Transfer Case

For information on Ford Color Coded Illustrations refer to OEM Color Coding .

1. Remove the front halfshaft RH. Refer to: Front Halfshaft RH - 3.5L Duratec (212kW/278PS), All-Wheel Drive (AWD) .
2. If equipped with PTU cooling system, drain the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
3. Remove the catalytic converter RH. Refer to: Catalytic Converter RH .
4. NOTE: Index-mark both the driveshaft flanges for installation.

   Remove the driveshaft-to-Power Transfer Unit (PTU) output flange bolts. Disconnect the driveshaft from the PTU and position it aside.

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5. Disconnect the PTU temperature sensor. Remove the PTU sensor connector from the bracket and position the harness aside.

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6. If equipped with PTU cooling system, disconnect the PTU temperature sensor.

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7. If equipped with PTU cooling system, remove the PTU cooler line bolt and position the PTU cooler lines aside.

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8. NOTE: The PTU vent hose should be replaced whenever a new PTU is installed.

   Disconnect the PTU vent hose.

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9. Drain the PTU fluid. Refer to: Transfer Case Draining and Filling .
10. Remove the PTU support bracket bolts and the PTU support bracket.

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11. Remove the PTU bolts.

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12. Remove the PTU bolts.

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13. NOTE: This is a tight fit, use care to not damage the transmission and PTU mating surfaces.

    Remove the PTU.

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14. Remove and discard the compression seal.

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