Input Shaft Seal: Removal

Remove the PTU. REFER to Power Transfer Unit (PTU) .
Using 307-003 (T57L-500-B), secure the PTU to the bench.

Fig 1: Holding PTU To Bench Using Transmission Holding Fixture
Courtesy of FORD MOTOR CO.
Remove the compression seal and discard.

Fig 2: View Of Compression Seal
Courtesy of FORD MOTOR CO.
NOTE: Do not press the seals lower than specified. Excessive force will damage the bearing below the seals.

NOTE: Both seals will need to be pressed lower into the PTU input shaft opening to break the seals outer sealant loose from the PTU.

NOTE: There is approximately a 5 mm (0.197 in) air gap between both seals and approximately 1 mm (0.039 in) air gap between the inner seal and the bearing race.

Using 206-040 (T88T-2598-F), press the outer seal downward until the lower seal contacts the bearing race.

Fig 3: Pressing Outer Seal Downward Using Parking Brake Bearing Installer (206-040)
Courtesy of FORD MOTOR CO.
Position the 308-777 /1 above the PTU input shaft opening.

Fig 4: Positioning Screw Guide (308-777/1)
Courtesy of FORD MOTOR CO.
Insert the 308-777 /2 into one of the screw guide holes. Press the 308-777 /2 downward until the shoulder of the punch touches the screw guide.

Fig 5: Inserting Punch Into Screw Guide Holes
Courtesy of FORD MOTOR CO.
NOTE: Do not overtighten the screws. Turn the 308-777 /3 until they are seated into the screw guide holes.

Install a 308-777 /3 into the screw guide hole.

Fig 6: Installing Screw Into Screw Guide Hole
Courtesy of FORD MOTOR CO.
Insert the 308-777 /2 into the opposing screw guide hole. Press the 308-777 /2 downward until the shoulder of the punch touches the screw guide.

Fig 7: Inserting Punch Into Opposing Screw Guide Hole
Courtesy of FORD MOTOR CO.
Install a 308-777 /3 into the screw guide hole.

Fig 8: Installing Screw Into Screw Guide Hole
Courtesy of FORD MOTOR CO.
Using the screw guide and 100-001 (T50T-100-A), remove the 2 seals and discard.

Fig 9: Removing Seals Using Screw Guide And Slide Hammer (100-001)
Courtesy of FORD MOTOR CO.
Using a non-marring tool, remove any excess red sealant material from the PTU input shaft opening.
Drain the PTU.
- Position the PTU output flange upward and tilt the PTU approximately 30 degrees toward the LH seal bore to allow the fluid to drain from the PTU input shaft opening.