Transfer Case - Power Transfer Unit (Ptu): Component Locations Ford Flex I

Special Tool(s)

SPECIAL TOOLS DESCRIPTION CHART Handle, Driver (32 in) 205-907 Installer, Halfshaft Oil Seal 308-431 Installer, Shaft Bearing Cup 308-221 (T94P-7025-BH) Remover, Halfshaft 205-241 Slide Hammer 100-01 (T50T-100-A)

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SPECIAL TOOLS DESCRIPTION CHART Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Installer, PTU Drive Gear Outer Oil Seal 308-430 Remover, Output Flange 307-523

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ITEM DESCRIPTION CHART

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) .
2. Remove the exhaust flexible pipe. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .
3. NOTE: Index-mark both the driveshaft flanges for installation. Remove the 4 driveshaft-to-Power Transfer Unit (PTU) output flange bolts. Disconnect the driveshaft from the PTU and position it aside. Using mechanic's wire, support the driveshaft.
4. 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.
5. Using the Drive Pinion Flange Holding Fixture, hold the output pinion flange. Remove and discard the pinion nut.
6. NOTE: Index-mark the output pinion flange to the pinion shaft. Using the Output Flange Remover, remove the output pinion flange.
7. Remove and discard the output shaft seal deflector.
8. Remove and discard the output shaft seal.
9. Remove and discard the collapsible spacer.

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1. Install the new collapsible spacer.
2. Using the PTU Drive Gear Outer Oil Seal Installer, install the output shaft seal.
3. Using the PTU Drive Gear Outer Oil Seal Installer, install the output shaft seal deflector.
4. NOTE: Install the output pinion flange to engage the spline as previously marked. Install the output pinion flange.
5. 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. If 0.3 Nm (3 lb-in) is exceeded, then the collapsible spacer will be damaged and a new collapsible spacer will be required. Using the Drive Pinion Flange Holding Fixture to hold the output pinion flange, install and tighten the new pinion flange nut.
6. Using the index mark, position the driveshaft and install the 4 driveshaft-to- PTU output flange bolts. Tighten to 70 Nm (52 lb-ft).
7. Install the exhaust flexible pipe. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .
8. Fill the PTU as necessary. For additional information, refer to «POWER TRANSFER UNIT (PTU) DRAINING AND FILLING»(ref-372778-S07961458642010093000000) .

SPECIAL TOOLS DESCRIPTION CHART Bearing Cup Remover 308-125 (T87P-7120-D) Handle, Driver (32 in) 205-907 Installer, PTU Linkshaft Seal 205-883 Installer, PTU Linkshaft Seal Dust Shield 205-882 Remover, Front Wheel Hub 205-D070 (D93P-1175-B) or equivalent Remover, Halfshaft 205-241

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