Material
| Item | Specification | Fill Capacity |
|---|---|---|
| MERCON® V Automatic Transmission Fluid XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 (Canada) | MERCON® V | |
| Motorcraft SAE 75W-140 Synthetic Rear Axle Lubricant XY-75W140-QL (US); CXY-75W140-1L (Canada) | WSL-M2C192-A | 0.53L (18 oz) |
Material
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 conduct the most appropriate service procedure.
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, this indicates the differential seals in the transaxle are also leaking and need to be replaced along with the intermediate shaft seal. Refer to AUTOMATIC TRANSAXLE/TRANSMISSION - AISIN AW21 article to replace the differential seals before replacing the intermediate shaft seal. Refer to the Intermediate Shaft Seal and Deflector procedure to replace the intermediate seal.
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 4
| Item | Part Number | Description |
|---|---|---|
| 1 | Intermediate shaft seal (part of kit 7275) | |
| 2 | Alignment washer (part of kit 7275) | |
| 3 | Cover seal (part of kit 7275) | |
| 4 | Seal deflector (part of kit 7275) |
PTU Leaks From the LH Side
If the leak is the red automatic transmission fluid, the compression seal needs replacement. This is between the PTU and transmission. Refer to Power Transfer Unit (PTU) in the Removal portion of this section.
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 5
| Item | Part Number | Description |
|---|---|---|
| 1 | Power Transfer Unit (PTU)-to-transaxle compression seal (7086) | |
| 2 | Transfer case driver gear seal (not serviceable) | |
| 3 | Transfer case driver gear seal (not serviceable) |
Cover Seal
Special Tools Illustration Tool Name Tool Number 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)
Output Shaft Seal
Special Tools Illustration Tool Name Tool Number Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A) Installer, PTU Drive Gear Outer Oil Seal 308-430 Remover, Output Flange 307-523
Scheme 6
| Item | Part Number | Description |
|---|---|---|
| 1 | Collapsible spacer (part of 7275 kit) | |
| 2 | Output shaft seal (part of 7275 kit) | |
| 3 | Output shaft seal deflector (part of 7275 kit) | |
| 4 | Output pinion flange (part of 7275 kit) | |
| 5 | Pinion flange nut (part of 7275 kit) |
Intermediate Shaft Seal and Deflector
Special Tools Illustration Tool Name Tool Number Bearing Cup Remover 308-125 (T87P-7120-D) Handle, Driver 32 in 205-907 Installer, PTU Link shaft Seal 205-883 Installer, PTU Link shaft Seal Dust Shield 205-882 Remover, Halfshaft 205-241
Scheme 7
Scheme 8
Scheme 9
| 5/8 in (16 mm) washer (used with 308-125) |
General Equipment
| Item | Specification |
|---|---|
| Metal Brake Parts Cleaner PM-4-A or PM-4-B (US); CPM-4 (Canada) | |
| Motorcraft MERCON® LV Automatic Transmission Fluid XT-10-QLV | MERCON® LV |
| Silicone Brake Caliper Grease and Dielectric Compound XG-3-A | ESE-M1C171-A |
Material