Power Transfer Unit - Vehicles Without: Power Transfer Unit Oil-to-Coolant Cooler

For information on Ford Color Coded Illustrations refer to: OEM COLOR CODING

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

   Install the PTU heat shield.

   Torque: 89 lb.in (10 Nm)

   Courtesy of FORD MOTOR COMPANY

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

   If equipped, install the PTU temperature sensor harness bracket.

   Torque: 97 lb.in (11 Nm)

   Courtesy of FORD MOTOR COMPANY

3. Install the new PTU to transmission compression seal.

   Courtesy of FORD MOTOR COMPANY

4. Install the PTU and mounting bolts.

   Torque: 76 lb.ft (103 Nm)

   Courtesy of FORD MOTOR COMPANY

5. Install the new PTU bolts.

   Torque: 76 lb.ft (103 Nm)

   Courtesy of FORD MOTOR COMPANY

6. Install the PTU support bracket and bolts.

   Torque: 35 lb.ft (48 Nm)

   Courtesy of FORD MOTOR COMPANY

7. Install the vent hose retainer.

   Courtesy of FORD MOTOR COMPANY

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

   Connect the PTU vent hose.

   Courtesy of FORD MOTOR COMPANY

9. If equipped, position back the wiring harness and connect retainer.

   Courtesy of FORD MOTOR COMPANY

10. If equipped, connect the PTU temperature sensor. Connect the motor connectors and retainers.

    Courtesy of FORD MOTOR COMPANY

11. Install the LH halfshaft. Refer to: Front Halfshaft LH
12. Install the intermediate shaft. Refer to: Intermediate Shaft
13. NOTE: Make sure that the installation marks are aligned.

    Courtesy of FORD MOTOR COMPANY

14. Install new PTU flange bolts.

    Torque: 26 lb.ft (35 Nm)

    Courtesy of FORD MOTOR COMPANY

15. Install the catalytic converter. Refer to: Catalytic Converter
16. Install the front subframe. Refer to: FRONT SUBFRAME
17. Fill the PTU.