Active Torque Coupling Clutch: Removal

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

NOTE: When replacing the RDU clutch, the ACT coil and yoke are a matched set and must be replaced also.

NOTE: When replacing the RDU clutch, the 4X4 control module will need to be reconfigured with the new Active Torque Coupling (ATC) bar code information. If the new bar code information does not match the existing 4X4 control module information, driveline damage or driveability concerns can occur.

NOTE: Removal steps may contain installation instructions.

Record the number for PCM (powertrain control module) entry before clutch is replaced.
With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
Remove the driveshaft. Refer to: Rear Driveshaft .
Disconnect the Active Torque Coupling (ATC) connector.

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Remove and discard the RDU coupler housing bolts.
Torque: 30 lb.ft (40 Nm)

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NOTE: When assembling use a 2 mm bead of silicone sealant.

NOTE: The RDU coupler housing should be dry. The presence of fluid in the housing cavity is most likely from a failed / overheated Active Torque Coupling (ATC). Clean any fluid from the housing before assembly.

Using a pry bar, remove the RDU coupler housing.

Use the General Equipment: Tire Lever

Material: Motorcraft ® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

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Using the special tool, remove and discard the companion flange bolt, remove the companion flange washer and the companion flange.
Use Special Service Tool: 205-126 (T78P-4851-A) Holding Fixture, Drive Pinion Flange.

Torque: 40 lb.ft (54 Nm)

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Index mark the companion flange and stub shaft.

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Remove the companion flange.

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Remove the RDU clutch coupler housing from the Intelligent Torque Controlled Coupling (ITCC).

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Remove and discard the stub shaft bolts, and remove the stub shaft.
Torque: 43 lb.ft (58 Nm)

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Remove and discard the Active Torque Coupling (ATC) coil snap ring.

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NOTE: The ATC coil and the ATC coil yoke must be replaced as a matched set.

Remove the Active Torque Coupling (ATC) coil.

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NOTE: The ATC coil and the ATC coil yoke must be replaced as a matched set.

Remove and discard the Active Torque Coupling (ATC) coil yoke bolts and remove the Active Torque Coupling (ATC) coil yoke.

Torque: 89 lb.in (10 Nm)

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Clean the mating surface of the RDU differential housing. Refer to: RTV Sealing Surface Cleaning and Preparation .

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Clean the mating surface of the RDU clutch coupler housing. Refer to: RTV Sealing Surface Cleaning and Preparation .

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