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

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 conduct 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.

1. Remove the intermediate shaft seal and deflector. For additional information, refer to «Intermediate Shaft Seal and Deflector»(ref-291915-S35483642482008073000000) .
2. 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.

INSTALLATION

1. Assemble the Driver Handle, the Halfshaft Oil Seal Installer and the Shaft Bearing Cup Installer as shown.
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-291915-S35483642482008073000000) .
4. Fill the PTU fluid as necessary. For additional information, refer to «Power Transfer Unit (PTU) Draining and Filling»(ref-291915-S28419391042008073000000) in this section.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-291857) article.
3. 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. Using a suitable torque wrench, measure and record the rotational torque.
5. Using the Drive Pinion Flange Holding Fixture, hold the output pinion flange. Remove and discard the pinion nut.
6. 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.

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. Install the output pinion flange.
5. Using the Drive Pinion Flange Holding Fixture to hold the output pinion flange, install and tighten the new pinion flange nut.
6. Position the driveshaft using the index mark and install the 4 driveshaft-to-PTU output flange bolts. Tighten bolts in a star pattern. Tighten to 70 Nm (52 lb-ft).
7. Install the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-291857) article.
8. Fill the PTU, if necessary. For additional information, refer to «Power Transfer Unit (PTU) Draining and Filling»(ref-291915-S28419391042008073000000) .

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 conduct 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. If the leak is red automatic transmission fluid, this indicates that 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. 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.

1. Remove the intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-291932) article.
2. Place a 16 mm (5/8 in) washer between the components of the Bearing Cup Remover as shown.
3. 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.
4. 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.

Note. The following illustration shows the correct orientation of the seal components when installed in the vehicle.

Scheme 1

1. Place the intermediate shaft seal on the PTU Link shaft Seal Installer and Driver Handle with the spring side facing away from the tool.
2. Using the PTU Link shaft Seal Installer and Driver Handle, install the intermediate shaft seal.
3. Place the alignment washer on the PTU Link shaft Seal Installer and Driver Handle with the beveled edge (white-striped side) facing towards the tool.
4. Using the PTU Link shaft 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. Position the deflector on the PTU Link shaft 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 deflector to a minimum of 66°C (150°F) and a maximum of 100°C (212°F) by concentrating the heat across the back of the installer while rotating, not directly on the deflector itself. 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. Install the seal deflector immediately after heating using the PTU Link shaft 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 or inner diameter white-colored tab. 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. Using brake parts cleaner, thoroughly clean the deflector and intermediate shaft area of any residual fluid that may have accumulated during the repair.
9. Install the intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-291932) article.
10. Top off the transmission fluid as necessary.

Scheme 2

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-291849) article.
2. Remove the driveshaft. For additional information, refer to «DRIVESHAFT»(ref-291930) article.
3. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-291857) article.
4. Remove the 2 Power Transfer Unit (PTU)-to-support bracket bolts, then remove the 3 PTU support bracket bolts and the PTU support bracket.
5. Remove the 5 PTU-to-transaxle bolts.
6. Separate the PTU from the transaxle. Remove the PTU from the vehicle.
7. Using a suitable tool, remove the compression seal and discard.

Material

Scheme 3

1. Using a suitable tool, install the new compression seal.
2. Position the PTU to the transaxle. Install the 5 PTU-to-transaxle bolts. Tighten to 90 Nm (66 lb-ft).
3. Position the PTU support bracket into place and install the 5 PTU support bracket bolts. Tighten the bolts to the transaxle to 70 Nm (52 lb-ft). Tighten the bolts to the engine to 70 Nm (52 lb-ft).
4. Install the driveshaft. For additional information, refer to «DRIVESHAFT»(ref-291930) article.
5. Install the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-291857) article.
6. Top off all fluids as necessary.