Output Shaft Seal: Removal

All vehicles 

• 1.
  
  Remove the front subframe. Refer to Uni-Body, Subframe and Mounting System .

All vehicles except GTDI 

• 2.
  
  Remove the exhaust Y-pipe-to-muffler and tail pipe flange nuts.
  • Discard the nuts and gasket.

• 3.
  
  
  NOTE: The resonator must be supported to prevent damage to the flexible pipe.

  Using a length of mechanic's wire, support the resonator.

GTDI vehicles 

• 4.
  
  Remove the 4 LH and RH exhaust flexible pipes-to-underbody catalytic converter nuts.
  • Discard the nuts and gasket.

All vehicles 

• 5.
  
  Index-mark the driveshaft. Marker. Discard the specified component. Follow local disposal regulations.

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• 6.
  
  
  NOTE: Rotational torque of the PTU rear output shaft flange must be measured and recorded using a Nm (lb-in) torque wrench for correct pinion bearing preload when reassembled. This will be the torque-to-turn measurement.

  General equipment: Torque wrench.

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• 7.
  
  Special Tool(s): Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A). Discard the specified component. Follow local disposal regulations.

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• 8.
  
  
  NOTE: Index-mark the output pinion flange to the pinion shaft.

  Marker. Special Tool(s): Remover, Output Flange 307-523.

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• 9.
  
  Remove and discard the output shaft seal.

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• 10.
  
  Remove the oil slinger.

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• 11.
  
  Remove the outer pinion bearing.

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• 12.
  
  Remove and discard the collapsible spacer.

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