Power Transfer Unit (PTU)

Fig 1: Power Transfer Unit Components With Torque Specifications

Courtesy of FORD MOTOR CO.

All vehicles 

NOTE: If necessary, install a new halfshaft seal - RH, All Wheel Drive (AWD). For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - 6F35 article.
1. Position the Power Transfer Unit (PTU) to the transaxle.
2. Install the 3 PTU-to-transaxle bolts.
   • Tighten to 70 Nm (52 lb-ft).
3. Install the PTU-to-transaxle bolt (M10).
   • Tighten to 47 Nm (35 lb-ft).
4. Connect the PTU vent tube.

   Except hybrid vehicles 

5. Install the PTU-to-engine bracket and the 6 bracket bolts.
   • Tighten to 48 Nm (35 lb-ft).

   Hybrid vehicles 

6. Install the PTU-to-engine bracket.
   1. Install the bracket with the outer PTU bracket-to-PTU bolt together.
   2. Install the inner PTU bracket-to-PTU bolt.
   3. Install the 4 PTU-to-engine bracket bolts.
      • Tighten to 48 Nm (35 lb-ft).
7. Install the exhaust bracket and the 2 bolts.
   • Tighten to 25 Nm (18 lb-ft).

   Vehicles equipped with 2.5L and hybrid 

8. Install the exhaust bracket and the 2 nuts.
   • Tighten to 36 Nm (27 lb-ft).

   Vehicles equipped with 3.0L 

9. Install the catalytic converter - 3.0L RH. For additional information, refer to EXHAUST SYSTEM article.

   Hybrid vehicles 

10. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM article.

    All vehicles 

11. Install the crossmember brace and the 4 bolts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 2: Locating Crossmember Brace Bolts

      Courtesy of FORD MOTOR CO.
12. Install the driveshaft. For additional information, refer to DRIVESHAFT article.
13. Install the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
14. Install the exhaust as required. For additional information, refer to EXHAUST SYSTEM article.
NOTE: The fluid level must be even with the bottom of the filler hole with the vehicle on flat, level ground.
Fig 3: Locating Fill Plug
Courtesy of FORD MOTOR CO.
15. Remove the fill plug and fill the PTU with specified lubricant.
16. Apply silicone sealant to the fill plug threads and install the plug.
    • Tighten to 34 Nm (25 lb-ft).
17. Check the transmission fluid level. For additional information, refer to Transmission Fluid Check under Preliminary Inspection in AUTOMATIC TRANSAXLE/TRANSMISSION - 6F35 article.