Power Transfer Unit - Vehicles With: Power Transfer Unit Oil-to-Coolant Cooler

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

Special Tool(s) / General Equipment 

1. Remove the front subframe. Refer to: Front Subframe .
2. NOTE: The installation step requires the aid of another technician.

   Remove and discard the driveshaft to PTU bolts and retaining straps.

   Torque: 26 lb.ft (35 Nm)

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3. Separate the driveshaft from the PTU flange.
   1. NOTE: Make sure that the component aligns with the installation mark.

      Index-mark the driveshaft and PTU flange.

   2. NOTE: Do not remove driveshaft from the PTU flange by pulling on the driveshaft tube. Damage to the CV-joint can result.

      Using general equipment, separate the driveshaft from the PTU flange. Use the General Equipment: Punch, Use the General Equipment: Copper Hammer

   3. Remove the driveshaft from the PTU flange.

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4. NOTE: This step is only necessary when installing a new PTU or replacing a PTU seal.

   Drain the PTU. Refer to: Power Transfer Unit Draining and Filling .

5. Disconnect the auxiliary pump connector and retainers.

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6. Disconnect the PTU motor connectors.

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7. If equipped, disconnect the PTU temperature sensor and retainers.

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8. Clamp the hoses.

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9. Release the hose clamps and position aside the PTU cooling system hoses.

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10. Remove the pump mounting nuts and position aside coolant pump along with hoses.

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11. Remove the intermediate shaft. Refer to: Intermediate Shaft .
12. Disconnect and position aside the PTU vent hose.

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13. Remove the vent hose retainer.

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14. Remove the PTU support bracket bolts and the PTU support bracket.

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15. Remove the PTU bolts.

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

    Remove the PTU bolts and the PTU.

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17. Remove and discard the PTU to transmission compression seal.

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18. NOTE: This step is only necessary when installing a new PTU or replacing a PTU seal.

    Remove the PTU heat shield bolts and PTU heat shield.

    Torque: 89 lb.in (10 Nm)

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19. NOTE: This step is only necessary when installing a new PTU or replacing a PTU seal.

    If equipped remove the PTU temperature sensor harness bracket.

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20. NOTE: This step is only necessary when installing a new PTU or replacing a PTU seal.

    If equipped remove the PTU oil temperature sensor.

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