Transfer Case - Power Transfer Unit: Removal & Installation Ford Edge I рестайлинг

Removal

Note. The PTU may leak different color fluids, red oil leak for 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 fluid is leaking to determine the most appropriate service procedure. This procedure will correct a brown/black (gear lube) leak from the RH side of the PTU. Refer to ANALYSIS OF LEAKAGE .

Note. This procedure is to be performed through the RH wheel opening. It is not necessary to remove the exhaust components to complete this repair.

1. Remove the intermediate shaft seal and deflector. Refer to «INTERMEDIATE SHAFT SEAL AND DEFLECTOR»(ref-494586-S14870147372012081400000) .
2. Remove the cover seal using the Slide Hammer, the extension from the Halfshaft Remover and a suitable seal puller inserted into the groove of the seal.

Scheme 1

Scheme 2

1. Assemble the Driver Handle, the Halfshaft Oil Seal Installer and the Shaft Bearing Cup Installer as shown in illustration.
2. Using the Driver Handle, the Halfshaft Oil Seal Installer and the Shaft Bearing Cup Installer, install the cover seal in the PTU.
3. Install the intermediate shaft seal and deflector. Refer to «INTERMEDIATE SHAFT SEAL AND DEFLECTOR»(ref-494586-S14870147372012081400000) .
4. Fill the PTU as necessary. Refer to «POWER TRANSFER UNIT (PTU) DRAINING AND FILLING»(ref-494586-S03392124802012081400000) .

All vehicles

Scheme 3

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to «JACKING & LIFTING»(ref-494560) . All vehicles except GTDI
2. Remove the 2 exhaust Y-pipe-to-muffler and tail pipe flange nuts. Discard the nuts and gasket.
3. 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. Remove the 4 driveshaft-to-PTU output flange bolts. Disconnect the driveshaft from the PTU and position it aside. Using mechanic's wire, support the driveshaft.
6. Using a suitable torque wrench, measure and record the rotational torque of the PTU output shaft.
7. Using the Drive Pinion Flange Holding Fixture, hold the output pinion flange. Remove and discard the pinion nut.
8. Using the Output Flange Remover, remove the output pinion flange.
9. Remove and discard the output shaft seal.
10. Remove the bearing from the output shaft.
11. Remove and discard the collapsible spacer.

Installation

All vehicles

Scheme 4

1. Install the new collapsible spacer.
2. Install the bearing onto the output shaft.
3. Using the PTU Drive Gear Outer Oil Seal Installer, install the output shaft seal.
4. Install the output pinion flange.
5. Using the Drive Pinion Flange Holding Fixture to hold the output pinion flange, install and tighten the new pinion flange nut.
6. Using the index mark, position the driveshaft and install the 4 driveshaft-to-PTU output flange bolts. Tighten to 70 Nm (52 lb-ft). GTDI vehicles
7. Install the new LH and RH exhaust flexible pipe-to-underbody catalytic converter gaskets and nuts. Tighten to 40 Nm (30 lb-ft). All vehicles except GTDI
8. Install the new exhaust Y-pipe-to-muffler and tail pipe flange gasket and nuts. Tighten to 40 Nm (30 lb-ft). All vehicles
9. Fill the PTU as necessary. Refer to «POWER TRANSFER UNIT (PTU) DRAINING AND FILLING»(ref-494586-S03392124802012081400000) .

Note. For High Resolution: A video version of this procedure is available on-line.

Note. For Low Resolution: A video version of this procedure is available on-line.

Note. The Power Transfer Unit (PTU) may leak different color fluids, red fluid leak for 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 fluid is leaking to determine the most appropriate service procedure. This procedure will correct a red fluid leak (automatic transmission fluid) from the intermediate shaft seal on the RH side of the PTU. For additional information, refer to ANALYSIS OF LEAKAGE under Power Transfer Unit (PTU).

Note. This procedure is to be performed through the RH wheel opening. It is not necessary to remove the exhaust components to complete this repair.

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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 RH front wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-494563) .
3. Apply the brake to keep the halfshaft from rotating and remove the front wheel hub nut. Do not discard the nut at this time.
4. Remove the brake flexible hose bracket bolt and disconnect the hose from the shock absorber.
5. Disconnect the wheel speed sensor harness from the shock absorber bracket.
6. Remove the RH brake disc. For additional information, refer to «FRONT DISC BRAKE»(ref-494591) .
7. Remove and discard the upper stabilizer bar link nut. Position the stabilizer bar link aside.
8. Remove and discard the ball joint-to-knuckle bolt and nut. Separate the lower control arm from the knuckle.
9. Using the Front Wheel Hub Remover, separate the halfshaft from the wheel hub.
10. Pull the knuckle outboard and rotate it toward the rear of the vehicle. Secure the knuckle assembly.
11. Remove the 2 intermediate shaft bracket bolts and the intermediate and halfshaft assembly. Inspect the intermediate shaft for pitting or damage in the seal contact area. Replace if necessary.
12. Place a 16 mm (5/8 in) washer between the components of the Transfer Case Bearing Cup Remover as shown in illustration.
13. Assemble the special tools as indicated in the following table and illustration: Item Description 1 308-125 2 Extension from 205-241 3 100-D112 Slide Hammer Master Set
14. Using the Transfer Case Bearing Cup Remover, the extension from the Halfshaft Remover, and a suitable slide hammer, remove the seal deflector. The seal deflector will have been damaged during removal. Remove all foreign material from the PTU before continuing with the repair.
15. Using the Transfer Case Bearing Cup Remover, the extension from the Halfshaft Remover, and a suitable slide hammer, remove the intermediate shaft seal, and if equipped, the alignment washer.

Note. The following illustration shows the correct orientation of the seal components when installed in the vehicle.

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1. Place the intermediate shaft seal on the PTU Linkshaft Seal Installer and Driver Handle with the spring side facing away from the tool.
2. Using the PTU Linkshaft Seal Installer and Driver Handle, install the intermediate shaft seal.
3. Place the alignment washer on the PTU Linkshaft Seal Installer and Driver Handle.
4. Using the PTU Linkshaft Seal Installer and Driver Handle, install the alignment washer by hand, pushing it in until it bottoms against the seal.
5. Position the deflector on the PTU Linkshaft Seal Dust Shield Installer using silicone brake caliper grease and dielectric compound to retain it to the installer. Using a suitable heat gun, heat the back of the tool to a minimum of 71°C (160°F) and a maximum of 93°C (200°F) by concentrating the heat across the back of the installer while rotating the tool. Once the optimum temperature is achieved on the tool, move the heat gun to the front of the tool and heat the inside of the deflector where it snaps onto the PTU shaft until the temperature of the deflector is a minimum of 93°C (200°F) to a maximum of 100°C (212°F). As an alternative method to heating the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry off the deflector and install.
6. Using a 5-pound or larger dead blow hammer, install the seal deflector immediately after heating using the PTU Linkshaft Seal Dust Shield Installer and Driver Handle.
7. Make sure the deflector is completely seated all the way around and there are no cracks on the face. The deflector is correctly installed when the face of the deflector is recessed 3-5 mm (0.12-0.20 in) into the pocket all the way around.
8. Once the deflector is fully seated, insert the seal protector into the PTU deflector ID.
9. Apply a thin coat of silicone brake caliper grease and dielectric compound to the intermediate shaft seal journal.
10. Partially install the intermediate and halfshaft assembly through the PTU deflector until the splines have cleared the seal protector. Pull the seal protector out of the deflector and off of the intermediate shaft. Complete the installation of the intermediate and halfshaft assembly.
11. Fully install the intermediate and halfshaft assembly and the 2 bolts. Tighten to 40 Nm (30 lb-ft)
12. Using metal brake parts cleaner, thoroughly clean the deflector and intermediate shaft area of any residual fluid that may have accumulated during the repair.
13. Position the halfshaft and ball joint into the wheel knuckle. Install the new ball joint bolt and nut. Tighten to 55 Nm (41 lb-ft).
14. Position the stabilizer bar link and install the new nut. Tighten to 90 Nm (66 lb-ft).
15. Install the RH brake disc. For additional information, refer to «FRONT DISC BRAKE»(ref-494591) .
16. Position the brake flexible hose bracket to the shock absorber and install the bolt. Tighten to 20 Nm (177 lb-in).
17. Connect the wheel speed sensor harness to the shock absorber bracket.
18. Apply the brake to keep the halfshaft from rotating. Using the previously removed wheel hub nut, seat the halfshaft into the front wheel hub. Tighten to 350 Nm (258 lb-ft). Remove and discard the wheel hub nut.
19. Apply the brake to keep the halfshaft from rotating and install a new wheel hub nut. Tighten to 350 Nm (258 lb-ft).
20. Install the RH front wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-494563) .
21. Fill the transaxle as necessary. For additional information, refer to «AUTOMATIC TRANSMISSION - 6F50/6F55»(ref-494558) .