Transfer Case - Power Transfer Unit: Other Ford Edge I рестайлинг

Power Transfer Unit (PTU)

The AWD system consists of the following

1. PTU
2. Rear driveshaft
3. AWD relay module
4. Rear axle with coupling device

The PTU is a mechanical device attached to the transaxle. It supplies torque to the rear axle through the rear driveshaft. The AWD relay module is an electronic device which controls the rear axle coupling to apply the torque generated from the PTU to the rear wheels when required.

Heat Protection Mode

During very extreme off-road operation, the All-Wheel Drive (AWD) system utilizes a heat protection mode to protect the Active Torque Coupling (ATC) solenoid (part of rear axle) from damage. If the system detects an overheat condition, it enters a locked mode. If the heat in the system continues to rise once in the locked mode, the AWD relay module disables the ATC solenoid. Allow the system to cool down at least 10 minutes with the ignition switch in the ON position.

For concerns with the AWD relay module or ATC, refer to FOUR WHEEL DRIVE (4WD) SYSTEMS .

Analysis of Leakage

Note. Inspection of the seal's mating journal should be performed every time a seal is replaced. The mating part/journal should be replaced if it has any of the following conditions: Radial wear groove that can be felt by running a finger nail across it where seal lip runs. Scratches, pitting, galling, nicks or other shaft damage under or near where the seal lip runs. Discoloration or coked oil on the shaft where the seal lip runs. Shaft corrosion under or near where the seal lip runs. Sharp edges or burrs on the shaft lead in chamfer. NEVER use emery cloth on journal finishes, replace the part.

The PTU may leak different color fluids, red oil leak for an automatic transmission fluid and brown/black gear lube for PTU fluid. The PTU seals prevent these types of fluids from leaking. It is important to note which color of fluid is leaking to determine the most appropriate service procedure.

PTU Leaks From the RH Side

Note. Remove and replace leaking seals using the information found in the INTERMEDIATE SHAFT SEAL AND DEFLECTOR or COVER SEAL replacement procedure. The specified tools called out in this procedure will allow seal replacement without causing damage to the Power Transfer Unit (PTU) casing/drive gear.

If the leak is red automatic transmission fluid, the PTU intermediate shaft seal needs replacement. This is inside the bore of the PTU shaft behind the deflector. Refer to the INTERMEDIATE SHAFT SEAL AND DEFLECTOR procedure.

If the leak is brown/black gear lube, the PTU larger cover seal needs replacement. This is located on the PTU cover behind the deflector. Refer to COVER SEAL procedure.

Note. The following figure is for reference only. The kit also includes a special tool (not pictured) that is used during seal installation only and is not intended to be left in the PTU as a sealing device.

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PTU Leaks From the LH Side

If the leak is the red automatic transmission fluid, the compression seal needs replacement. This is between the PTU and transmission. Refer to POWER TRANSFER UNIT (PTU) in the Removal portion .

If the leak is brown/black and venting fluid from the top of the PTU, the PTU is overfilled due to the input shaft seals leaking red automatic transmission fluid into the PTU. Replace the input shaft seals, refer to INPUT SHAFT SEAL .

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Cover Seal

SPECIAL TOOLS CHART Handle, Driver (32 in) 205-907 Installer, Halfshaft Oil Seal 308-431 Installer, Shaft Bearing Cup 308-221 (T94P-7025-BH) Remover, Halfshaft 205-241 Slide Hammer 100-01 (T50T-100-A)

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Output Shaft Seal

SPECIAL TOOLS CHART Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Installer, PTU Drive Gear Outer Oil Seal 308-430 Remover, Output Flange 307-523

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Intermediate Shaft Seal and Deflector

SPECIAL TOOLS CHART Handle, Driver 32 in 205-907 Installer, PTU Linkshaft Seal 205-883 Installer, PTU Linkshaft Seal Dust Shield 205-882 Remover, Front Wheel Hub 205-D070 (D93P-1175-B) or equivalent Remover, Halfshaft 205-241 Remover, Transfer Case Bearing Cup 308-125 (T87P-7120-D) Slide Hammer Master Set 100-D112 or equivalent

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GENERAL EQUIPMENT

MATERIAL SPECIFICATIONS

Input Shaft Seal

SPECIAL TOOLS CHART Holding Fixture, Transmission 307-003 (T57L-500-B) Installer, Parking Brake Bearing 206-040 (T88T-2598-F) Remover/Installer, PTU Input Shaft Seal 308-777 (includes 308-777/1, 308-777/2, 308-777/3, 308-777/4 and 308-777/5) Slide Hammer 100-001 (T50T-100-A)

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1. Remove the Power Transfer Unit (PTU). For additional information, refer to «POWER TRANSFER UNIT (PTU)»(ref-494586-S12929243482012081400000) .
2. Using the Transmission Holding Fixture, secure the PTU to the bench.
3. Remove the compression seal and discard. NOTE: Do not press the seals lower than specified. Excessive force will damage the bearing below the seals. NOTE: Both seals will need to be pressed lower into the PTU input shaft opening to break the seals outer sealant loose from the PTU. NOTE: There is approximately a 5 mm (0.196 in) air gap between both seals and approximately 1 mm (0.039 in) air gap between the inner seal and the bearing race.
4. Using the Parking Brake Bearing Installer, press the outer seal downward until the lower seal contacts the bearing race.
5. Position the Screw Guide above the PTU input shaft opening.
6. Insert the Punch into one of the Screw Guide holes. Press the Punch downward until the shoulder of the Punch touches the Screw Guide. NOTE: Do not overtighten the Screws. Turn the Screws until they are seated into the Screw Guide holes.
7. Install a Screw into the Screw Guide hole.
8. Insert the Punch into the opposing Screw Guide hole. Press the Punch downward until the shoulder of the Punch touches the Screw Guide.
9. Install a Screw into the Screw Guide hole.
10. Using the Screw Guide and Slide Hammer, remove the 2 seals and discard.
11. Using a non-marring tool, remove any excess red sealant material from the PTU input shaft opening.
12. Drain the PTU. Position the PTU output flange upward and tilt the PTU approximately 30 degrees toward the LH seal bore to allow the fluid to drain from the PTU input shaft opening.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-494560) .
2. Remove the intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-494589) .
3. Remove the 4 bolts and support the driveshaft with a length of mechanic's wire.
4. Remove the exhaust flexible pipe and the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-494567) .
5. Remove the 2 roll restrictor shield nuts and the roll restrictor shield.
6. Remove the 2 roll restrictor through bolts and the roll restrictor.
7. Remove the 5 PTU support bracket bolts and the PTU support bracket.
8. Using a long extension, loosen but do not remove the 2 LH side PTU-to-transaxle bolts.
9. Remove the 3 RH side PTU-to-transaxle bolts and the 2 LH side PTU-to-transaxle bolts previously loosened.
10. Separate the PTU from the transaxle and remove it from the vehicle.
11. Using a suitable tool, remove the compression seal and discard.

SPECIAL TOOLS CHART Handle 205-153 (T80T-4000-W) Remover/Installer, PTU Input Shaft Seal 308-777 (includes 308-777/1, 308-777/2, 308-777/3, 308-777/4 and 308-777/5)

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1. Clean the Power Transfer Unit (PTU) input shaft opening.
2. Position the inner seal above the PTU input shaft opening with the spring facing toward the PTU. Using the Seal Installer and the Handle, install the seal.
3. Position the outer seal above the PTU input shaft opening with the spring facing away from the PTU. Using the Seal Installer and the Handle, install the seal.
4. Install the new compression seal.
5. Install the PTU. For additional information, refer to «POWER TRANSFER UNIT (PTU)»(ref-494586-S04823988842012081400000) .
6. Fill the PTU as necessary. For additional information, refer to «POWER TRANSFER UNIT (PTU) DRAINING AND FILLING»(ref-494586-S03392124802012081400000) .

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1. Using a suitable tool, install the new compression seal.
2. Using a suitable pry bar, move the engine forward. Install a block of wood to hold the engine in the forward position. Install the PTU with the output flange facing the passenger side, filler plug facing upward. Rotate the PTU to the transaxle. Install the 5 PTU-to-transaxle bolts. Tighten to 90 Nm (66 lb-ft).
3. Position the PTU support bracket into place and hand-tighten the 5 PTU support bracket bolts. Tighten the bolts to the transaxle to 70 Nm (52 lb-ft). Tighten the bolts to the engine to 70 Nm (52 lb-ft).
4. Install the roll restrictor and the 2 roll restrictor through bolts. Tighten to 115 Nm (85 lb-ft).
5. Install the roll restrictor shield and the 2 roll restrictor shield nuts. Tighten to 9 Nm (80 lb-in).
6. Install the exhaust flexible pipe and RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-494567) .
7. Install the intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-494589) .
8. Line up the index marks on the driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts. Tighten to 70 Nm (52 lb-ft).
9. Remove and discard the filler plug.
10. Fill the PTU, if necessary. The fluid must be even with the bottom of the fill opening.
11. Install a new filler plug. Tighten to 20 Nm (177 lb-in).