Analysis of Leakage

WARNING: This page is about a different variant/trim than selected.

The PTU may leak different color fluids, red oil leak for an 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 of fluid is leaking to determine the most appropriate service procedure.

PTU Leaks From the RH Side

NOTE: Remove and replace leaking seals using the information found in the INTERMEDIATE SHAFT SEAL AND DEFLECTOR or COVER SEAL replacement procedure. The specified tools called out will allow seal replacement without causing damage to the Power Transfer Unit (PTU) casing/drive gear.

If the leak is red automatic transmission fluid, then the PTU intermediate shaft seal needs replacement. This is inside the bore of the PTU shaft behind the deflector. Refer to the INTERMEDIATE SHAFT SEAL AND DEFLECTOR .

If the leak is brown/black gear lube, then the PTU larger cover seal needs replacement. This is located on the PTU cover behind the deflector. Refer to COVER SEAL .

NOTE: The following figure is for reference only. The kit also includes a special tool (not pictured) that is used during seal installation only and is not intended to be left in the PTU as a sealing device.

Fig 1: Identifying PTU Leaks From RH Side

Courtesy of FORD MOTOR CO.

ITEM DESCRIPTION CHART

Item	Description
1	Intermediate shaft seal (part of kit 7275)
2	Alignment washer (part of kit 7275)
3	Cover seal (part of kit 7275)
4	Seal deflector (part of kit 7275)

PTU Leaks From the LH Side

If the leak is the red automatic transmission fluid, the compression seal needs replacement. This is between the PTU and transmission. Refer to POWER TRANSFER UNIT (PTU) .

If the leak is brown/black, the PTU is overfilled and venting fluid from the top of the PTU . Flush and fill the PTU . Refer to POWER TRANSFER UNIT (PTU) DRAINING AND FILLING .

Fig 2: Identifying PTU Leaks From LH Side

Courtesy of FORD MOTOR CO.

ITEM DESCRIPTION CHART

Item	Description
1	Power Transfer Unit (PTU)-to-transaxle compression seal (7086)
2	Transfer case driver gear seal (not serviceable)
3	Transfer case driver gear seal (not serviceable)