Transfer Case - Power Transfer Unit (Ptu): Removal & Installation Mercury Sable V

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-293504-S25799292582008080700000) .
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-293504-S25799292582008080700000) .
4. Fill the PTU fluid as necessary. For additional information, refer to «Power Transfer Unit (PTU) Draining and Filling»(ref-293504-S27117507652008080700000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING AND LIFTING»(ref-293448) article.
2. Remove the exhaust flexible pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-293456) 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-293456) article.
8. Fill the PTU, if necessary. For additional information, refer to «Power Transfer Unit (PTU) Draining and Filling»(ref-293504-S27117507652008080700000) .

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»(ref-293448) article.
2. Remove the RH front wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-293452) 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»(ref-293510) 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 1

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»(ref-293510) 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»(ref-293452) article.
15. 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-293448) article.
2. Remove the RH halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-293513) article.
3. Remove the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-293456) 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 3

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»(ref-293456) article.
8. Install the RH front halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-293513) article.
9. Top off fluids as necessary.