Power Transfer Unit

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)

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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)

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3. NOTE: Make sure that a new gasket is installed.

   Install a new gasket.

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4. Install the new PTU to transmission compression seal.

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5. Install the PTU and mounting bolts.

   Torque: 76 lb.ft (103 Nm)

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6. Install the new PTU bolts and hand tighten at this stage.

   Torque: 76 lb.ft (103 Nm)

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7. Tighten in the sequence shown.

   Torque: 81 lb.ft (110 Nm)

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8. Install the PTU support bracket and bolts.

   Torque: 35 lb.ft (48 Nm)

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9. Position the catalytic converter in the vehicle.

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10. Install the catalytic converter mounting bracket hand tighten at this stage.

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11. NOTE: Make sure that the new exhaust manifold nuts are installed.

    Install the exhaust manifold nuts.

    Torque: 41 lb.ft (55 Nm)

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12. 1. Tighten the lower bracket nut.

       Torque: 35 lb.ft (47.5 Nm)

    2. Tighten the PIA nut.

       Torque: 35 lb.ft (47.5 Nm)

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13. Install the heat shield.

    Torque: 93 lb.in (10.5 Nm)

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14. Install the EGR cooler inlet tube. Refer to: Exhaust Gas Recirculation (EGR) Cooler Inlet Tube .
15. • Connect the catalyst monitor sensor connector and harness retainers.
    • Connect the HO2S connector and harness retainer.

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

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

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18. Install the vent hose retainer.

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

    Connect the PTU vent hose.

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20. NOTE: Make sure that the installation marks are aligned.

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21. Install new PTU flange bolts.

    Torque: 26 lb.ft (35 Nm)

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22. Install the intermediate shaft. Refer to: Intermediate Shaft .
23. Fill the PTU.
24. Install the front subframe. Refer to: Front Subframe .
25. 1. If the engine appearance cover stud bolt is loosened or removed, it must be installed/tightened into the valve cover.

       Torque: 62 lb.in (7 Nm)

    2. Position the engine appearance cover onto the engine with the grommets aligned with the studs.
    3. Press down on the engine appearance cover at each grommet location to attach the grommets onto the studs.
    4. Install the engine appearance cover nut.

       Torque: 44 lb.in (5 Nm)

    Courtesy of FORD MOTOR COMPANY

26. Check the exhaust system for leaks.