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 PLUGSCourtesy 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 Limited2009 TRANSFER CASE Power Transfer Unit - Compass & Patriot


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Saturday, September 08, 2012 2:16:38 PM © 2006 Mitchell Repair Information Company, LLC.

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Saturday, September 08, 2012 2:16:41 PM Page 1 © 2006 Mitchell Repair Information Company, LLC.

Fig. 2: AIR CLEANER ASSEMBLYCourtesy of CHRYSLER LLC

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 PLUGSCourtesy of CHRYSLER LLC

7. Remove drain plug (2) at PTU and allow fluid to drain. 8. Reinstall drain plug.

Fig. 4: MARK PROP SHAFTCourtesy of CHRYSLER LLC

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 BOLTSCourtesy of CHRYSLER LLC

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 - 8439Courtesy of CHRYSLER LLC

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 BOLTSCourtesy of CHRYSLER LLC

17. Remove the four maniverter heat shield bolts (1).


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Fig. 8: MANIVERTER SIDE HEAT SHIELDCourtesy of CHRYSLER LLC

18. Remove the two retaining bolts (2) and one nut (1) from the maniverter side heat shield (3).

Fig. 9: SUPPORT MANIVERTERCourtesy of CHRYSLER LLC

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 BRACKETCourtesy of CHRYSLER LLC

21. Raise the vehicle on the hoist. 22. Remove the four (1) engine to maniverter bracket bolts.

Fig. 11: REAR ENGINE MOUNTCourtesy of CHRYSLER LLC

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 BOLTSCourtesy of CHRYSLER LLC

25. Remove the PTU mounting bolts (1, 2).

Fig. 13: JACK AT TRANS MOUNTCourtesy of CHRYSLER LLC


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26. Install a screw jack (2) on front engine mount bracket (1).

Fig. 14: REAR MOUNT PTU BOLTSCourtesy of CHRYSLER LLC

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 PTUCourtesy of CHRYSLER LLC

30. Roll the PTU (1) forward and down to remove.

DISASSEMBLY

DISASSEMBLY

Fig. 16: EXTENSION AND PINION HOUSING BOLTCourtesy of CHRYSLER LLC

1. Remove extension housing bolts.


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Fig. 17: EXTENSION HOUSING O-RINGCourtesy of CHRYSLER LLC

2. Remove the extension housing. 3. Remove the extension housing O-ring.

Fig. 18: DUST SHIELD OFF PTUCourtesy of CHRYSLER LLC

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 HOUSINGCourtesy of CHRYSLER LLC

6. Remove the pinion housing.


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Fig. 21: PINION HOUSING SHIMCourtesy of CHRYSLER LLC

7. Remove the pinion housing shim. 8. Remove the pinion housing O-ring.

Fig. 22: PINION SHAFT NUTCourtesy of CHRYSLER LLC

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 NUTCourtesy of CHRYSLER LLC

10. Remove the output shaft nut, using the Output Shaft Nut Socket 9921 and Spline Socket 9922.

Fig. 24: PRESS PINIONCourtesy of CHRYSLER LLC


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11. Press the output shaft from the housing using a press.

Fig. 25: PINION SHAFT SPACERCourtesy of CHRYSLER LLC

12. Remove the output shaft spacer.

Fig. 26: PINION SHAFT BEARING.Courtesy of CHRYSLER LLC


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13. Remove the output shaft bearing.

Fig. 27: REMOVE SMALL SIDE BEARING CUP PINION HOUSINGCourtesy of CHRYSLER LLC

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

Fig. 28: REMOVE LARGE SIDE BEARING CUP PINION HOUSINGCourtesy of CHRYSLER LLC


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

Fig. 29: PULL PINION HEAD BEARINGCourtesy of CHRYSLER LLC

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 COVERCourtesy of CHRYSLER LLC


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18. Remove the inspection cover bolts (1).

Fig. 31: REMOVE INSPECTION COVERCourtesy of CHRYSLER LLC

19. Remove the inspection cover.

Fig. 32: SIDE COVERCourtesy of CHRYSLER LLC


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20. Remove the side cover bolts (1).

Fig. 33: REMOVE SIDE COVER.Courtesy of CHRYSLER LLC

21. Remove the side cover from case.

Fig. 34: CARRIERCourtesy of CHRYSLER LLC

22. Remove the carrier assembly.


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Fig. 35: CARRIER BEARING CUP AND SEAL.Courtesy of CHRYSLER LLC

23. Remove bearing cup by hand (1) or by using a pick.

Fig. 36: COVER SIDE CUP AND SHIMCourtesy of CHRYSLER LLC

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 SEALCourtesy of CHRYSLER LLC

25. Remove the inner seal from the PTU cover. 26. Remove the outer seal from the PTU cover.

Fig. 38: CARRIER RACE HOUSING SIDECourtesy of CHRYSLER LLC

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.Courtesy of CHRYSLER LLC

29. Remove the carrier case seal.

Fig. 40: RING GEAR BOLTSCourtesy of CHRYSLER LLC


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30. Remove the ring gear bolts.

Fig. 41: RING GEARCourtesy of CHRYSLER LLC

31. Remove the ring gear.

Fig. 42: REMOVE DIFFERENTIAL SIDE BEARINGCourtesy of CHRYSLER LLC


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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 BEARINGCourtesy of CHRYSLER LLC

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 BEARINGCourtesy of CHRYSLER LLC

1. Install output side spool shaft bearing using Installer C-3095-A.

Fig. 45: SPOOL SHAFT RING GEAR SIDE BEARINGCourtesy of CHRYSLER LLC

2. Install ring gear side bearing using Installer 8148.


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Fig. 46: RING GEARCourtesy of CHRYSLER LLC

3. Install the ring gear.

Fig. 47: RING GEAR BOLTSCourtesy of CHRYSLER LLC

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 SEALCourtesy of CHRYSLER LLC

5. Install the carrier case seal using Installer 9851 and Handle C- 4171.

Fig. 49: CARRIER RACE HOUSING SIDECourtesy of CHRYSLER LLC

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 SEALCourtesy of CHRYSLER LLC

8. Install the inner seal into the PTU cover using Installer 9852 and Handle C-4171.

Fig. 51: INSTALL CARRIER COVER OUTER SEALCourtesy of CHRYSLER LLC

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 SHIMCourtesy of CHRYSLER LLC

10. Install the shim (1) under the bearing cup (3). 11. Install bearing cup by hand (3).


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 BEARINGCourtesy of CHRYSLER LLC

15. Install the output shaft head bearing on to the pinion shaft using Installer 9714 and a Press.

Fig. 55: INSTALL PINION HEAD BEARING CUPCourtesy of CHRYSLER LLC


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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 CUPCourtesy of CHRYSLER LLC

17. Install the output shaft tail bearing cup using Installer 9855 and Handle C-4171.

Fig. 57: PINION SHAFT SPACERCourtesy of CHRYSLER LLC


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18. Install the output shaft spacer onto the output shaft.

Fig. 58: OUTPUT SHAFT TAIL BEARINGCourtesy of CHRYSLER LLC

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 NUTCourtesy of CHRYSLER LLC


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21. Install the output shaft nut (1) onto the output shaft (2).

Fig. 60: INSTALL PINION NUTCourtesy of CHRYSLER LLC

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 SHIMCourtesy of CHRYSLER LLC

25. Install the pinion housing O-ring (3). 26. Install the pinion housing shim (1).

Fig. 62: PINION SHAFT SEALCourtesy of CHRYSLER LLC

27. Install the output shaft seal using Installer 9851 and Handle C-4171.


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Fig. 63: EXTENSION HOUSING O-RINGCourtesy of CHRYSLER LLC

28. Install a new extension housing O-ring.

Fig. 64: PINION HOUSINGCourtesy of CHRYSLER LLC

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 PTUCourtesy of CHRYSLER LLC

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: VENTCourtesy of CHRYSLER LLC

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 SHIELDCourtesy of CHRYSLER LLC


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37. Install the vent shield and bolts. tighten the bolts to 23 N.m (17 ft. lbs.).

Fig. 69: INSPECTION COVERCourtesy of CHRYSLER LLC

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 PTUCourtesy of CHRYSLER LLC

1. Roll the PTU in, moving from front to back (1) .

Fig. 71: PTU INSTALLCourtesy of CHRYSLER LLC

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 MOUNTCourtesy of CHRYSLER LLC

3. Lower screw jack (2) until rear mount through bolt can be installed.

Fig. 73: REAR ENGINE MOUNTCourtesy of CHRYSLER LLC

4. Install rear mount through bolt (2) and tighten bolt to 75 Nm (55 ft. lbs.).


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Fig. 74: FRONT ENGINE MOUNTCourtesy of CHRYSLER LLC

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-RINGCourtesy of CHRYSLER LLC

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 BOLTSCourtesy of CHRYSLER LLC

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 ASSEMBLYCourtesy of CHRYSLER LLC

12. Install the air box (1). 13. Install engine trim cover. 14. Raise the vehicle on the hoist. 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

TORQUEDESCRIPTION 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-4487Courtesy of CHRYSLER LLC

Fig. 79: INSTALLER, CUP - 6061Courtesy of CHRYSLER LLC

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 through75 55 -

Bolts, PTU Mounting 58 43 -


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Fig. 80: PULLER, BEARING/GEAR - 6444Courtesy of CHRYSLER LLC

Fig. 81: JAWS, PULLER - 6451Courtesy of CHRYSLER LLC

Fig. 82: CUP - 8148Courtesy of CHRYSLER LLC

Fig. 83: O2 SENSOR WRENCH - 8439Courtesy of CHRYSLER LLC


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Fig. 84: INSTALLER, BEARING - 9714Courtesy of CHRYSLER LLC

Fig. 85: INSTALLER, SEAL - 9715Courtesy of CHRYSLER LLC


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Fig. 86: SPLINED SOCKET - 9742Courtesy of CHRYSLER LLC



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Fig. 90: INSTALLER, BEARING CUP - 9855Courtesy of CHRYSLER LLC


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Fig. 91: WRENCH, PINION NUT - 9921Courtesy of CHRYSLER LLC

Fig. 92: SOCKET, SPLINED - 9922Courtesy of CHRYSLER LLC

Fig. 93: PULLER, PRESS - C-293-PACourtesy of CHRYSLER LLC

Fig. 94: BLOCK SET, PULLER - C-293-37Courtesy of CHRYSLER LLC


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Fig. 95: INSTALLER, BEARING - C-3095-ACourtesy of CHRYSLER LLC

Fig. 96: DRIVER HANDLE, UNIVERSAL - C-4171Courtesy of CHRYSLER LLC

Fig. 97: INSTALLER, BEARING - L-4411Courtesy of CHRYSLER LLC

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 SEALCourtesy of CHRYSLER LLC

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 SEALCourtesy of CHRYSLER LLC

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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Courtesy of CHRYSLER LLC

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 SEALCourtesy of CHRYSLER LLC

4. Using a drift remove both inner and outer seals.

INSTALLATION

INSTALLATION


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Fig. 102: INSTALL CARRIER COVER INNER SEALCourtesy of CHRYSLER LLC

1. Install the inner seal into the PTU cover using Installer 9852 and Handle C-4171.

Fig. 103: INSTALL CARRIER COVER OUTER SEALCourtesy of CHRYSLER LLC

2. Install the outer seal into the PTU cover using Installer 9853 and Handle C-4171.


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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 PTUCourtesy of CHRYSLER LLC


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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 PTUCourtesy of CHRYSLER LLC

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 BOLTSCourtesy of CHRYSLER LLC

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

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