Transfer Case - Power Transfer Unit (Ptu): Removal & Installation Ford Flex I

Removal

Note. The Power Transfer Unit (PTU) may leak different color fluids, red oil leak for 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 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 . For additional information, refer to ANALYSIS OF LEAKAGE .

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. For additional information, refer to «INTERMEDIATE SHAFT SEAL AND DEFLECTOR»(ref-372778-S12039003762010093000000) .
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 Slide Hammer, the extension from the Halfshaft Remover and a suitable seal puller inserted into the groove of the seal.

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1. Assemble the Driver Handle, the Halfshaft Oil Seal Installer and the Shaft Bearing Cup Installer as shown in illustration.
2. Using the Driver Handle, the Halfshaft Oil Seal Installer and the Shaft Bearing Cup Installer, install the cover seal in the PTU .
3. Install the intermediate shaft seal and deflector. For additional information, refer to «INTERMEDIATE SHAFT SEAL AND DEFLECTOR»(ref-372778-S12039003762010093000000) .
4. Fill the PTU as necessary. For additional information, refer to «POWER TRANSFER UNIT (PTU) DRAINING AND FILLING»(ref-372778-S07961458642010093000000) .

Note. For High Resolution: Click here to view a video version of this procedure .

Note. For Low Resolution: Click here to view a video version of this procedure .

Note. The Power Transfer Unit (PTU) may leak different color fluids, red oil leak for 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 fluid is leaking to determine the most appropriate service procedure. This procedure will correct a red oil leak (automatic transmission fluid) from the intermediate shaft seal on the RH side of the PTU . For additional information, refer to ANALYSIS OF LEAKAGE .

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. For additional information, Refer to «JACKING AND LIFTING»(ref-372753) .
2. Remove the RH front wheel and tire. For additional information, Refer to «WHEELS AND TIRES»(ref-372756) .
3. Apply the brake to keep the halfshaft from rotating and remove the front wheel hub nut. Do not discard the nut at this time.
4. Remove the RH brake disc. For additional information, Refer to «FRONT DISC BRAKE»(ref-372770) .
5. NOTE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts. Remove and discard the ball joint nut. Separate the lower control arm from the knuckle.
6. Using the Front Wheel Hub Remover, separate the halfshaft from the wheel hub.
7. Pull the knuckle outboard and rotate it toward the rear of the vehicle. Secure the knuckle assembly.
8. Remove the 2 intermediate shaft bracket nuts and the intermediate and halfshaft assembly. Inspect the intermediate shaft for pitting or damage in the seal contact area. Replace if necessary.
9. NOTE: The following instruction will prevent the Bearing Cup Remover from opening too far which would make removing the intermediate shaft seal deflector difficult. Place a 16 mm (5/8 in) washer between the components of the Bearing Cup Remover as shown in illustration. NOTE: Failure to utilize the recommend tools may result in serious damage to the Power Transfer Unit (PTU).
10. Assemble the special tools as indicated in the following table and illustration: SPECIAL TOOLS DESCRIPTION CHART Item Description 1 308-125 2 Extension for 205-241 3 5-pound or larger slide hammer
11. NOTE: Using a 5-pound or larger slide hammer eases the removal of the seal deflector. Using the Bearing Cup Remover, the extension from the Halfshaft Remover and a suitable slide hammer, 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.
12. Using the Bearing Cup Remover, the extension from the Halfshaft Remover and a suitable slide hammer, 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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ITEM DESCRIPTION CHART

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1. Place the intermediate shaft seal on the PTU Linkshaft Seal Installer and Driver Handle with the spring side facing away from the tool.
2. Using the PTU Linkshaft Seal Installer and Driver Handle, install the intermediate shaft seal.
3. Place the alignment washer on the PTU Linkshaft Seal Installer and Driver Handle with the beveled edge (white-striped side) facing towards the tool.
4. NOTE: Do not use force when installing the alignment washer or damage to the washer can occur. Using the PTU Linkshaft Seal Installer and Driver Handle, install the alignment washer by hand, pushing it in until it bottoms against the seal. When installed, the white-striped side should be facing out.
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 (212°F). Overheating will damage the deflector. If the deflector is damaged, a new deflector must be used. NOTE: Apply a small amount of silicone brake caliper grease and dielectric compound to the inner lip of the deflector where it installs on the tube inside the PTU before heating. This will ease the installation of the deflector. Position the deflector on the PTU Linkshaft Seal Dust Shield Installer 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 (160°F) and a maximum of 93°C (200°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 (200°F) to a maximum of 100°C (212°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 PTU Linkshaft Seal Dust Shield Installer and Driver Handle.
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 3-5 mm (0.12-0.20 in) into the pocket all the way around.
8. Once the deflector is fully seated, insert the seal protector into the PTU deflector ID.
9. Apply a thin coat of silicone brake caliper grease and dielectric compound to the intermediate shaft seal journal.
10. NOTE: A slight effort may be required to fully seat the intermediate and halfshaft assembly as it passes through the alignment washer. Partially install the intermediate and halfshaft assembly through the PTU deflector until the splines have cleared the seal protector. Pull the seal protector out of the deflector and off of the intermediate and halfshaft assembly. Tighten to 40 Nm (30 lb-ft).
11. Fully install the intermediate and halfshaft assembly and the 2 nuts. Tighten to 25 Nm (18 lb-ft).
12. NOTE: A significant amount of residual fluid will collect between the seal and deflector during this repair. This is a normal condition and should not be misinterpreted as a leak after the repair is complete. Using brake parts cleaner, thoroughly clean the deflector and intermediate shaft area of any residual fluid that may have accumulated during the repair.
13. Position the halfshaft and ball joint into the wheel knuckle. Install the new ball joint nut. Tighten to 150 Nm (111 lb-ft).
14. Install the RH brake disc. For additional information, Refer to «FRONT DISC BRAKE»(ref-372770) .
15. NOTE: Do not tighten the halfshaft nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied. Apply the brake to keep the halfshaft from rotating. Using the previously removed wheel hub nut, seat the halfshaft into the front wheel hub. Tighten to 350 Nm (258 lb-ft). Remove and discard the wheel hub nut.
16. NOTE: The wheel hub nut contains a one-time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur. Apply the brake to keep the halfshaft from rotating and install a new wheel hub nut. Tighten to 350 Nm (258 lb-ft).
17. Install the RH front wheel and tire. For additional information, Refer to «WHEELS AND TIRES»(ref-372756) .
18. Inspect the transmission fluid level and add clean, specified fluid as necessary.

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PARTS 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 RH halfshaft. For additional information, Refer to «FRONT DRIVE HALFSHAFTS»(ref-372781) .
3. Remove the RH catalytic converter. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .
4. NOTE: To maintain the initial driveshaft balance, index-mark the driveshaft flange and the output flange. Remove the 4 driveshaft-to-output flange bolts, then disconnect the driveshaft from the output flange. Position the driveshaft aside.
5. Remove the 5 Power Transfer Unit (PTU) support bracket bolts and the support bracket.
6. Position the engine roll restrictor aside. Remove the 2 engine roll restrictor-to-transaxle bolts. Loosen the rear engine roll restrictor bolt and pivot the roll restrictor downward.
7. NOTE: Position a drain pan under the vehicle. Remove the 5 PTU bolts. 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.
8. Using a small screwdriver, remove and discard the compression seal.

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PARTS 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. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent). Using a suitable holding device, hold the steering wheel in the straight-ahead position.
3. Remove the 4 retainers and the underbody shield.
4. Remove the intermediate shaft. For additional information, Refer to «FRONT DRIVE HALFSHAFTS»(ref-372781) .
5. Remove the RH catalytic converter. For additional information, Refer to «EXHAUST SYSTEM»(ref-372760) .
6. NOTE: To maintain the initial driveshaft balance, index-mark the driveshaft flange and the output flange. Remove the 4 driveshaft-to-output flange bolts, then disconnect the driveshaft from the output flange. Position the driveshaft aside.
7. 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) . Remove the steering shaft bolt and disconnect the steering column shaft from the steering gear. Discard the bolt.
8. Remove the bolt and disconnect the 2 Electronic Power Assist Steering (EPAS) electrical connectors (1 shown in illustration) and the wiring retainer (not shown in illustration).
9. Remove the 3 bolts and the RH turbocharger lower bracket.
10. Remove the 3 bolts and the Power Transfer Unit (PTU) support bracket.
11. Position the rear engine roll restrictor aside in the following sequence. Remove the 2 engine roll restrictor-to-transaxle bolts. Loosen the engine roll restrictor-to-frame bolt and pivot the roll restrictor downward.
12. Remove the front engine roll restrictor bolt and position the engine roll restrictor aside.
13. Position a jackstand under the rear of the subframe.
14. NOTE: RH shown in illustration, LH similar. Remove the subframe bracket-to-body bolts.
15. NOTE: RH shown in illustration, LH similar. Remove the subframe rear bolts and the subframe brackets. Discard the bolts.
16. Position a jackstand under the front roll restrictor bracket and raise the engine far enough to allow the PTU to be removed.
17. NOTE: Position a drain pan under the vehicle. Remove the 5 PTU bolts. Pull the PTU outward to separate it from the transaxle. Rotate the output flange upward, then turn it and remove the PTU from the vehicle.
18. Using a small screwdriver, remove and discard the compression seal.