Output Shaft Seal: Removal

WARNING: This page is about a different car, the 2007 Lincoln MKX and 2007 Ford Edge. However, it is still accessible from the selected car via links, so may be relevant.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
All vehicles except Gasoline Turbocharged Direct Injection (GTDI)
Remove the 2 exhaust Y-pipe-to-muffler and tail pipe flange nuts, refer to EXHAUST SYSTEM .
- Discard the nuts and gasket.

NOTE: The resonator must be supported to prevent damage to the flexible pipe.

Using a length of mechanic's wire, support the resonator.
- Using mechanic's wire, support the resonator.

GTDI All vehicles

Remove the 4 LH and RH exhaust flexible pipes-to-underbody catalytic converter nuts.
- Discard the nuts and gasket.

All vehicles

NOTE: Index-mark both the driveshaft flanges for installation.

Remove the 4 driveshaft-to-Power Transfer Unit (PTU) output flange bolts. Disconnect the driveshaft from the PTU and position it aside.
- Using mechanic's wire, support the driveshaft.

NOTE: Rotational torque of the PTU rear output shaft flange must be measured and recorded using a Nm (lb-in) torque wrench for correct pinion bearing preload when reassembled. This will be the torque-to-turn measurement.

Using a suitable torque wrench, measure and record the rotational torque of the PTU output shaft.

Fig 1: Measuring Rotational Torque Using A Suitable Torque Wrench

Courtesy of FORD MOTOR CO.

Using the Drive Pinion Flange Holding Fixture, hold the output pinion flange. Remove and discard the pinion nut.

Fig 2: Holding Output Pinion Flange Using Special Tool (205-126)

Courtesy of FORD MOTOR CO.

NOTE: Index-mark the output pinion flange to the pinion shaft.

Using the Output Flange Remover, remove the output pinion flange.

Fig 3: Removing Output Pinion Flange Using Special Tool (307-523)

Courtesy of FORD MOTOR CO.

Remove and discard the output shaft seal.
Remove and discard the collapsible spacer.