Transfer Case - Power Transfer Unit (ptu) Ford Taurus X I

Material

Material

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

a Refer to the procedure in this article.

The All-Wheel Drive (AWD) system consists of the following

1. Power Transfer Unit (PTU)
2. Rear driveshaft
3. 4X4 control module
4. Rear axle with coupling device

The PTU is a gearbox that attaches to the transaxle. The RH intermediate shaft passes through the PTU and engages the differential side gear as in normal Front Wheel Drive (FWD) applications. The PTU directs power to the rear driveshaft through a helical gear spline coupled to the transaxle differential case, a helical gear drop (idler gear) and hypoid/helical ring gear assembly and pinion set. The PTU is sealed from the transaxle and has its own oil sump.

Serviceable components of the PTU are limited to the output shaft seal and flange, intermediate shaft seal and deflector, the cover seal and the PTU-transaxle compression seal. The internal components are not serviced. Do not remove the cover of the PTU. If any of the geared components, bearings, case cover or internal shafts are worn or damaged, a new PTU must be installed.

Principles of Operation

The Power Transfer Unit (PTU) is a gearbox that attaches to the transaxle. The RH intermediate shaft passes through the PTU and engages the differential side gear as in normal Front Wheel Drive (FWD) applications. The PTU directs power to the rear driveshaft through a helical gear spline coupled to the transaxle differential case, a helical gear drop (idler gear) and hypoid/helical ring gear assembly and pinion set. The PTU is sealed from the transaxle and has its own oil sump.

Serviceable components of the PTU are limited to the output shaft seal and flange, intermediate shaft seal and deflector, the cover seal and the PTU-transaxle compression seal. The internal components are not serviced. Do not remove the cover of the PTU. If any of the geared components, bearings, case cover or internal shafts are worn or damaged, a new PTU must be installed.

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 article.

Inspection and Verification

1. Verify the customer concern.
2. Inspect for obvious signs of mechanical damage. VISUAL INSPECTION CHART Mechanical Power Transfer Unit (PTU) Halfshafts and CV joints Driveshaft and U-joints Wheel/tire size and brand Matching tire size and brand Tire pressure
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and Go to «Symptom Chart - Power Transfer Unit (PTU)»(/ford/taurus-x/i-2007-2009/remont/transfer-case/#transfer-case-power-transfer-unit-ptu) .

Symptom Chart - Power Transfer Unit (PTU)

Symptom Chart - Power Transfer Unit (PTU)

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, 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 1

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 article.

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 2

Power Transfer Unit (PTU) Draining and Filling

Material

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) in the Removal portion of this article.

Note. Fill level checks are done in-vehicle only. Let the vehicle sit 10 minutes after the road test before checking the fluid level.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
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).

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)

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»(/ford/taurus-x/i-2007-2009/remont/transfer-case/#transfer-case-power-transfer-unit-ptu__intermediate-shaft-seal-and-deflector) .
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»(/ford/taurus-x/i-2007-2009/remont/transfer-case/#transfer-case-power-transfer-unit-ptu__intermediate-shaft-seal-and-deflector) .
4. Fill the PTU fluid as necessary. For additional information, refer to «Power Transfer Unit (PTU) Draining and Filling»(/ford/taurus-x/i-2007-2009/remont/transfer-case/#transfer-case-power-transfer-unit-ptu__power-transfer-unit-ptu-draining-and) .

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 3

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) 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»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) article.
8. Fill the PTU, if necessary. For additional information, refer to «Power Transfer Unit (PTU) Draining and Filling»(/ford/taurus-x/i-2007-2009/remont/transfer-case/#transfer-case-power-transfer-unit-ptu__power-transfer-unit-ptu-draining-and) .

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 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

Scheme 4

Scheme 5

Scheme 6

General Equipment

Material

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. 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the RH front wheel and tire. For additional information, refer to «WHEELS AND TIRES»(/ford/taurus-x/i-2007-2009/remont/wheel-tire-system/#wheels-tires) article.
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»(/ford/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#front-disc-brake-system) article.
5. 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. Place a 16 mm (5/8 in) washer between the components of the Bearing Cup Remover as shown.
10. 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.
11. 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 7

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. 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. 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 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 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 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. Install the intermediate and halfshaft assembly and the 2 nuts. Tighten to 25 Nm (18 lb-ft).
9. Using brake parts cleaner, thoroughly clean the deflector and intermediate shaft area of any residual fluid that may have accumulated during the repair.
10. Position the halfshaft and ball joint into the wheel knuckle. Install the new ball joint nut. Tighten to 150 Nm (111 lb-ft).
11. Install the RH brake disc. For additional information, refer to «FRONT DISC BRAKE»(/ford/taurus-x/i-2007-2009/remont/mechanical-hydraulic/#front-disc-brake-system) article.
12. 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.
13. Apply the brake to keep the halfshaft from rotating and install a new wheel hub nut. Tighten to 350 Nm (258 lb-ft).
14. Install the RH front wheel and tire. For additional information, refer to «WHEELS AND TIRES»(/ford/taurus-x/i-2007-2009/remont/wheel-tire-system/#wheels-tires) article.
15. Top off the transmission fluid as necessary.

Scheme 8

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(/ford/taurus-x/i-2007-2009/remont/hoistjack/#jacking-and-lifting) article.
2. Remove the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/taurus-x/i-2007-2009/remont/axle-shafts/#front-drive-halfshafts) article.
3. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) article.
4. 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. 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. Inspect the compression seal for wear or damage. Install a new seal as necessary. Using a small screwdriver, remove and discard the compression seal.

Scheme 9

1. Using a suitable tool, install the new compression seal.
2. Position the PTU in place and install the 5 PTU bolts. Tighten to 90 Nm (66 lb-ft).
3. Position the PTU support bracket in place and install the 3 PTU support bracket-to-engine bolts. Tighten to 70 Nm (52 lb-ft).
4. Install the 2 PTU support bracket-to-transaxle bolts. Tighten to 70 Nm (52 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. Install the 4 driveshaft-to-output flange bolts. Tighten the bolts in a star-pattern. Tighten to 70 Nm (52 lb-ft).
7. Install the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(/ford/taurus-x/i-2007-2009/remont/exhaust/#exhaust-system) article.
8. Install the RH front halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(/ford/taurus-x/i-2007-2009/remont/axle-shafts/#front-drive-halfshafts) article.
9. Top off fluids as necessary.

See also:
• FOUR WHEEL DRIVE (4WD) SYSTEMS
• REAR DRIVE AXLE/DIFFERENTIAL
• WHEELS AND TIRES
• BRAKE SYSTEM - GENERAL INFORMATION
• SUSPENSION SYSTEM - GENERAL INFORMATION
• DRIVELINE SYSTEM - GENERAL INFORMATION
• VEHICLE DYNAMIC SYSTEMS
• JACKING AND LIFTING
• EXHAUST SYSTEM
• FRONT DISC BRAKE
• FRONT DRIVE HALFSHAFTS
• Symptom Chart - Power Transfer Unit (PTU)
• Power Transfer Unit (PTU) Draining and Filling
• Analysis of Leakage
• Intermediate Shaft Seal and Deflector
• Cover Seal