LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2004 >> Freestar Base >> Repair and Diagnosis >> External Pages >> Different car >> Section 1848 (Power Transfer Unit (PTU)) >> In-Vehicle Servicing >> Output Flange >> Installation
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Output Flange: Installation

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the PTU rear output shaft flange to engage the spline as previously marked. Install the PTU rear output shaft flange.
  2. NOTE: Do not overtighten the pinion nut. Refer to the rotational torque previously recorded with a Nm (in-lb) torque wrench. Overtightening the pinion nut will damage the collapsible spacer.
    NOTE: If the rotational torque is less than specification, tighten the drive pinion nut in small increments until it is within specification. Do not tighten the drive pinion nut more than 3 Nm (27 lb-in) or the collapsible spacer will be damaged. If the rotation torque is higher than specification, the collapsible spacer has been compressed too far and a new collapsible spacer must be installed.
  3. Using the Drive Pinion Flange Holding Fixture, install the pinion nut.
  4. Fig 1: Special Tool & Pinion Nut
    GF0025462Courtesy of FORD MOTOR CO.
  5. Install the driveshaft. For additional information, refer to DRIVESHAFT article.