Component Test
The PTU may leak different color fluids, red for automatic transmission fluid and brown/black gear lube for PTU fluid. The PTU seals prevent these types of fluids from leaking externally. It is important to note which color of fluid is leaking to determine the most appropriate service procedure.
NOTE:
Inspection of the seal's mating journal should be performed every time a seal is replaced. The mating part/journal should be replaced if it has any of the following conditions: Radial wear groove that can be felt by running a finger nail across it where seal lip runs. Scratches, pitting, galling, nicks or other shaft damage under or near where the seal lip runs. Discoloration or coked oil on the shaft where the seal lip runs. Shaft corrosion under or near where the seal lip runs. Sharp edges or burrs on the shaft lead in chamfer. NEVER use emery cloth on journal finishes, replace the part.
- Inspect the RH side of the PTU for leaks. If no leaks are found, GO to Step 2.NOTE: Remove and replace leaking seals using the information found in the Intermediate Shaft Seal and Deflector or Cover Seal replacement procedure in this information. The specified tools called out in this procedure allow seal replacement without causing damage to the PTU casing/drive gear.
- If the leak is red automatic transmission fluid, replace the PTU intermediate shaft seal located inside the bore of the PTU shaft, behind the deflector. REFER to Intermediate Shaft Seal and Deflector .
- If the leak is brown/black gear lube, replace the PTU larger cover seal located on the PTU cover, behind the deflector. REFER to Cover Seal .
Courtesy of FORD MOTOR CO.
Item Service Part Number Description 1 7H459 Intermediate shaft seal (part of kit 7H459) 2 7H459 Alignment washer (part of kit 7H459) 3 7H459 Cover seal (part of kit 7H459) 4 7H459 Seal deflector (part of kit 7H459) - Inspect the LH side of the PTU for leaks.
- If the leak is red automatic transmission fluid, replace the compression seal located between the PTU and transmission. REFER to Power Transfer Unit (PTU) .
- If the leak is brown/black and venting fluid from the top of the PTU, the PTU is overfilled due to the input shaft seals leaking red automatic transmission fluid into the PTU. Replace the input shaft seals, REFER to Input Shaft Seal .
Courtesy of FORD MOTOR CO.
Item Service Part Number Description 1 7086 PTU-to-transaxle compression seal 2 - Transfer case drive gear seal (7H469) 3 - Transfer case drive gear seal (7H469)