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

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

Materials 

1. NOTE: This step is only necessary when installing a new component.

   Install the PTU heat shield.

   Torque: 10 Nm

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2. NOTE: This step is only necessary when installing a new component.

   If equipped, install the PTU temperature sensor harness bracket.

   Torque: 11 Nm

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3. If removed, lubricate and inspect the O-ring.

   Material: Gear/Transmission Fluid - SAE 75W-85 (WSS-M2C942-A)

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4. Install the PTU oil temperature sensor.

   Torque: 17 Nm

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5. Install the new PTU to transmission compression seal.

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6. Install the PTU and mounting bolts.

   Torque: 103 Nm

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7. Install the new PTU bolts.

   Torque: 103 Nm

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8. Install the PTU support bracket and bolts.

   Torque: 48 Nm

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9. Install the intermediate shaft. Refer to: Intermediate Shaft .
10. Clean and inspect the inboard end of the halfshaft.

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11. Install the O-Ring and circlip on the intermediate shaft.

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12. Install the RH halfshaft on the intermediate shaft.

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13. Install the vent hose retainer.

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14. Connect the PTU vent hose.

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15. Install the coolant pump and hoses. Install the pump mounting nuts.

    Torque: 9 Nm

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16. Install the PTU cooling system hoses and connect the hose clamps. Remove the hose clamps.

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17. If equipped, connect the PTU temperature sensor and install retainers.

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18. Connect the PTU motor connectors.

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19. Connect the auxillary pump connector and retainers.

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20. Install the catalytic converter. Refer to: Catalytic Converter .
21. NOTE: Make sure that the installation marks are aligned.

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22. Install new PTU flange bolts.

    Torque: 35 Nm

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23. Check PTU fluid level and adjust as necessary. Refer to: Power Transfer Unit Fluid Level Check .
24. Install the front subframe. Refer to: Front Subframe .
25. Check engine coolant level and adjust as necessary. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
26. Check transmission fluid level and adjust as necessary. Refer to: Transmission Fluid Level Check .