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Home >> Ford >> 2000 >> Taurus LX, 3.0 2, AX4N >> Repair and Diagnosis >> External Pages >> Different car >> Section 1380 (Transfer Case - Power Transfer Unit (PTU)) >> In-Vehicle Repair >> Intermediate Shaft Seal and Deflector >> Removal

Intermediate Shaft Seal and Deflector: Removal

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: For High Resolution: A video version of this procedure is available on-line.
NOTE: For Low Resolution: A video version of this procedure is available on-line.
NOTE: The Power Transfer Unit (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 fluid is leaking to determine the most appropriate service procedure. This procedure will correct a red oil leak (automatic transmission fluid) from the intermediate shaft seal on the RH side of the PTU. If the leak is red automatic transmission fluid, this indicates that 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 transaxle only) to replace the differential seals before replacing the intermediate shaft seal. For additional information, refer to ANALYSIS OF LEAKAGE .
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.
  1. Remove the intermediate shaft. For additional information, refer to REMOVAL (FWD) and/or REMOVAL (AWD) .
  2. Place a 16 mm (5/8 in) washer between the components of the Bearing Cup Remover as shown in illustration.
    NOTE: The following instruction will prevent the Bearing Cup Remover from opening too far which would make removing the intermediate shaft seal deflector difficult.
    Fig 1: Identifying Bearing Cup Remover
    G06064402Courtesy of FORD MOTOR CO.
    NOTE: Failure to utilize the recommended tools may result in serious damage to the Power Transfer Unit (PTU).
  3. Assemble the special tools as indicated in the following table and illustration:
    ITEM DESCRIPTION TABLE

    Item Description
    1 308-125
    2 Extension from 205-241
    3 5-pound or larger slide hammer
    Fig 2: Identifying Special Tools (308-125) & (205-241)
    G06064403Courtesy of FORD MOTOR CO.
  4. 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.
    NOTE: Using a 5-pound or larger slide hammer eases the removal of the seal deflector.
    Fig 3: Identifying Bearing Cup Remover And Halfshaft Remover
    G06064404Courtesy of FORD MOTOR CO.
  5. Using the Bearing Cup Remover, the extension from the Halfshaft Remover and a suitable slide hammer, remove the intermediate shaft seal, and if equipped, the alignment washer.
    Fig 4: Identifying Bearing Cup Remover And Halfshaft Remover
    G06064405Courtesy of FORD MOTOR CO.
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