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Home >> Ford >> 2018 >> Taurus Limited, FWD, Gas >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 5 (Transfer Case - Power Transfer Unit (PTU)) >> Removal And Installation >> Intermediate Shaft Seal and Deflector >> Installation

Intermediate Shaft Seal and Deflector: Installation

WARNING: This page is about a different variant/trim than selected.
NOTE: The following illustration shows the correct orientation of the seal components when installed in the vehicle.
GFD341867Courtesy of FORD MOTOR COMPANY
Item Description
1 Intermediate shaft seal (part of 7275 kit) -- retains red automatic transmission fluid used in the transmission
2 Alignment washer (part of 7275 kit) -- supports and centers the intermediate shaft in the seal
3 Cover Seal (part of 7275 kit) -- keeps dust/dirt away from the intermediate shaft seal
4 Seal deflector (part of 7275 kit) -- keeps dust/dirt away from the PTU input shaft seal
5 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

All vehicles 

  1. Special Tool(s): Installer, PTU Linkshaft Seal 205-883, Handle, Driver 812.8 mm (32 in) 205-907.
    GFD341868Courtesy of FORD MOTOR COMPANY
  2. Special Tool(s): Installer, PTU Linkshaft Seal 205-883, Handle, Driver 812.8 mm (32 in) 205-907.
    GFD341869Courtesy of FORD MOTOR COMPANY
  3. Special Tool(s): Installer, PTU Linkshaft Seal 205-883, Handle, Driver 812.8 mm (32 in) 205-907.
    GFD341870Courtesy of FORD MOTOR COMPANY
  4. NOTE: Do not use force when installing the alignment washer or damage to the washer can occur.

    Special Tool(s): Installer, PTU Linkshaft Seal 205-883, Handle, Driver 812.8 mm (32 in) 205-907.

    GFD341869Courtesy of FORD MOTOR COMPANY
  5. NOTE: Do not overheat (melt) the seal deflector. Monitor the temperature of the deflector with a 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: Apply a small amount of silicone brake caliper grease and dielectric compound to the inner lip of the deflector where it installs on the tube inside the PTU before heating. This will ease the installation of the deflector.

    Hot air gun. Special Tool(s): Installer, Front Axle Bushing 205-346, Handle, Driver 812.8 mm (32 in) 205-907. Position the deflector on the Installer, Front Axle Bushing 205-346 using silicone brake caliper grease and dielectric compound to retain it to the Installer, Front Axle Bushing 205-346. Using a hot air 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).

    • 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.

    GFD341871Courtesy of FORD MOTOR COMPANY
  6. General Equipment: 5-Pound Dead Blow Hammer Special tool(s): Installer, Front Axle Bushing 205-346, Handle, Driver 812.8 mm (32 in) 205-907. Install the seal deflector immediately after heating.
    GFD341872Courtesy 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.
    GFD341873Courtesy of FORD MOTOR COMPANY
  8. NOTE: A significant amount of residual fluid will collect between the seal and deflector during this repair. This is a normal condition and should not be misinterpreted as a leak after the repair is complete.

    Using metal brake parts cleaner, thoroughly clean the deflector and intermediate shaft area of any residual fluid that may have accumulated during the repair.

    All Vehicles except 3.5L GTDI 

  9. Install the RH halfshaft. Refer to Front Drive Halfshafts .

    Vehicles with 3.5L GTDI 

  10. Install the RH intermediate shaft. Refer to Front Drive Halfshafts .

    All vehicles 

  11. Fill the transmission as necessary. Refer to Automatic Transmission - 6F50/6F55 .
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