Intermediate Shaft Seal and Deflector: Removal

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

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 . 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.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Remove the RH front wheel and tire. For additional information, refer to WHEELS & TIRES .
Apply the brake to keep the halfshaft from rotating and remove the front wheel hub nut.
- Do not discard the nut at this time.
  
  Fig 1: Locating Front Wheel Hub Nut
  Courtesy of FORD MOTOR CO.
Remove the RH brake disc. For additional information, refer to FRONT DISC BRAKE .

NOTE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correct retention of these parts.

Remove and discard the ball joint nut.
- Separate the lower control arm from the knuckle.
  
  Fig 2: Locating Discard Ball Joint Nut
  Courtesy of FORD MOTOR CO.
Using the Front Wheel Hub Remover, separate the halfshaft from the wheel hub.

Fig 3: Separating Halfshaft From Wheel Hub
Courtesy of FORD MOTOR CO.
Pull the knuckle outboard and rotate it toward the rear of the vehicle.
- Secure the knuckle assembly.
  
  Fig 4: Pulling Knuckle Outboard
  Courtesy of FORD MOTOR CO.
Remove the 2 intermediate shaft bracket nuts and the intermediate and halfshaft assembly.
- Inspect the intermediate shaft for pitting or damage in the seal contact area. Replace if necessary.
  
  Fig 5: Locating Intermediate Shaft Bracket Nuts
  Courtesy of FORD MOTOR CO.

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 6: Placing Washer Between Components Of Bearing Cup Remover

Courtesy of FORD MOTOR CO.

NOTE: Failure to utilize the recommend tools may result in serious damage to the Power Transfer Unit (PTU).

Place a 16 mm (5/8 in) washer between the components of the Bearing Cup Remover as shown in illustration.

Assemble the special tools as indicated in the following table and illustration:

ITEM DESCRIPTION CHART

Item	Description
1	308-125
2	Extension for 205-241
3	5-pound or larger slide hammer

Fig 7: Identifying Special Tools

Courtesy of FORD MOTOR CO.

NOTE: Using a 5-pound or larger slide hammer eases the removal of the seal deflector.

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.
  
  Fig 8: Removing Seal Deflector
  Courtesy of FORD MOTOR CO.
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 9: Removing Intermediate Shaft Seal
Courtesy of FORD MOTOR CO.