT SHIELD BOLTS AND CLIPS

Courtesy of CHRYSLER LLC

6. Install the PTU Heat shield (3).

7. Install PTU-to-transaxle mount bracket upper bolts (1) and tighten to 54 N.m
(40 ft. lbs.).

Fig. 8: LOWER HEAT SHIELD BOLT

Courtesy of CHRYSLER LLC

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

8. Install the lower heat shield bolt (2) and tighten to 22 N.m (30 ft. lbs.).

Fig. 9: Rear Transmission Bracket To Transmission Bolts

Courtesy of CHRYSLER LLC

9. Install transmission rear mount bolts (2) and tighten to 54 N.m (40 ft. lbs.).
10. Install propeller shaft assembly. Refer to INSTALLATION .
11. Install exhaust to engine. Refer to INSTALLATION .
12. Install the crossmember. Refer to INSTALLATION .
13. Install right halfshaft assembly. Refer to INSTALLATION .
SPECIFICATIONS

POWER TRANSFER UNIT

TORQUE SPECIFICATIONS
DESCRIPTION N.m Ft. Lbs. In. Lbs.
Bolt, PTU-to-
22 30 -
Transaxle Lower
Bolts, Oil Pan-to-
54 40 -
Transaxle
Bolt, PTU-to- 54 40 -
Transaxle Upper
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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Bolt, Mount/Bracket- 54 40 -
to-PTU
Plug, PTU Drain/Fill 35 26 -
Bolt, PTU cover-to
28 20 -
housing
SPECIAL TOOLS

POWER TRANSFER UNIT

Fig. 10: Universal Handle C-4171

Courtesy of CHRYSLER LLC

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 11: Installer 6536-A

Courtesy of CHRYSLER LLC

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 12: Installer, 9321

Courtesy of CHRYSLER LLC

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 13: Installer, 9683

Courtesy of CHRYSLER LLC

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 14: Installer, 9684

Courtesy of CHRYSLER LLC

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 15: Spanner Wrench 6958

Courtesy of CHRYSLER LLC

Fig. 16: Puller 1026

Courtesy of CHRYSLER LLC
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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

O-RING-DIFFERENTIAL CARRIER

REMOVAL

DIFFERENTIAL CARRIER SEAL

Fig. 17: O-Ring At PTU

Courtesy of CHRYSLER LLC

NOTE: The Power Transfer Unit must be removed from the vehicle
to replace this O-ring.

1. Remove PTU from transaxle. See REMOVAL.

2. Remove the O-ring.
INSTALLATION

DIFFERENTIAL CARRIER SEAL

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 18: O-Ring At PTU

Courtesy of CHRYSLER LLC

1. Install a new O-ring (1).

2. Install the PTU to the transaxle. See INSTALLATION.
3. Check PTU fluid level. See STANDARD PROCEDURE.
SEAL-HALF SHAFT INNER

REMOVAL

HALF SHAFT INNER SEAL

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 19: Removing Outer Halfshaft Seal

Courtesy of CHRYSLER LLC

1 - SCREWDRIVER
2 - SEAL

1. Remove Power Transfer Unit. See REMOVAL.

2. Remove outer halfshaft seal (2).

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 20: PTU End Cover Removal/Installation

Courtesy of CHRYSLER LLC

1 - END COVER
2 - BOLT

3. Remove power transfer unit end cover (1).

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 21: Inner Seal Removal

Courtesy of CHRYSLER LLC

1 - SEAL

4. Using suitable screwdriver or punch, remove inner halfshaft seal (1) and
discard.
INSTALLATION

HALF SHAFT INNER SEAL

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 22: Inner Seal Installation

Courtesy of CHRYSLER LLC

1 - SEAL INSTALLER 9683

2 - DRIVER HANDLE C-4171

1. Using Driver Handle C-4171 (2) and Installer 9683 (1), install inner halfshaft
seal until it bottoms in bore. See Fig. 22.
2. Install roller bearing.

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 23: PTU End Cover Removal/Installation

Courtesy of CHRYSLER LLC

1 - END COVER
2 - BOLT

3. Install end cover (1)to PTU housing. Install and torque end cover-to-housing
bolts (2) to 28 N.m (20 ft. lbs.).

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 24: Installing Outer Halfshaft Seal

Courtesy of CHRYSLER LLC

1 - DRIVER HANDLE C-4171

2 - SEAL INSTALLER 6536A
3 - SEAL

4. Using driver Handle C-4171 (1) and seal Installer 6536A (2), install outer
halfshaft seal (3).
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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

5. Install PTU assembly. See INSTALLATION.

SEAL-INPUT SHAFT

REMOVAL

INPUT SHAFT SEAL

Fig. 25: Preparing Seal For Removal

Courtesy of CHRYSLER LLC

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

1 - INPUT SHAFT SEAL

2 - DRILL AND BIT

1. Remove power transfer unit. See REMOVAL.

2. Using drill and suitable bit (2), drill hole in input shaft seal (1) to facilitate
removal with slide hammer. Use care not to damage the shaft sealing
surface.
3. Using slide hammer and suitable screw, remove input shaft seal.
INSTALLATION

INPUT SHAFT SEAL

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 26: Input Shaft Seal Installation

Courtesy of CHRYSLER LLC

1 - TOOL L-4429-3
2 - TOOL 9321

1. Using Handle C4171 (1) and Installer L-4429-3 (2), install input shaft seal.
2. Install Power Transfer Unit. See INSTALLATION.
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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

SEAL-OUTER HALF SHAFT

REMOVAL

OUTER HALFSHAFT SEAL

Fig. 27: Removing Outer Halfshaft Seal

Courtesy of CHRYSLER LLC

1 - SCREWDRIVER
2 - SEAL

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

1. Remove right halfshaft assembly. Refer to REMOVAL .

2. Using suitable screwdriver (1), remove outer halfshaft seal (2).
INSTALLATION

OUTER HALFSHAFT SEAL

Fig. 28: Installing Outer Halfshaft Seal

Courtesy of CHRYSLER LLC

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

1 - DRIVER HANDLE C-4171

2 - SEAL INSTALLER 6536A
3 - SEAL

1. Install outer halfshaft seal using Handle C-4171 and Installer 6536A.
2. Install right halfshaft assembly. Refer to INSTALLATION .
SEAL-OUTPUT FLANGE

REMOVAL

OUTPUT FLANGE SEAL REMOVAL

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

Fig. 29: Output Flange Nut Removal/Installation

Courtesy of CHRYSLER LLC

1 - SPANNER WRENCH 6958

1. Remove propeller shaft. Refer to REMOVAL .

2. Using Spanner Wrench 6958 (1) and suitable ratchet and socket, remove output
flange nut. See Fig. 29

Fig. 30: Output Flange Removal

Courtesy of CHRYSLER LLC

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

1 - PULLER 1026
2 - OUTPUT FLANGE

3. Install Puller 1026 (1) and remove PTU output flange (2).
4. Using suitable screwdriver, remove seal and discard.
INSTALLATION

OUTPUT FLANGE SEAL REMOVAL

Fig. 31: Output Flange Seal Installation

Courtesy of CHRYSLER LLC

1 - INSTALLER 9684
2 - HANDLE C-4171
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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

1. Using Installer 9684 (1) and Handle C-4171(2), install new PTU output flange
seal. See Fig. 31.

Fig. 32: Output Flange Installation

Courtesy of CHRYSLER LLC

1 - HANDLE C-4171
2 - INSTALLER 9321
3 - OUTPUT FLANGE

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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

2. Using Installer 9321 (2) and Handle C-4171 ,(1) install output flange (3).
Lightly tap on flange until sufficient threads are exposed to start flange nut by
hand.

Fig. 33: Output Flange Nut Removal/Installation

Courtesy of CHRYSLER LLC

1 - SPANNER WRENCH 6958

3. Using Spanner Wrench 6958 (1), install and torque output flange nut to 102
N.m (75 ft. lbs.) torque.
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 2007 Chrysler Sebring
2007 TRANSFER CASE Power Transfer Unit - Sebring

4. Install propeller shaft. Refer to INSTALLATION .

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