Transfer Case - Power Transfer Unit: Removal & Installation Ford Explorer V

Removal

Note. The PTU may leak different color fluids, red for automatic transmission fluid and brown/black gear lube for PTU fluid. The PTU seals prevent these types of fluids from leaking externally. 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 Leakage Inspection .

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. Remove the intermediate shaft seal and deflector. REFER to «Intermediate Shaft Seal and Deflector»(ref-517578-S31678000092012121200000) .
2. NOTE: There is a bearing inside the PTU directly behind the cover seal. The bearing is not serviced. Remove the cover seal using the 100-001 (T50T-100-A), the extension from the 205-241 (T86P-3514-A) and a suitable dent puller inserted into the groove of the seal.

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1. Assemble 205-907 , 308-431 and 308-221 (T94P-7025-BH) as shown in illustration.
2. Using the 205-907 , 308-431 and 308-221 (T94P-7025-BH), install the cover seal in the PTU.
3. Install the intermediate shaft seal and deflector. REFER to «Intermediate Shaft Seal and Deflector»(ref-517578-S31678000092012121200000) .
4. Fill the PTU as necessary. REFER to «Power Transfer Unit (PTU) Draining and Filling»(ref-517578-S16137952672012121200000) .

Note. The PTU may leak different color fluids, red for automatic transmission fluid and brown/black gear lube for PTU fluid. The PTU seals prevent these types of fluids from leaking externally. 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. REFER to Leakage Inspection .

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. 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. NOTE: The following instruction will prevent the 308-125 (T87P-7120-D) from opening too far which would make removing the intermediate shaft seal deflector difficult. Place a 16 mm (0.6299 in) washer between the components of the 308-125 (T87P-7120-D) as shown in illustration.
4. NOTE: Failure to utilize the recommend tools may result in serious damage to the PTU. Assemble the special tools as indicated in the following table and illustration: Item Description 1 308-125 (T87P-7120-D) 2 Extension from 205-241 (T86P-3514-A) 3 100-D112
5. NOTE: Using the 5-pound 100-D112 eases the removal of the seal deflector. Using the 308-125 (T87P-7120-D), the extension from the 205-241 (T86P-3514-A) and 100-D112 , 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.
6. >Using the 308-125 (T87P-7120-D), the extension from the 205-241 (T86P-3514-A) and 100-D112 , remove the intermediate shaft seal, and if equipped, the alignment washer.

Installation

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 205-883 and 205-907 with the spring side facing away from the tool.
2. Using the 205-883 and 205-907 , install the intermediate shaft seal.
3. Place the alignment washer on the 205-883 and 205-907 .
4. NOTE: Do not use force when installing the alignment washer or damage to the washer can occur. Using the 205-883 and 205-907 , install the alignment washer by hand, pushing it in until it bottoms against the seal.
5. NOTE: Do not overheat (melt) the seal deflector. Monitor the temperature of the deflector with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating. Do not allow the temperature to exceed 100 C (211.9 F). Overheating will damage the deflector. If the deflector is damaged, a new deflector must be used. Position the deflector on the 205-882 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 (159.7 F) and a maximum of 93 C (199.3 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 (199.3 F) to a maximum of 100 C (211.9 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 205-882 and 205-907 .
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 mm (0.1181 in)-5 mm (0.1969 in) into the pocket all the way around.
8. Once the deflector is fully seated, insert the seal protector into the PTU deflector inside diameter.
9. Install the RH halfshaft. REFER to «HALFSHAFT - RH, ALL WHEEL DRIVE (AWD)»(ref-517549-S00449975692012121200000) .

1. NOTE: Install a new compression seal whenever the PTU is removed from the vehicle. Using a suitable tool, install the new compression seal.
2. NOTE: It may be necessary to rotate the output shaft flange in either direction to align the splines of the PTU to the splines of the transaxle. Position the PTU and install the 5 PTU bolts. Tighten to 90 Nm (66 lb-ft).
3. Position the engine roll restrictor to the transaxle and install the engine roll restrictor bracket and the 2 bolts. Tighten the engine roll restrictor-to-transaxle bolts to 103 Nm (76 lb-ft). Tighten the rear engine roll restrictor bolt to 90 Nm (66 lb-ft).
4. Position the PTU support bracket. Install the 3 PTU support bracket-to-engine bolts. Tighten to 48 Nm (35 lb-ft). Install the 2 PTU support bracket-to-PTU bolts. Tighten to 48 Nm (35 lb-ft). NOTE: Line up the index marks made during removal. Install the 4 driveshaft-to-output flange bolts. Tighten to 70 Nm (52 lb-ft). Install the RH catalytic converter. REFER to «CATALYTIC CONVERTER - RH, FWD»(ref-517548-S23530022892012121200000) or REFER to «CATALYTIC CONVERTER - RH, AWD»(ref-517548-S18883039122012121200000) . Install the RH halfshaft. REFER to «HALFSHAFT - RH, ALL WHEEL DRIVE (AWD)»(ref-517549-S00449975692012121200000) . Inspect the transmission fluid level and add clean, specified fluid as necessary.