Power Transfer Unit (PTU)

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. 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 & LIFTING
Remove the LH and RH front half shafts. For additional information, refer to FRONT DRIVE HALFSHAFTS .
Remove the 2 front exhaust pipe nuts.

Fig 1: Locating Front Exhaust Pipe Nuts
Courtesy of FORD MOTOR CO.
Remove the 2 front exhaust pipe studs.
Remove the 2 rear exhaust pipe nuts.

Fig 2: Identifying Nuts For Rear Exhaust Pipe
Courtesy of FORD MOTOR CO.
Remove the 2 catalytic converter pipe bolts, disconnect the rubber hanger and remove the pipe.

Fig 3: Identifying Nuts For Catalytic Converter Pipe
Courtesy of FORD MOTOR CO.

NOTE: To maintain the initial driveshaft balance, index-mark the driveshaft flange and the output flange.

Index-mark the driveshaft.
Remove the 2 outer driveshaft brace bolts.

Fig 4: Identifying Driveshaft Cross Brace Mounting Bolts
Courtesy of FORD MOTOR CO.
Remove the 6 driveshaft flange bolts from the front driveshaft flange.

Fig 5: Locating Driveshaft Flange Bolts
Courtesy of FORD MOTOR CO.
Remove the upper power transfer unit (PTU) bracket bolts and the bracket, if equipped.

Fig 6: Removing Upper Power Transfer Unit Bracket Bolts
Courtesy of FORD MOTOR CO.

NOTE: Do not rotate the PTU with the vent cap and filter pointing downward. This will prevent damage to the vent filter.

Remove the 4 PTU bolts and the PTU.