Intermediate Shaft Seal and Deflector: Installation

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.

NOTE: The following illustration shows the correct orientation of the seal components when installed in the vehicle.

Fig 1: Identifying Correct Orientation Of Seal Components

Courtesy of FORD MOTOR CO.

ITEM DESCRIPTION TABLE

Item	Description
1	Intermediate shaft seal (part of 7275 kit) - retains red Automatic Transmission Fluid (ATF) used in the transaxle
2	Alignment washer (part of 7275 kit) - supports and centers the intermediate shaft in the seal
3	Seal deflector (part of 7275 kit) - keeps dust/dirt away from the intermediate shaft seal and Power Transfer Unit (PTU) input shaft seal
4	Seal protector (part of 7275 kit) - protects intermediate shaft seal from damage by the intermediate shaft splines during installation. Must be removed before shaft is fully installed

Place the intermediate shaft seal on the PTU Linkshaft Seal Installer and Driver Handle with the spring side facing away from the tool.

Fig 2: Locating Intermediate Shaft Seal & PTU Linkshaft Seal Installer
Courtesy of FORD MOTOR CO.
Using the PTU Linkshaft Seal Installer and Driver Handle, install the intermediate shaft seal.

Fig 3: Installing Intermediate Shaft Seal Using PTU Linkshaft Seal Installer & Driver Handle
Courtesy of FORD MOTOR CO.
Place the alignment washer on the PTU Linkshaft Seal Installer and Driver Handle with the beveled edge (white-striped side) facing towards the tool.

Fig 4: Placing PTU Linkshaft Seal Installer & Driver Handle With Beveled Edge
Courtesy of FORD MOTOR CO.
Using the PTU Linkshaft Seal Installer and Driver Handle, install the alignment washer by hand, pushing it in until it bottoms against the seal.
- When installed, the white-striped side should be facing out.
NOTE: Do not use force when installing the alignment washer or damage to the washer can occur.

Fig 5: Installing Alignment Washer Using PTU Linkshaft Seal Installer & Driver Handle
Courtesy of FORD MOTOR CO.
Position the deflector on the PTU Linkshaft Seal Dust Shield Installer using silicone brake caliper grease and dielectric compound to retain it to the installer. Using a suitable heat gun, heat the deflector 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 100°C (212°F).
- 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.
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: Apply a small amount of silicone brake caliper grease and dielectric compound to the inner lip of the deflector where it installs on the tube inside the PTU before heating. This will ease the installation of the deflector.

Fig 6: Identifying Special Tools (205-907) & (205-882)
Courtesy of FORD MOTOR CO.
Using a 5-pound or larger dead blow hammer, install the seal deflector immediately after heating using the PTU Linkshaft Seal Dust Shield Installer and Driver Handle.

Fig 7: Identifying PTU Linkshaft Seal Dust Shield Installer And Driver Handle
Courtesy of FORD MOTOR CO.
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.

Fig 8: Locating Deflector Position
Courtesy of FORD MOTOR CO.
Once the deflector is fully seated, insert the seal protector into the PTU deflector ID.

Fig 9: Inserting Seal Protector Into PTU Deflector ID
Courtesy of FORD MOTOR CO.
Apply a thin coat of silicone brake caliper grease and dielectric compound to the intermediate shaft seal journal.
Partially install the intermediate and halfshaft assembly through the PTU deflector until the splines have cleared the seal protector. Pull the seal protector out of the deflector and off of the intermediate shaft. Complete the installation of the intermediate and halfshaft assembly.
NOTE: A slight effort may be required to fully seat the intermediate and halfshaft assembly as it passes through the alignment washer.

Fig 10: Installing Intermediate & Halfshaft Assembly Through Deflector
Courtesy of FORD MOTOR CO.
Fully install the intermediate and halfshaft assembly and the 2 bolts.
- Tighten to 40 Nm (30 lb-ft).
Fig 11: Installing Intermediate & Halfshaft Assembly
Courtesy of FORD MOTOR CO.
Using metal brake parts cleaner, thoroughly clean the deflector and intermediate shaft area of any residual fluid that may have accumulated during the repair.
NOTE: A significant amount of residual fluid will collect between the seal and deflector during this repair. This is a normal condition and should not be misinterpreted as a leak after the repair is complete.

Fig 12: Locating Intermediate Shaft Bolts
Courtesy of FORD MOTOR CO.
Top off the transmission fluid as necessary.