Transfer Case - Power Transfer Unit (Ptu): Other Ford Taurus VI

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 42

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 in the Removal portion of this information.

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 .

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ITEM DESCRIPTION CHART

Material

MATERIAL SPECIFICATION

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 in the Removal portion of this information.

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 44

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-355694) .
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 N.m (177 lb-in).

General Equipment

GENERAL EQUIPMENT SPECIFICATION

MATERIAL SPECIFICATION

MATERIAL SPECIFICATION

Scheme 45

ITEM DESCRIPTION CHART

1. Using a suitable tool, install the new compression seal.
2. Position the PTU and install the 5 PTU bolts. Tighten to 90 N.m (66 lb-ft).
3. Position the PTU support bracket and install the 3 PTU support bracket-to-engine bolts. Tighten to 48 N.m (35 lb-ft).
4. Install the 2 PTU support bracket-to-transaxle bolts. Tighten to 48 N.m (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 N.m (76 lb-ft). Tighten the rear engine roll restrictor bolt to 90 N.m (66 lb-ft).
6. Install the 4 driveshaft-to-output flange bolts. Tighten to 70 N.m (52 lb-ft).
7. Install the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-355701) .
8. Install the RH front halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-355723) .
9. Inspect the transmission fluid level and add clean, specified fluid as necessary.

MATERIAL SPECIFICATION

Scheme 46

ITEM DESCRIPTION CHART

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

1. Using a suitable tool, install the new compression seal.
2. Position the PTU and install the 5 bolts. Tighten to 90 N.m (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. Position the subframe brackets and loosely install the 4 bolts.
6. Install the 2 subframe rear bolts. Tighten to 150 N.m (111 lb-ft).
7. Tighten the 4 subframe bracket-to-body bolts to 55 N.m (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 N.m (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 N.m (76 lb-ft). Tighten the rear engine roll restrictor bolt to 90 N.m (66 lb-ft).
11. Position the PTU support bracket in place and install the 3 bolts. Tighten to 48 N.m (35 lb-ft).
12. Install the RH turbocharger lower bracket and the 3 bolts. Tighten the bolt to 19 N.m (168 lb-in). Tighten the 2 bolts to 48 N.m (35 lb-ft).
13. Connect the 2 Electronic Power Assist Steering (EPAS) electrical connectors (1 shown) and attach the wiring retainer (not shown) and install the bolt. Tighten to 9 N.m (80 lb-in).
14. Install the steering intermediate shaft onto the steering gear and install a new bolt. Tighten to 20 N.m (177 lb-in).
15. Install the 4 driveshaft-to-output flange bolts. Tighten to 70 N.m (52 lb-ft).
16. Install the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-355701) .
17. Install the RH front halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-355723) .
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.