Transfer Case - Power Transfer Unit: Other Ford Explorer V

Material(s)

MATERIAL(S)

Heat Protection Mode

During very extreme off-road operation, the AWD system utilizes a heat protection mode to protect the 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 4X4 control module disables the ATC solenoid. Before continuing with normal operation, allow the system to cool down at least 10 minutes with the ignition switch in the ON position.

General Procedure

Note. Install a new PTU any time the PTU has been submerged in water.

Note. PTU 's equipped with a drain plug are serviceable in the vehicle. They do not require PTU removal.

Note. Do not drain the PTU unless contamination is suspected. To drain the PTU fluid on PTU 's without a drain plug, remove the PTU from the vehicle. The fluid that is drained may appear black and have a pungent odor. Do not mistake this for contaminated fluid. REFER to Power Transfer Unit (PTU) .

Note. Fill level checks are done in-vehicle only. Let the vehicle sit 10 minutes after the road test before checking the fluid level.

Scheme 46

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. NOTE: Clean the area around the fill plug before removing. Remove and discard the fill plug.
3. With the vehicle on a flat, level surface, fill the PTU. The fluid must be even with the bottom of the fill opening. Fluid capacity is 0.53 L (0.56 qt).
4. Install a new fill plug. Tighten to 20 Nm (177 lb-in).

General Equipment

Scheme 47

Scheme 48

1. With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
2. Remove the RH halfshaft. REFER to «HALFSHAFT - RH, ALL WHEEL DRIVE (AWD)»(ref-517549-S00449975692012121200000) .
3. Remove the RH catalytic converter. REFER to «CATALYTIC CONVERTER - RH, FWD»(ref-517548-S23530022892012121200000) or REFER to «CATALYTIC CONVERTER - RH, AWD»(ref-517548-S18883039122012121200000) .
4. NOTE: To maintain the initial driveshaft balance, index-mark the driveshaft flange and the output flange.
5. Remove the 4 driveshaft-to-output flange bolts, then disconnect the driveshaft from the output flange. Position the driveshaft aside.
6. Remove the PTU support bracket. Remove the 2 PTU support bracket-to-PTU bolts. Remove the 3 PTU support bracket-to-engine bolts.
7. Position the engine roll restrictor aside. Remove the 2 engine roll restrictor-to-transaxle bolts and the engine roll restrictor bracket. Loosen the rear engine roll restrictor bolt and pivot the engine roll restrictor downward.
8. NOTE: Position a drain pan under the vehicle.
9. Remove the 5 PTU bolts and pull the PTU outward and separate it from the transaxle. Rotate the output flange upward, then turn it and remove the PTU from the vehicle.
10. Using a small screwdriver, remove and discard the compression seal.

Input Shaft Seal