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Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Transfer Case - Power Transfer Unit (PTU)) >> In-Vehicle Repair >> Output Shaft Seal >> Installation

Output Shaft Seal: Installation

WARNING: This page is about a different variant/trim than selected.
  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
    G06064388Courtesy of FORD MOTOR CO.
  3. Using the PTU  Drive Gear Outer Oil Seal Installer, install the output shaft seal deflector.
    Fig 2: Installing Output Shaft Seal
    G06064388Courtesy of FORD MOTOR CO.
  4. NOTE: Install the output pinion flange to engage the spline as previously marked.
  5. Install the output pinion flange.
  6. NOTE: 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.
    Fig 3: Locating Discard Pinion Nut
    G06064386Courtesy of FORD MOTOR CO.
  7. Using the Drive Pinion Flange Holding Fixture to hold the output pinion flange, install and tighten the new pinion flange nut.
  8. Using the index mark, position the driveshaft and install the 4 driveshaft-to- PTU  output flange bolts.
    • Tighten to 70 Nm (52 lb-ft).
  9. Install the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM .
  10. Fill the PTU  as necessary. For additional information, refer to POWER TRANSFER UNIT (PTU) DRAINING AND FILLING  .