Transfer Case - Power Transfer Unit (ptu) Ford Five Hundred I

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

Torque from the engine goes through the transaxle to the power transfer unit (PTU). Torque is transferred from the driveshaft to the rear axle, which drives the rear halfshafts.

The vehicle is equipped with an intelligent all wheel drive (AWD) system that is always active and requires no driver input. The AWD system combines transparent all-surface operation, and is capable of handling all road conditions, including street and highway driving as well as winter driving. The AWD system continuously monitors vehicle conditions and automatically adjusts the torque distribution between the front and rear wheels. During normal operation, most of the torque is sent to the front wheels. If wheel slip between the front and rear wheels is detected, or if the vehicle is under heavy acceleration (HIGH THROTTLE position), the AWD system increases torque to the rear wheels to prevent or control wheel slip.

Serviceable components of the PTU include 3 seals, the input shaft oil slinger, the halfshaft dust seal, the vent cap fitting, the vent cap and filter and the output flange. If any of the internal geared components, bearings or shafts are worn or damaged, a new PTU must be installed. The PTU is sealed from the transaxle and has its own oil sump.

Scheme 1

Refer to DRIVELINE SYSTEM-GENERAL INFORMATION .

Power Transfer Unit (PTU) Draining and Filling

MATERIAL SPECIFICATIONS

Note. The power transfer unit (PTU) is lubed for life and is not to be drained unless a leak is suspected. To drain the PTU fluid, the PTU must be removed from the vehicle. For additional information, refer to POWER TRANSFER UNIT (PTU) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
2. Remove the fill plug and washer. Fill the PTU with axle lubricant to the specified level.
3. Install a new washer and fill plug. Tighten to 49 Nm (36 lb-ft).

Special Tool(s)

SPECIAL TOOL DESCRIPTION Installer, Output Shaft Oil Seal 308-246 (T96P-7127-A)

Removal

1. Remove the output flange. For additional information, refer to «OUTPUT FLANGE»(/ford/five-hundred/i-2004-2007/remont/transfer-case/#transfer-case-power-transfer-unit-ptu) .
2. Remove and discard the output shaft seal.

Installation

1. Using the special tool, install the new output shaft seal.
2. Install a new vent cap and filter.
3. Install the output flange. For additional information, refer to «OUTPUT FLANGE»(/ford/five-hundred/i-2004-2007/remont/transfer-case/#transfer-case-power-transfer-unit-ptu) .

SPECIAL TOOL DESCRIPTION Halfshaft Seal Installer, PTU 205-815

Scheme 2

Scheme 3

1. Remove the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
2. Remove and discard the power transfer unit (PTU) dust seal.
3. Remove and discard the PTU oil seal.

1. Using the special tool, install a new PTU oil seal.
2. Install a new PTU dust seal.
3. Install a new vent cap and filter.
4. Install the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .

Scheme 4

1. Remove the driveshaft. For additional information, refer to «DRIVESHAFT»(/ford/five-hundred/i-2004-2007/remont/driveshaft-universal-joints/#driveshaft) .
2. Remove the output flange nut. To install, tighten to 100 Nm (74 lb-ft).
3. Remove the output flange.
4. To install, reverse the removal procedure.

Scheme 5

Scheme 6

1. Remove the power transfer unit (PTU). For additional information, refer to «POWER TRANSFER UNIT (PTU)»(/ford/five-hundred/i-2004-2007/remont/transfer-case/#transfer-case-power-transfer-unit-ptu) .
2. Remove the input shaft oil slinger.
3. Remove and discard the input shaft seal.

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting)
2. Remove the LH and RH front half shafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
3. Remove the 2 front exhaust pipe nuts.
4. Remove the 2 front exhaust pipe studs.
5. Remove the 2 rear exhaust pipe nuts.
6. Remove the 2 catalytic converter pipe bolts, disconnect the rubber hanger and remove the pipe.
7. Index-mark the driveshaft.
8. Remove the 2 outer driveshaft brace bolts.
9. Remove the 6 driveshaft flange bolts from the front driveshaft flange.
10. Remove the upper power transfer unit (PTU) bracket bolts and the bracket, if equipped.
11. Remove the 4 PTU bolts and the PTU.

SPECIAL TOOL DESCRIPTION Installer, Power Take Off Halfshaft Seal 205-815

1. Using the special tool, install a new input shaft seal.
2. Install the input shaft oil slinger.
3. Install a new vent cap and filter.
4. Install the power transfer unit (PTU). For additional information, refer to «POWER TRANSFER UNIT (PTU)»(/ford/five-hundred/i-2004-2007/remont/transfer-case/#transfer-case-power-transfer-unit-ptu) .

Material

MATERIAL SPECIFICATIONS

Scheme 13

Scheme 14

1. Wipe off any residual grease or contaminants from the PTU splines. Apply a thin, uniform coating of grease to all of the PTU spline surfaces before assembly.
2. Position the power transfer unit (PTU) in place and install the 4 PTU bolts. Tighten to 90 Nm (66 lb-ft).
3. Install the upper PTU bracket and the upper PTU bracket bolts. Tighten to 55 Nm (41 lb-ft).
4. Install the LH and RH halfshafts. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/five-hundred/i-2004-2007/remont/axle-shafts/#front-drive-halfshafts) .
5. Line up the index marks made during removal.
6. Install the driveshaft brace and the 2 driveshaft brace bolts. Tighten to 30 Nm (22 lb-ft).
7. Install the 6 driveshaft flange bolts. Tighten to 30 Nm (22 lb-ft).
8. Position the catalytic converter pipe, install the 2 catalytic converter pipe bolts and connect the rubber hanger. Tighten to 40 Nm (30 lb-ft).
9. Install the 2 rear exhaust pipe nuts. Tighten to 40 Nm (30 lb-ft).
10. Install the 2 front exhaust pipe studs.
11. Install the 2 front exhaust pipe nuts. Tighten to 40 Nm (30 lb-ft).

See also:
• DRIVELINE SYSTEM-GENERAL INFORMATION
• JACKING & LIFTING
• FRONT DRIVE HALFSHAFTS
• DRIVESHAFT
• POWER TRANSFER UNIT (PTU)