Power Transfer Unit

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING

1. NOTE: This step is only necessary when installing a new component.

   If equipped, install the PTU temperature sensor harness bracket.

   Torque

   : 11 Nm

   Courtesy of FORD MOTOR COMPANY

2. Install the new PTU to transmission compression seal.

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3. Install the PTU and mounting bolts.

   Torque

   : 103 Nm

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4. Install the PTU support bracket and bolts.

   Torque

   : 48 Nm

   Courtesy of FORD MOTOR COMPANY

5. Install the intermediate shaft. Refer to: Intermediate Shaft .
6. Clean and inspect the inboard end of the halfshaft.

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7. Install the O-Ring and circlip on the intermediate shaft.

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8. Install the RH halfshaft on the intermediate shaft.

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9. Install the vent hose retainer.

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10. Connect the PTU vent hose.

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11. Install the coolant pump and hoses. Install the pump mounting nuts.

    Torque

    : 9 Nm

    Courtesy of FORD MOTOR COMPANY

12. Install the PTU cooling system hoses and connect the hose clamps. Remove the hose clamp pliers.

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13. If equipped, connect the PTU temperature sensor and install retainers.

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14. Connect the PTU motor connectors.

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15. Connect the auxillary pump connector and retainers.

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16. Install the PTU heat shield and PTU heat shield bolts.

    Torque

    : 11 Nm

    Courtesy of FORD MOTOR COMPANY

17. NOTE: Make sure that new components are installed.

    Install new studs and gasket.

    Torque

    : 25 Nm

    Courtesy of FORD MOTOR COMPANY

18. NOTE: Only tighten the bolts finger tight at this stage.

    Position back the catalytic converter in the vehicle. Loosely install the catalytic converter mount bracket bolts.

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19. Install the catalytic converter to turbo flange nuts.

    Torque

    : 48 Nm

    Courtesy of FORD MOTOR COMPANY

20. Tighten the catalytic converter mount bracket bolts.

    Torque

    :Bolts: 30 NmThrough bolt: 48 Nm

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21. NOTE: Make sure that the installation marks are aligned.

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22. Install new PTU flange bolts.

    Torque

    : 35 Nm

    Courtesy of FORD MOTOR COMPANY

23. Connect the catalyst monitor sensor.

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24. Connect the HO2S.

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25. Install the RHCAC intake pipe. Refer to: Charge Air Cooler (CAC) Intake Pipe .
26. Install the RH air cleaner outlet pipe. Refer to: AIR CLEANER OUTLET PIPE RH .
27. Install the engine appearance cover.

    Torque

    :Nut: 4. 8 NmBolt: 10. 5 Nm

    Courtesy of FORD MOTOR COMPANY

28. Check PTU fluid level and adjust as necessary. Refer to: Power Transfer Unit Fluid Level Check .
29. Install the front subframe. Refer to: Front Subframe .
30. Check the engine coolant level and adjust as necessary. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
31. Check the transmission fluid level and adjust as necessary. Refer to: Transmission Fluid Level Check .