Analysis of Leakage

WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

The PTU may leak different color fluids, red oil leak for automatic transmission fluid and brown/black gear lube for PTU fluid. The PTU seals prevent these types of fluids from leaking. It is important to note which color of fluid is leaking to determine the most appropriate service procedure.

PTU Leaks From the RH Side

NOTE: Remove and replace leaking seals using the information found in the Intermediate Shaft Seal and Deflector or Cover Seal . The specified tools called out in this procedure will allow seal replacement without causing damage to the Power Transfer Unit (PTU) casing/drive gear.

If the leak is red automatic transmission fluid, this indicates the differential seals in the transaxle are also leaking and need to be replaced along with the intermediate shaft seal. Refer to DIFFERENTIAL SEALS -- LH , DIFFERENTIAL SEALS -- RH, FRONT WHEEL DRIVE (FWD) and/or DIFFERENTIAL SEALS -- RH, ALL WHEEL DRIVE (AWD) (3.5L with Aisin AWF21 only) to replace the differential seals before replacing the intermediate shaft seal. Refer to the Removal procedure to replace the intermediate seal.

If the leak is brown/black gear lube, then the PTU larger cover seal needs replacement. This is located on the PTU cover behind the deflector. Refer to the Removal procedure.

Fig 1: Identifying Intermediate Shaft Seal, Alignment Washer, Cover Seal & Seal Deflector

Courtesy of FORD MOTOR CO.

ITEM DESCRIPTION TABLE

Item	Description
1	Intermediate shaft seal (part of kit 7275)
2	Alignment washer (part of kit 7275)
3	Cover seal (part of kit 7275)
4	Seal deflector (part of kit 7275)

PTU Leaks From the LH Side

If the leak is red automatic transmission fluid, the compression seal needs replacement. This is between the PTU and transmission. Refer to Power Transfer Unit (PTU) .

If the leak is brown/black gear lube, the PTU is overfilled and venting fluid from the top of the PTU. Flush and fill the PTU. Refer to POWER TRANSFER UNIT (PTU) DRAINING AND FILLING .

Fig 2: Identifying Power Transfer Unit (PTU)-To-Transaxle Compression Seal & Transfer Case Driver Gear Seal

Courtesy of FORD MOTOR CO.

ITEM DESCRIPTION TABLE

Item	Description
1	Power Transfer Unit (PTU)-to-transaxle compression seal (7086)
2	Transfer case driver gear seal (not serviceable)
3	Transfer case driver gear seal (not serviceable)