Output Shaft Seal: Installation

All vehicles 

1. Install the new collapsible spacer.
2. Using the PTU Drive Gear Outer Oil Seal Installer, install the output shaft seal.
Fig 1: Installing Output Shaft Seal Using Special Tool (308-430)
Courtesy of FORD MOTOR CO.
NOTE: Install the output pinion flange to engage the spline as previously marked
3. Install the output pinion flange.
CAUTION: Refer to the rotational torque previously recorded with the Nm (lb-in) torque wrench. Tighten the pinion nut in small increments until it is within 0.3 Nm (3 lb-in) of the reference measurement. If 0.3 Nm (3 lb-in) is exceeded, then the collapsible spacer will be damaged and a new collapsible spacer will be required.
4. Using the Drive Pinion Flange Holding Fixture to hold the output pinion flange, install and tighten the new pinion flange nut.
Fig 2: Holding Output Pinion Flange Using Special Tool (205-126)
Courtesy of FORD MOTOR CO.
5. Using the index mark, position the driveshaft and install the 4 driveshaft-to-PTU output flange bolts.
   • Tighten to 70 Nm (52 lb-ft).

GTDI vehicles 

6. Install the new LH and RH exhaust flexible pipe-to-underbody catalytic converter gaskets and nuts.
   • Tighten to 40 Nm (30 lb-ft).

All vehicles except GTDI 

7. Install the new exhaust Y-pipe-to-muffler and tail pipe flange gasket and nuts.
   • Tighten to 40 Nm (30 lb-ft).

All vehicles 

8. Fill the PTU as necessary. For additional information, refer to Power Transfer Unit (PTU) Draining and Filling  Power Transfer Unit (PTU) Draining and Filling.