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Power Transfer Unit (PTU) - Overhaul

WARNING: This page is about a different car, the 2016 Lincoln MKS. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S)

GFD89054Courtesy of FORD MOTOR COMPANY
 Slide Hammer 100-001
GFD88888Courtesy of FORD MOTOR COMPANY
 Holding Fixture, Drive Pinion Flange 205-126
GFD88889Courtesy of FORD MOTOR COMPANY
 Handle 205-153
GFD88890Courtesy of FORD MOTOR COMPANY
 Remover, Halfshaft 205-241
GFD88891Courtesy of FORD MOTOR COMPANY
 Installer, Front Axle Bushing
GFD88892Courtesy of FORD MOTOR COMPANY
 Installer, PTU Linkshaft Seal
GFD88893Courtesy of FORD MOTOR COMPANY
 Installer, Parking Brake Bearing 206-040
GFD88894Courtesy of FORD MOTOR COMPANY
 Holding Fixture, Transmission 307-003
GFD88896Courtesy of FORD MOTOR COMPANY
 Remover, Output Flange 307-523
GFD88897Courtesy of FORD MOTOR COMPANY
 Remover, Transfer Case Bearing 308-125
GFD88898Courtesy of FORD MOTOR COMPANY
 Installer, Shaft Bearing Cup
GFD88899Courtesy of FORD MOTOR COMPANY
 Installer, PTO Drive Gear Outer Oil Seal
GFD88900Courtesy of FORD MOTOR COMPANY
 Installer, Halfshaft Oil Seal
GFD89055Courtesy of FORD MOTOR COMPANY
 Remover and Installer, PTU Input Shaft Seal
GENERAL EQUIPMENT

Flat-Bladed Screwdriver
Slide Hammer
Slide Hammer Dent Puller
Spatula
MATERIAL

Item Specification
Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound XG-3-A ESE-M1C171-A
Motorcraft® SAE 75W-140 Synthetic Rear Axle Lubricant XY-75W140-QL (US); CXY-75W140-1L (Canada) WSL-M2C192-A and GL-5
Ultra Silicone Sealant TA-29 -

All Vehicles 

  1. 1.

    Remove the PTU (Power Transfer Unit). Refer to POWER TRANSFER UNIT (PTU) - 3.7L , or POWER TRANSFER UNIT (PTU) - 3.5L GTDI .

  1. 2.

    Using the special tool, secure the PTU (Power Transfer Unit) to the bench.

    Special Tool: 307-003 Holding Fixture, Transmission

GFD88902Courtesy of FORD MOTOR COMPANY

  1. 3.

    Inspect the case exterior for cracks.
GFD88903Courtesy of FORD MOTOR COMPANY

  1. 4.

    Remove the temperature sensor clip bracket.
GFD88904Courtesy of FORD MOTOR COMPANY

  1. 5.

    NOTE: The following instruction will prevent the 308-125 (T87P-7120-D) from opening too far which would make removing the intermediate shaft seal deflector difficult.

    Place a 16mm (5/8 in) washer on the special tool as shown in illustration.

    Special Tool: 308-125 Remover, Transfer Case Bearing

GFD88905Courtesy of FORD MOTOR COMPANY

  1. 6.

    NOTE: The intermediate shaft seal deflector may break when removed. Remove all foreign materials from the PTU before continuing with the repair.

    Using the special tools, remove and discard the halfshaft deflector.

    Special Tool: 205-241 Remover, Halfshaft

    Special Tool: 308-125 Remover, Transfer Case Bearing

    Equipment: Slide Hammer

GFD88906Courtesy of FORD MOTOR COMPANY

  1. 7.

    Using the special tool, remove and discard the halfshaft intermediate shaft seal and alignment washer.

    Special Tool: 205-241 Remover, Halfshaft

    Special Tool: 308-125 Remover, Transfer Case Bearing

    Equipment: Slide Hammer

GFD88907Courtesy of FORD MOTOR COMPANY

  1. 8.

    Using the special tools, remove and discard the RH cover seal.

    Special Tool: 205-241 Remover, Halfshaft

    Equipment: Slide Hammer

GFD88908Courtesy of FORD MOTOR COMPANY

  1. 9.

    Remove and discard the compression seal.

    Special Tool: 205-241 Remover, Halfshaft

    Equipment: Slide Hammer

GFD88909Courtesy of FORD MOTOR COMPANY

  1. 10.

    NOTE: Do not press the seals lower than specified. Excessive force will damage the bearing below the seals.
    NOTE: Both seals will need to be pressed lower into the transfer case input shaft opening to break the seals outer sealant loose from the transfer case.
    NOTE: There is approximately a 5 mm (0.196 in) air gap between both seals and approximately 1 mm (0.039 in) air gap between the inner seal and the bearing race.

    Using the special tool, press the outer seal downward until the lower seal contacts the bearing race.

    Special Tool: 206-040 Installer, Parking Brake Bearing

GFD88910Courtesy of FORD MOTOR COMPANY

  1. 11.

    Position the special tool above the PTU input shaft opening.

    Special Tool: 308-777 Remover and Installer, PTU Input Shaft Seal

GFD88911Courtesy of FORD MOTOR COMPANY

  1. 12.

    Insert the special tool into one of the screw guide holes. Press the special tool downward until the shoulder of the punch touches the screw guide.

    Special Tool: 308-777 Remover and Installer, PTU Input Shaft Seal

GFD88912Courtesy of FORD MOTOR COMPANY

  1. 13.

    NOTE: Do not overtighten the screws. Turn the 308-777 /3 until they are seated into the screw guide holes.

    Install the special tool into the screw guide hole.

    Special Tool: 308-777 Remover and Installer, PTU Input Shaft Seal

GFD88913Courtesy of FORD MOTOR COMPANY

  1. 14.

    Insert the special tool into the opposing screw guide hole. Press the special tool downward until the shoulder of the punch touches the screw guide.

    Special Tool: 308-777 Remover and Installer, PTU Input Shaft Seal

GFD88914Courtesy of FORD MOTOR COMPANY

  1. 15.

    Install the special tool into the screw guide hole.

    Special Tool: 308-777 Remover and Installer, PTU Input Shaft Seal

GFD88915Courtesy of FORD MOTOR COMPANY

  1. 16.

    Using the special tools, remove and discard the 2 input shaft seals.

    Special Tool: 308-777 Remover and Installer, PTU Input Shaft Seal

    Special Tool: 100-001 Slide Hammer

GFD88916Courtesy of FORD MOTOR COMPANY

Vehicles without PTU cooler 

  1. 17.

    Remove the PTU temperature sensor heat shield bolts and the heat shield.
GFD88917Courtesy of FORD MOTOR COMPANY

  1. 18.

    Remove the PTU temperature sensor and the temperature sensor wiring retainer clip.
GFD88918Courtesy of FORD MOTOR COMPANY

  1. 19.

    Remove the drain plug.
GFD88919Courtesy of FORD MOTOR COMPANY

  1. 20.

    Remove the fill plug.
GFD88920Courtesy of FORD MOTOR COMPANY

Vehicles with PTU cooler 

  1. 21.

    Remove the PTU temperature sensor heat shield bolts and the heat shield.
GFD88921Courtesy of FORD MOTOR COMPANY

  1. 22.

    If equipped with PTU cooling, remove the PTU temperature sensor.
GFD88922Courtesy of FORD MOTOR COMPANY

  1. 23.

    If equipped with PTU cooling, remove the PTU cooler housing bolts and PTU cooler housing.
GFD88923Courtesy of FORD MOTOR COMPANY

  1. 24.

    If equipped with PTU cooling, remove the PTU cooler housing gasket and discard.
GFD88924Courtesy of FORD MOTOR COMPANY

All Vehicles 

  1. 25.

    Remove the PTU cover bolts.
GFD88925Courtesy of FORD MOTOR COMPANY
WARNING: When removing the PTU cover, the fluid may emit a sulfur odor. Perform the repair in a well ventilated area to reduce exposure. Avoid getting the fluid on clothes and skin. Wear protective gloves such as Nitrile.

  1. 26.

    Remove the PTU cover.

    Equipment: Flat-Bladed Screwdriver

GFD88926Courtesy of FORD MOTOR COMPANY

  1. 27.

    Remove the ring gear assembly.
GFD88927Courtesy of FORD MOTOR COMPANY

  1. 28.

    Remove the idler gear shaft and the idler gear assembly
GFD89056Courtesy of FORD MOTOR COMPANY
NOTE: The position of the idler gear thrust washer

  1. 29.

    Remove and discard the washer.
GFD88929Courtesy of FORD MOTOR COMPANY

  1. 30.

    Remove the input gear assembly.
GFD88930Courtesy of FORD MOTOR COMPANY

  1. 31.

    Index mark the output pinion flange to the pinion shaft.
GFD88931Courtesy of FORD MOTOR COMPANY

  1. 32.

    Using the special tool, hold the output pinion flange. Remove and discard the pinion nut.

    Special Tool: 205-126 Holding Fixture, Drive Pinion Flange

GFD88932Courtesy of FORD MOTOR COMPANY

  1. 33.

    Using the special tool, remove the output pinion flange.

    Special Tool: 307-523 Remover, Output Flange

GFD88933Courtesy of FORD MOTOR COMPANY

  1. 34.

    Remove and discard the output shaft seal.
GFD88934Courtesy of FORD MOTOR COMPANY

  1. 35.

    Remove the oil slinger.
GFD88935Courtesy of FORD MOTOR COMPANY

  1. 36.

    Remove the outer pinion bearing.
GFD88936Courtesy of FORD MOTOR COMPANY

  1. 37.

    Remove and discard the collapsible spacer.
GFD88937Courtesy of FORD MOTOR COMPANY

  1. 38.

    Remove the pinion gear.
GFD88938Courtesy of FORD MOTOR COMPANY

  1. 39.

    Inspect the PTU ring gears and bearing for damage. INSTALL a new PTU if damage is present.
GFD88939Courtesy of FORD MOTOR COMPANY

  1. 40.

    Inspect the PTU input gear and bearings for damage. INSTALL a new PTU if damage is present.
GFD88940Courtesy of FORD MOTOR COMPANY

  1. 41.

    Inspect the PTU pinion gear and bearing for damage. INSTALL a new PTU if damage is present.
GFD88941Courtesy of FORD MOTOR COMPANY

  1. 42.

    Inspect the PTU idler gear and bearing for damage. Replace as necessary.
GFD89057Courtesy of FORD MOTOR COMPANY

  1. 43.

    Inspect the PTU idler gear shaft for damage. Replace as necessary.
GFD89058Courtesy of FORD MOTOR COMPANY

  1. 44.

    Inspect the PTU bearing races and thrust surface for damage. INSTALL a new PTU if damage is present.
GFD88942Courtesy of FORD MOTOR COMPANY

  1. 45.

    Inspect the PTU outer pinion bearing race for damage. INSTALL a new PTU if damage is present.
GFD88943Courtesy of FORD MOTOR COMPANY

  1. 46.

    Inspect the PTU cover bearing and bearing race for damage. INSTALL a new PTU if damage is present.
GFD88944Courtesy of FORD MOTOR COMPANY

  1. 47.

    Thoroughly clean the internal components. Use a soft bristle brush to remove contamination and deposits. Allow parts to air dry. Inspect the components for damage, replace as necessary.
GFD89059Courtesy of FORD MOTOR COMPANY

  1. 48.

    Remove the contamination and deposits from the PTU housing and cover using a plastic scraper. Clean the PTU housing and cover using a soft bristle brush to remove the contamination. Clean any remaining lip seal coating that may still be present on the housing or cover bores with a wire brush. Make sure the vent fitting and housing pockets are clean and clear.
GFD88947Courtesy of FORD MOTOR COMPANY

  1. 49.

    Clean the PTU case and cover flange sealing surfaces. Engine System - General Information .
GFD88950Courtesy of FORD MOTOR COMPANY

  1. 50.

    To begin assembly, lightly coat the output shaft bearings in clean axle lubricant. Install the PTU output shaft into the PTU case.

    Material: Gear/Transmission Fluid - SAE 75W-140 WSL-M2C192-A

GFD88951Courtesy of FORD MOTOR COMPANY

  1. 51.

    Install the new collapsible spacer.
GFD88952Courtesy of FORD MOTOR COMPANY

  1. 52.

    Lightly coat with clean axle lubricant and install the outer pinion bearing.

    Material: Gear/Transmission Fluid - SAE 75W-140 WSL-M2C192-A

GFD88953Courtesy of FORD MOTOR COMPANY

  1. 53.

    Install the oil slinger.
GFD88935Courtesy of FORD MOTOR COMPANY

  1. 54.

    Using the special tool, install the output shaft seal.

    Special Tool: 308-430 Installer, PTO Drive Gear Outer Oil Seal

GFD88954Courtesy of FORD MOTOR COMPANY

  1. 55.

    NOTE: Install a new output pinion flange and deflector if the output shaft seal mating surface is damaged.

    Inspect the output pinion flange and deflector for damage, replace as necessary.

GFD88955Courtesy of FORD MOTOR COMPANY

  1. 56.

    NOTE: Install the output pinion flange to engage the spline as previously marked.

    Install the output pinion flange.

GFD88956Courtesy of FORD MOTOR COMPANY

  1. 57.

    Using the special tool to hold the output pinion flange, install a new pinion flange nut.

    Special Tool: 205-126 Holding Fixture, Drive Pinion Flange

    Torque: 142 Nm

GFD88957Courtesy of FORD MOTOR COMPANY

  1. 58.

    Lightly coat the input shaft bearings and gear with clean axle lubricant. Install the input shaft into the PTU case.

    Material: Gear/Transmission Fluid - SAE 75W-140 WSL-M2C192-A

GFD88958Courtesy of FORD MOTOR COMPANY

  1. 59.

    NOTE: The kit may include a subassembly of the idler gear, bearings, shaft and thrust washer retained by a plastic ring. Remove and discard the ring.

    Lightly coat the idler gear, bearings, shaft and thrust washer with clean axle lubricant. Insert the 2 new idler bearings in the idler gear bore (no orientation required). Insert the new idler shaft through bearings. Coat the thrust face in the PTU case with clean axle lubricant and install the idler gear subassembly.

    Material: Gear/Transmission Fluid - SAE 75W-140 WSL-M2C192-A

GFD88959Courtesy of FORD MOTOR COMPANY

  1. 60.

    Lightly coat the ring gear shaft and bearings with clean axle lubricant. Install the ring gear shaft into the PTU case.

    Material: Gear/Transmission Fluid - SAE 75W-140 WSL-M2C192-A

GFD88960Courtesy of FORD MOTOR COMPANY

  1. 61.

    Orient the idler shaft "D" by lightly fitting the cover over it and rotating to the correct position. Remove the cover.
GFD88961Courtesy of FORD MOTOR COMPANY

  1. 62.

    Make sure that the mating faces are clean and free of foreign material. Engine System - General Information .
GFD88962Courtesy of FORD MOTOR COMPANY

  1. 63.

    NOTE: If the PTU cover is not installed within 10 minutes of application of the silicone, new sealant must be applied.

    Apply a continuous 3-4mm bead of sealant to the inside of the cover flange surface. Make sure there are no gaps in the sealer. Allow to set for 5-10 minutes before installing the cover.

    Material: Silicone Sealant -

GFD88963Courtesy of FORD MOTOR COMPANY

  1. 64.

    Noting the two dowels and the idler gear shaft orientation, carefully install cover and hand start the bolts. Tighten the bolts in 2 stages per sequence shown in illustration.

    Torque:

    Stage 1: 37 Nm

    Stage 2: 47 Nm

Fig 1: Cover Bolts Tightening Sequence
GFD88964Courtesy of FORD MOTOR COMPANY

  1. 65.

    NOTE: Position the inner seal above the PTU input shaft opening with the spring facing toward the PTU.

    Using the special tools, install the seal.

    Special Tool: 205-153 Handle

    Special Tool: 308-777 Remover and Installer, PTU Input Shaft Seal

GFD88965Courtesy of FORD MOTOR COMPANY

  1. 66.

    NOTE: Position the outer seal above the PTU input shaft opening with the spring facing away from the PTU.

    Using the special tools, install the seal.

    Special Tool: 205-153 Handle

    Special Tool: 308-777 Remover and Installer, PTU Input Shaft Seal

GFD88966Courtesy of FORD MOTOR COMPANY

  1. 67.

    Install the new compression seal.

    Special Tool: 205-153 Handle

    Special Tool: 308-777 Remover and Installer, PTU Input Shaft Seal

GFD88966Courtesy of FORD MOTOR COMPANY

  1. 68.

    Special Tool: 308-777 Remover and Installer, PTU Input Shaft Seal cover seal.

    Special Tool: 308-221

    Installer, Shaft Bearing Cup

    Special Tool: 308-431

    Installer, Halfshaft Oil Seal

    Special Tool: 205-153 Handle

GFD88967Courtesy of FORD MOTOR COMPANY

  1. 69.

    Place the intermediate shaft seal on the special tools with the spring side facing away from the tool.

    Special Tool: 205-153 Handle

    Special Tool: 205-883 Installer, PTU Linkshaft Seal

GFD88968Courtesy of FORD MOTOR COMPANY

  1. 70.

    Using the special tools, install the intermediate shaft seal.

    Special Tool: 205-153 Handle

    Special Tool: 205-883 Installer, PTU Linkshaft Seal

GFD88969Courtesy of FORD MOTOR COMPANY

  1. 71.

    Place the alignment washer on the special tool.

    Special Tool: 205-153 Handle

    Special Tool: 205-883 Installer, PTU Linkshaft Seal

GFD88970Courtesy of FORD MOTOR COMPANY

  1. 72.

    NOTE: Do not use force when installing the alignment washer or damage to the washer can occur.

    Using the special tool, install the alignment washer by hand, pushing it in until it bottoms against the seal.

    Special Tool: 205-153 Handle

    Special Tool: 205-883 Installer, PTU Linkshaft Seal

GFD88971Courtesy of FORD MOTOR COMPANY

  1. 73.

    NOTE: Do not overheat (melt) the seal deflector. Monitor the temperature of the deflector with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating. Do not allow the temperature to exceed 100°C (212°F). Overheating will damage the deflector. If the deflector is damaged, a new deflector must be used.
    NOTE: 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.

    Position the deflector on the special tool 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).

    Special Tool: 205-346 Installer, Front Axle Bushing

    Special Tool: 205-153 Handle

    Material: Grease - Silicone ESE-M1C171-A

GFD88972Courtesy of FORD MOTOR COMPANY

  1. 74.

    Using the special tools, install the intermediate shaft deflector.

    Special Tool: 205-346 Installer, Front Axle Bushing

    Special Tool: 205-153 Handle

GFD88973Courtesy of FORD MOTOR COMPANY

  1. 75.

    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.
GFD88974Courtesy of FORD MOTOR COMPANY

  1. 76.

    Install the PTU drain plug.

    Torque: 12 Nm

GFD88919Courtesy of FORD MOTOR COMPANY

Vehicles with PTU cooler 

  1. 77.

    Install the PTU cooler housing gasket.
GFD88975Courtesy of FORD MOTOR COMPANY

  1. 78.

    Clean the PTU cooler housing.
GFD88976Courtesy of FORD MOTOR COMPANY

  1. 79.

    Install the PTU cooler housing and the PTU cooler housing bolts. The PTU temperature sensor, heat shield and bolts will be installed after the fluid fill.

    Torque: 12 Nm

GFD88923Courtesy of FORD MOTOR COMPANY

Vehicles without PTU cooler 

  1. 80.

    NOTE: Install a new O-ring before installing the PTU temperature sensor.

    Using a new O-ring, install the PTU temperature sensor and the temperature sensor wiring retainer clip.

    Torque: 14 Nm

GFD88918Courtesy of FORD MOTOR COMPANY

  1. 81.

    Install the PTU temperature sensor heat shield and the bolts.

    Torque: 12 Nm

GFD88917Courtesy of FORD MOTOR COMPANY

All Vehicles 

  1. 82.

    Install the temperature sensor clip bracket.

    Torque: 10 Nm

GFD88904Courtesy of FORD MOTOR COMPANY

  1. 83.

    Install the PTU. Refer to POWER TRANSFER UNIT (PTU) - 3.7L , or POWER TRANSFER UNIT (PTU) - 3.5L GTDI . .
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