Transfer Case - Power Transfer Unit (Ptu): Removal & Installation Ford Taurus VI

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.

1. Remove the intermediate shaft seal and deflector. For additional information, refer to «INTERMEDIATE SHAFT SEAL AND DEFLECTOR»(ref-355720-S37265351642010012800000) .
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.

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1. Assemble the Driver Handle, the Halfshaft Oil Seal Installer and the Shaft Bearing Cup Installer as shown in figure.
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-355720-S37265351642010012800000) .
4. Fill the PTU as necessary. For additional information, refer to «POWER TRANSFER UNIT (PTU) DRAINING AND FILLING»(ref-355720-S22588413702010012800000) .

Note. For High Resolution: A video version of this procedure is available on-line .

Note. For Low Resolution: A video version of this procedure is available on-line .

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 & LIFTING»(ref-355694) .
2. Remove the RH front wheel and tire. For additional information, refer to «WHEELS & TIRES»(ref-355697) .
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-355711) .
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 in figure.
10. Assemble the special tools as indicated in the following table and illustration: ITEM DESCRIPTION CHART Item Description 1 308-125 2 Extension for 205-241 3 5-pound or larger slide hammer
11. 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. 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 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. 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 N.m (30 lb-ft).
11. Fully install the intermediate and halfshaft assembly and the 2 nuts. Tighten to 25 N.m (18 lb-ft).
12. 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 N.m (111 lb-ft).
14. Install the RH brake disc. For additional information, refer to «FRONT DISC BRAKE»(ref-355711) .
15. 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 N.m (258 lb-ft). Remove and discard the wheel hub nut.
16. Apply the brake to keep the halfshaft from rotating and install a new wheel hub nut. Tighten to 350 N.m (258 lb-ft).
17. Install the RH front wheel and tire. For additional information, refer to «WHEELS & TIRES»(ref-355697) .
18. Inspect the transmission fluid level and add clean, specified fluid as necessary.

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ITEM DESCRIPTION CHART

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-355694) .
2. Remove the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-355723) .
3. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-355701) .
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. Using a small screwdriver, remove and discard the compression seal.

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ITEM DESCRIPTION CHART

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-355694) .
2. 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 RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-355723) .
5. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-355701) .
6. Remove the 4 driveshaft-to-output flange bolts, then disconnect the driveshaft from the output flange. Position the driveshaft aside.
7. 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) and the wiring retainer (not shown).
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. Remove the subframe bracket-to-body bolts.
15. 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. 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.