Power Transfer Unit - Vehicles Without: 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. Remove the catalytic converter. Refer to: Catalytic Converter - 4WD .
3. NOTE: The installation step requires the aid of another technician.

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

   Courtesy of FORD MOTOR COMPANY

4. 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: PunchUse the General Equipment: Copper Hammer

   3. Remove the driveshaft from the PTU flange.

   Courtesy of FORD MOTOR COMPANY

5. Drain the PTU. Refer to: Power Transfer Unit Draining and Filling .
6. Remove the intermediate shaft. Refer to: Intermediate Shaft .
7. Remove the LH halfshaft. Refer to: Front Halfshaft LH .
8. If equipped, disconnect the PTU temperature sensor. Disconnect the motor connectors and retainers.

   Courtesy of FORD MOTOR COMPANY

9. Disconnect and position aside the PTU vent hose.

   Courtesy of FORD MOTOR COMPANY

10. Remove the vent hose retainer.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

12. Remove the PTU bolts.

    Courtesy of FORD MOTOR COMPANY

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

    Remove the PTU bolts and the PTU.

    Courtesy of FORD MOTOR COMPANY

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

    Courtesy of FORD MOTOR COMPANY

15. 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)

    Courtesy of FORD MOTOR COMPANY

16. 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.

    Courtesy of FORD MOTOR COMPANY

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

    If equipped remove the PTU oil temperature sensor.

Courtesy of FORD MOTOR COMPANY