Transfer Case - Power Transfer Unit: Component Locations Ford Explorer V

Special Tool(s)

Illustration Name Number TKIT Number Handle, 32" Driver 205-907 TKIT-2008DH-FLM Installer, Halfshaft Oil Seal 308-431 TKIT-2001-FLM TKIT-2005U-M Installer, Shaft Bearing Cup 308-221 (T94P-7025-BH) TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 Remover, Halfshaft 205-241 (T86P-3514-A) - Slide Hammer 100-001 (T50T-100-A)

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Illustration Name Number TKIT Number Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) - Installer, PTO Drive Gear Outer Oil Seal 308-430 TKIT-2001-FLM TKIT-2005U-M Remover, Output Flange 307-523 TKIT-2005S1-F TKIT-2005S-F TKIT-2005S-ROW

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1. NOTE: With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. NOTE: Index-mark both the driveshaft flanges for installation. 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.
3. 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. Using a suitable torque wrench, measure and record the rotational torque of the PTU output shaft.
4. Using the 205-126 (T78P-4851-A), hold the output pinion flange. Remove and discard the pinion nut.
5. NOTE: Index-mark the output pinion flange to the pinion shaft. Using the 307-523 , remove the output pinion flange.
6. Remove and discard the output shaft seal.
7. Remove and discard the collapsible spacer.

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1. Install the new collapsible spacer.
2. Using the 308-430 , install the output shaft seal.
3. NOTE: Install the output pinion flange to engage the spline as previously marked. Install the output pinion flange.
4. 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 Nm (3 lb-in) of the reference measurement. If 0 Nm (3 lb-in) is exceeded, then the collapsible spacer will be damaged and a new collapsible spacer will be required. Using the 205-126 (T78P-4851-A) to hold the output pinion flange, install and tighten the new pinion flange nut.
5. Using the index mark, position the driveshaft and install the 4 driveshaft-to-PTU output flange bolts. Tighten to 70 Nm (52 lb-ft).
6. Fill the PTU as necessary. REFER to «Power Transfer Unit (PTU) Draining and Filling»(ref-517578-S16137952672012121200000) .

Illustration Name Number TKIT Number Remover, Transfer Case Bearing Cup 308-125 (T87P-7120-D) TKIT-1987-FLM TKIT-1987-LM Handle, 32" Driver 205-907 TKIT-2008DH-FLM Installer, PTU Linkshaft Seal 205-883 TKIT-2007FA-FLM Installer, PTU Linkshaft Seal Dust Shield 205-882 TKIT-2007FA-FLM Remover, Halfshaft 205-241 (T86P-3514-A) - Slider Hammer Master Set 100-D112

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Illustration Name Number TKIT Number Adapter For 303-224 (Handle) 205-153 (T80T-4000-W) - Holding Fixture, Transmission 307-003 (T57L-500-B) - Installer, Parking Brake Bearing 206-040 (T88T-2598-F) TKIT-1988-F TKIT-1988-FLM Remover & Installer, PTU Input Shaft Seal; contains 308-777/1, 308-777/2, 308-777/3, 308-777/4, and 308-777/5 308-777 TKIT-2011-AW-FL Slide Hammer 100-001 (T50T-100-A)

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1. Remove the PTU. REFER to «Power Transfer Unit (PTU)»(ref-517578-S28506350842012121200000) .
2. Using 307-003 (T57L-500-B), secure the PTU to the bench.
3. Remove the compression seal and discard.
4. 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 (0.197 in) air gap between both seals and approximately 1 mm (0.039 in) air gap between the inner seal and the bearing race. Using 206-040 (T88T-2598-F), press the outer seal downward until the lower seal contacts the bearing race.
5. Position the 308-777 /1 above the PTU input shaft opening.
6. Insert the 308-777 /2 into one of the screw guide holes. Press the 308-777 /2 downward until the shoulder of the punch touches the screw guide.
7. NOTE: Do not overtighten the screws. Turn the 308-777 /3 until they are seated into the screw guide holes. Install a 308-777 /3 into the screw guide hole.
8. Insert the 308-777 /2 into the opposing screw guide hole. Press the 308-777 /2 downward until the shoulder of the punch touches the screw guide.
9. Install a 308-777 /3 into the screw guide hole.
10. Using the screw guide and 100-001 (T50T-100-A), 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. Clean the PTU input shaft opening.
2. Position the inner seal above the PTU input shaft opening with the spring facing toward the PTU. Using 308-777 /4 and 205-153 (T80T-4000-W), install the seal.
3. Position the outer seal above the PTU input shaft opening with the spring facing away from the PTU. Using 308-777 /5 and 205-153 (T80T-4000-W), install the seal.
4. Install the new compression seal.
5. Install the PTU. REFER to «Power Transfer Unit (PTU)»(ref-517578-S28506350842012121200000) .
6. Fill the PTU as necessary. REFER to «Power Transfer Unit (PTU) Draining and Filling»(ref-517578-S16137952672012121200000) .