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

Heat Protection Mode

During very extreme off-road operation, the All-Wheel Drive (AWD) system utilizes a heat protection mode to protect the Active Torque Coupling (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. Allow the system to cool down at least 10 minutes with the ignition switch in the ON position.

For concerns with the 4X4 control module or ATC , Refer to FOUR WHEEL DRIVE (4WD) SYSTEMS .

Analysis of Leakage

The PTU may leak different color fluids, red oil leak for an automatic transmission fluid and brown/black gear lube for PTU fluid. The PTU seals prevent these types of fluids from leaking. It is important to note which color of fluid is leaking to determine the most appropriate service procedure.

Power Transfer Unit (PTU) Leaks From the RH Side

Note. Remove and replace leaking seals using the information found in the INTERMEDIATE SHAFT SEAL AND DEFLECTOR or COVER SEAL replacement procedure. The specified tools called out in this procedure will allow seal replacement without causing damage to the Power Transfer Unit (PTU) casing/drive gear.

If the leak is red automatic transmission fluid, then the PTU intermediate shaft seal needs replacement. This is inside the bore of the PTU shaft behind the deflector. Refer to the INTERMEDIATE SHAFT SEAL AND DEFLECTOR procedure.

If the leak is brown/black gear lube, then the PTU larger cover seal needs replacement. This is located on the PTU cover behind the deflector. Refer to COVER SEAL procedure.

Scheme 52

ITEM DESCRIPTION CHART

Power Transfer Unit (PTU) Leaks From the LH Side

If the leak is red automatic transmission fluid, the compression seal needs replacement. This is between the PTU and transmission. Refer to POWER TRANSFER UNIT (PTU) - 3.5L or POWER TRANSFER UNIT (PTU) - 3.5L GTDI .

If the leak is brown/black, the PTU is overfilled and venting fluid from the top of the PTU . Flush and fill the PTU . Refer to POWER TRANSFER UNIT (PTU) DRAINING AND FILLING .

Scheme 53

ITEM DESCRIPTION CHART

Material

MATERIAL SPECIFICATIONS

Note. A new Power Transfer Unit (PTU) must be installed any time the PTU has been submerged in water.

Note. The Power Transfer Unit (PTU) is not to be drained unless contamination is suspected. To drain the PTU fluid, the PTU must be removed from the vehicle. The fluid that is drained may appear black and have a pungent odor. Do not mistake this for contaminated fluid. For additional information, refer to POWER TRANSFER UNIT (PTU) - 3.5L or POWER TRANSFER UNIT (PTU) - 3.5L GTDI .

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 54

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) .
2. Clean the area around the filler plug before removing.
3. Remove and discard the filler plug.
4. With the vehicle on a flat, level surface, fill the PTU with lubricant. The fluid must be even with the bottom of the fill opening. Fluid capacity is 0.53L (18 oz).
5. Install a new filler plug. Tighten to 20 Nm (177 lb-in).

General Equipment

GENERAL EQUIPMENT

MATERIAL SPECIFICATIONS

MATERIAL SPECIFICATIONS

Scheme 55

PARTS DESCRIPTION CHART

Scheme 56

1. NOTE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is removed from the vehicle. Using a suitable tool, install the new compression seal.
2. Position the PTU and install the 5 PTU bolts. Tighten to 90 Nm (66 lb-ft).
3. Position the PTU support bracket and install the 3 PTU support bracket-to-engine bolts. Tighten to 48 Nm (35 lb-ft).
4. Install the 2 PTU support bracket-to-transaxle bolts. Tighten to 48 Nm (35 lb-ft).
5. Position the engine roll restrictor to the transaxle and install 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).
6. NOTE: Line up the index marks made during removal. Install the 4 driveshaft-to-output flange bolts. Tighten to 70 Nm (52 lb-ft).
7. Install the RH catalytic converter. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .
8. Install the RH front halfshaft. For additional information, Refer to «FRONT DRIVE HALFSHAFTS»(ref-372781) .
9. Inspect the transmission fluid level and add clean, specified fluid as necessary.

MATERIAL SPECIFICATIONS

Scheme 57

PARTS DESCRIPTION CHART

Scheme 58

Scheme 59

Scheme 60

1. NOTE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is removed from the vehicle. Using a suitable tool, install the new compression seal.
2. Position the PTU and install the 5 bolts. Tighten to 90 Nm (66 lb-ft).
3. Lower the engine and remove the jackstand from the front of the roll restrictor.
4. Using the jackstand, raise the subframe into the installed position.
5. NOTE: RH shown in illustration, LH similar. Position the subframe brackets and loosely install the 4 bolts.
6. NOTE: RH shown in illustration, LH similar. Install the 2 subframe rear bolts. Tighten to 150 Nm (111 lb-ft).
7. NOTE: RH shown in illustration, LH similar. Tighten the 4 subframe bracket-to-body bolts to 55 Nm (41 lb-ft).
8. Remove the jackstand from the subframe.
9. Position the front engine roll restrictor to the bracket and install the bolt. Tighten the front engine roll restrictor bolt to 90 Nm (66 lb-ft).
10. Position the rear engine roll restrictor to the transaxle and install the 3 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).
11. Position the PTU support bracket in place and install the 3 bolts. Tighten to 48 Nm (35 lb-ft).
12. Install the RH turbocharger lower bracket and the 3 bolts. Tighten the bolt to 19 Nm (168 lb-in). Tighten the 2 bolts to 48 Nm (35 lb-ft).
13. Connect the 2 Electronic Power Assist Steering (EPAS) electrical connectors (1 shown in illustration) and attach the wiring retainer (not shown in illustration) and install the bolt. Tighten to 9 Nm (80 lb-in).
14. NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, Refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-372796) . Install the steering intermediate shaft onto the steering gear and install a new bolt. Tighten to 20 Nm (177 lb-in).
15. NOTE: Align the index marks made during removal. Install the 4 driveshaft-to-output flange bolts. Tighten to 70 Nm (52 lb-ft).
16. Install the RH catalytic converter. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .
17. Install the intermediate shaft. For additional information, Refer to «FRONT DRIVE HALFSHAFTS»(ref-372781) .
18. Install the underbody shield and the 4 retainers.
19. Remove the locking device from the steering wheel.
20. Inspect the transmission fluid level and add clean, specified fluid as necessary.