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Intermediate Shaft Seal: Installation

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  1. Place the intermediate shaft seal on the special tool with the spring side facing away from the tool. Use Special Service Tool: 205-883 Installer, PTU Linkshaft Seal, 205-907 Handle, 32 Driver.
    GFD281992Courtesy of FORD MOTOR COMPANY
  2. Using the special tool, install the intermediate shaft seal. Use Special Service Tool: 205-883 Installer, PTU Linkshaft Seal, 205-907 Handle, 32 Driver.
    GFD281993Courtesy of FORD MOTOR COMPANY
  3. Place the alignment washer on the special tool. Use Special Service Tool: 205-883 Installer, PTU Linkshaft Seal, 205-907 Handle, 32 Driver.
    GFD281994Courtesy of FORD MOTOR COMPANY
  4. NOTE: Do not use force when installing the alignment washer or damage to the washer can occur.

    Using the special tool, install the alignment washer by hand, pushing it in until it bottoms against the seal. Use Special Service Tool: 205-883 Installer, PTU Linkshaft Seal, 205-907 Handle, 32 Driver.

    GFD281993Courtesy of FORD MOTOR COMPANY
  5. 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 deg. C (212 deg. F). Overheating will damage the deflector. If the deflector is damaged, a new deflector must be used.
    NOTE: 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.

    Position the deflector on the special tool 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 deg. C (160 deg. F) and a maximum of 93 deg. C (200 deg. 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 deg. C (200 deg. F) to a maximum of 100 deg. C (212 deg. F). Use Special Service Tool: 308-221 (T94P-7025-BH) Installer, Shaft Bearing Cup, 205-907 Handle, 32 Driver.

    Material: Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)

    GFD281995Courtesy of FORD MOTOR COMPANY
  6. Using the special tools, install the intermediate shaft deflector. Use Special Service Tool: 308-221 (T94P-7025-BH) Installer, Shaft Bearing Cup, 205-907 Handle, 32 Driver.
    GFD281996Courtesy of FORD MOTOR COMPANY
  7. 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 3-5 mm (0.12-0.20 in) into the pocket all the way around.
    GFD281997Courtesy of FORD MOTOR COMPANY
  8. Position back the knuckle assembly.
    GFD281998Courtesy of FORD MOTOR COMPANY
  9. Install the RH halfshaft. Refer to: Front Halfshaft RH - 3.5L Duratec (212kW/278PS), All-Wheel Drive (AWD) .
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