Transfer Case - Power Transfer Unit (Ptu): Other Ford Escape III

Heat Protection PTU

During off-road operation or heavy trailer towing the AWD system may implement a heat protection mode to protect the PTU from damage. The AWD system will reduce commanded torque to half as the temperature approaches its limit. Once the temperature limit is reached, then 2WD only is commanded.

For concerns with the AWD system 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 is felt by running a finger nail across where the 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, automatic transmission fluid and a brown/black gear lube for PTU fluid. The PTU seals prevent these types of fluids from leaking. Its important to note the color of fluid 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 Input Shaft Seal or Cover Seal replacement procedure. The specified tools called out in this procedure allows seal replacement without causing damage to the PTU casing/drive gear.

If the leak is automatic transmission fluid, the PTU input shaft seal needs to be replaced. This is inside the bore of the PTU. REFER to the INPUT SHAFT SEAL .

If the leak is brown/black gear lube, the PTU larger cover seal needs to be replaced. This is located on the PTU cover. REFER to COVER SEAL .

PTU Leaks From the LH Side

If the leak is automatic transmission fluid, the compression seal needs to be replaced. This is between the PTU and transmission. REFER to POWER TRANSFER UNIT (PTU) .

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 automatic transmission fluid into the PTU. Replace the input shaft seals, REFER to INPUT SHAFT SEAL .

Intermediate Shaft Seal

SPECIAL TOOLS Handle 205-153 (T80T-4000-W) Installer, Outboard Cover Seal 308-876 Slide Hammer 100-001 (T50T-100-A)

Scheme 12

Scheme 13

1. Remove the RH halfshaft. Refer to «FRONT DRIVE HALFSHAFTS»(ref-569562) .
2. Special Tool(s): Slide Hammer 100-011 (T50T-100-A). General Equipment: Dent Puller.

Scheme 14

1. NOTE: The seal is correctly installed if it is flush with the PTU case cover. Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Outboard Cover Seal 308-876.
2. Install the RH halfshaft. Refer to «FRONT DRIVE HALFSHAFTS»(ref-569562) .

Output Shaft Seal

SPECIAL TOOLS Installer, Output Seal 308-877

Output Flange

SPECIAL TOOLS Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)

Scheme 15

Scheme 16

1. Remove the PTU. Refer to «POWER TRANSFER UNIT (PTU)»(ref-569566-S38521648302013072700000) .
2. 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.
3. Special Tool(s): Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A). Discard the specified component. Follow local disposal regulations.
4. Marker.

Scheme 17

Scheme 18

1. Install the seal deflector on the output flange using a press.
2. Visual check.
3. NOTE: Refer to the rotational torque previously recorded with the Nm (lb-in) torque wrench. Tighten the pinion nut in small increments until it is within 0.3 Nm (3 lb-in) of the reference measurement. New nut. Special Tool(s): Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A).
4. Install the PTU. Refer to «POWER TRANSFER UNIT (PTU)»(ref-569566-S38521648302013072700000) .

Input Shaft Seal

SPECIAL TOOLS Handle 205-153 (T80T-4000-W) Installer, Input Seal 308-878

Scheme 19

1. Remove the Power Transfer Unit (PTU). Refer to «POWER TRANSFER UNIT (PTU)»(ref-569566-S38521648302013072700000) .
2. Remove the input shaft assembly.

Scheme 20

1. Special Tool(s): Handle 205-153 (T80T-4000-W), Installer, Input Seal 308-878.
2. Install the input shaft assembly.
3. Tighten to 14 Nm (124 lb-in).
4. Install the PTU. Refer to «POWER TRANSFER UNIT (PTU)»(ref-569566-S38521648302013072700000) .

Cover Seal

SPECIAL TOOLS Handle 205-153 (T80T-4000-W) Installer, Inboard Cover Seal 308-875

Scheme 21