Transfer Case Vent: Installation

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

Inspect the condition of the PTU vent hole.
- By hand, insert the new PTU vent into the PTU cover and measure the distance between the PTU cover and the vent as indicated.
- If the measurement is less than specification, install a new PTU.
  
  Fig 1: Identifying Distance Between PTU Cover And Vent
  Courtesy of FORD MOTOR CO.

CAUTION: Do not apply silicone sealant to the power transfer unit (PTU) vent hole as it may cause damage to the PTU internal components.

Fig 2: Locating Areas For Applying Bead Of Silicone Gasket And Sealant To PTU Vent

Courtesy of FORD MOTOR CO.

Apply a bead of silicone gasket and sealant to the PTU vent where indicated.

NOTE: Drive the PTU vent in until the special tool bottoms out against the PTU rear cover boss.

Fig 3: Identifying Special Tool

Courtesy of FORD MOTOR CO.

Using the special tool, install the PTU vent.
Measure the depth of the PTU vent.
- If the vent is too high, repeat Step 3.
  
  Fig 4: Identifying Depth Of PTU Vent
  Courtesy of FORD MOTOR CO.

CAUTION: Make sure the power transfer unit (PTU) vent boot is correctly aligned.

NOTE: Use a soapy water solution to lubricate the PTU breather boot.

Fig 5: Identifying Power Transfer Unit (PTU) Vent Boot Correctly Aligned Position

Courtesy of FORD MOTOR CO.

Install the PTU vent boot.
Install the PTU. For additional information, refer to POWER TRANSFER UNIT (PTU) - MANUAL TRANSAXLE in the Installation portion of this article.