Intermediate Shaft Seal and Deflector: Installation

NOTE: The following illustration shows the correct orientation of the seal components when installed in the vehicle.

Fig 1: Identifying Correct Orientation Of Seal Components

Courtesy of FORD MOTOR CO.

Item	Service Part Number	Description
1	7275	Intermediate shaft seal (part of 7275 kit) - retains red transmission fluid used in the transaxle
2	7275	Alignment washer (part of 7275 kit) - supports and centers the intermediate shaft in the seal
3	7275	Cover seal (part of 7275 kit) - seals the intermediate shaft to the PTU
4	7275	Seal deflector (part of 7275 kit) - keeps dust/dirt away from the intermediate shaft seal and PTU input shaft seal
5	7275	Seal protector (part of 7275 kit) - protects intermediate shaft seal from damage by the intermediate shaft splines during installation. Must be removed before shaft is fully installed

Place the intermediate shaft seal on the 205-883 and 205-907 with the spring side facing away from the tool.

Fig 2: Locating Intermediate Shaft Seal
Courtesy of FORD MOTOR CO.
Using the 205-883 and 205-907 , install the intermediate shaft seal.

Fig 3: Installing Intermediate Shaft Seal And/Or Alignment Washer
Courtesy of FORD MOTOR CO.
Place the alignment washer on the 205-883 and 205-907 .

Fig 4: Locating Alignment Washer
Courtesy of FORD MOTOR CO.
NOTE: Do not use force when installing the alignment washer or damage to the washer can occur.

Using the 205-883 and 205-907 , install the alignment washer by hand, pushing it in until it bottoms against the seal.

Fig 5: Installing Intermediate Shaft Seal And/Or Alignment Washer
Courtesy of FORD MOTOR CO.
NOTE: Do not overheat (melt) the seal deflector. Monitor the temperature of the deflector with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating. Do not allow the temperature to exceed 100 C (211.9 F). Overheating will damage the deflector. If the deflector is damaged, a new deflector must be used.

Position the deflector on the 205-882 using Silicone Brake Caliper Grease and Dielectric Compound to retain it to the installer. Using a suitable heat gun, heat the back of the tool to a minimum of 71 C (159.7 F) and a maximum of 93 C (199.3 F) by concentrating the heat across the back of the installer while rotating the tool. Once the optimum temperature is achieved on the tool, move the heat gun to the front of the tool and heat the inside of the deflector where it snaps onto the PTU shaft until the temperature of the deflector is a minimum of 93 C (199.3 F) to a maximum of 100 C (211.9 F).
- As an alternative method to heating the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry off the deflector and install.
Fig 6: Heating Back Of Tool Using Suitable Heat Gun
Courtesy of FORD MOTOR CO.
Using a 5-pound or larger dead blow hammer, install the seal deflector immediately after heating using the 205-882 and 205-907 .

Fig 7: Identifying Seal Deflector Using Dead Blow Hammer
Courtesy of FORD MOTOR CO.
Make sure the deflector is completely seated all the way around and there are no cracks on the face. The deflector is correctly installed when the face of the deflector is recessed 3 mm (0.1181 in)-5 mm (0.1969 in) into the pocket all the way around.

Fig 8: Inspecting Seal Deflector
Courtesy of FORD MOTOR CO.
Once the deflector is fully seated, insert the seal protector into the PTU deflector inside diameter.

Fig 9: Identifying Seal Protector
Courtesy of FORD MOTOR CO.
Install the RH halfshaft. REFER to HALFSHAFT - RH, ALL WHEEL DRIVE (AWD) .