Intermediate Shaft Seal Deflector: Removal

WARNING: This page is about a different car, the 2011 Mercury Milan and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: This procedure is to be performed through the RH wheel opening. It is not necessary to remove the exhaust components to complete this repair.

Remove the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.

NOTE: The following instruction will prevent the Transfer Case Bearing Cup Remover from opening too far which would make removing the intermediate shaft seal deflector difficult.

Fig 1: Identifying Special Tool (308-125) And Washer

Courtesy of FORD MOTOR CO.

NOTE: Failure to utilize the recommended tools may result in serious damage to the Power Transfer Unit (PTU).

Place a 16 mm (5/8 in) washer between the components of the Transfer Case Bearing Cup Remover as shown in the illustration.

Assemble the special tools as indicated in the following table and illustration:

Fig 2: Special Tools Assembling Sequence

Courtesy of FORD MOTOR CO.

ITEM DESCRIPTION

Item	Description
1	308-125
2	Extension from 205-241
3	100-D112 Slide Hammer Master Set

NOTE: Using a Slide Hammer Master Set eases the removal of the seal deflector.

Using the Bearing Cup Remover, the extension from the Halfshaft Remover and a suitable slide hammer, remove the seal deflector.
- The seal deflector will have been damaged during removal. Remove all foreign material from the PTU before continuing with the repair.
  
  Fig 3: Removing Seal Deflector Using Special Tools
  Courtesy of FORD MOTOR CO.