Output Shaft Seal: Installation

All vehicles 

1. Install the new collapsible spacer.
2. Install the bearing onto the output shaft.
3. Using the PTU Drive Gear Outer Oil Seal Installer, install the output shaft seal.
   Fig 1: Installing Output Shaft Seal Using PTU Drive Gear Outer Oil Seal Installer

   Courtesy of FORD MOTOR CO.
NOTE: Install the output pinion flange to engage the spline as previously marked.
4. Install the output pinion flange.
NOTE: Refer to the rotational torque previously recorded with the Nm (lb-in) torque wrench. Tighten the pinion nut in small increments until it is within 0.3 Nm (3 lb-in) of the reference measurement. If 0.3 Nm (3 lb-in) is exceeded, then the collapsible spacer will be damaged and a new collapsible spacer will be required.
Fig 2: Holding Output Pinion Flange Using Drive Pinion Flange Holding Fixture
Courtesy of FORD MOTOR CO.
5. Using the Drive Pinion Flange Holding Fixture to hold the output pinion flange, install and tighten the new pinion flange nut.
6. Using the index mark, position the driveshaft and install the 4 driveshaft-to-PTU output flange bolts.
   • Tighten to 70 Nm (52 lb-ft).

     GTDI vehicles 

7. Install the new LH and RH exhaust flexible pipe-to-underbody catalytic converter gaskets and nuts.
   • Tighten to 40 Nm (30 lb-ft).

     All vehicles except GTDI 

8. Install the new exhaust Y-pipe-to-muffler and tail pipe flange gasket and nuts.
   • Tighten to 40 Nm (30 lb-ft).

     All vehicles 

9. Fill the PTU as necessary. Refer to POWER TRANSFER UNIT (PTU) DRAINING AND FILLING .