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: 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. Remove the catalytic converter. Refer to: Catalytic Converter .
5. Disconnect the auxillary 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. Use the General Equipment: Hose Clamp(s)

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9. NOTE: Be prepared to collect escaping fluid.

   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. Separate the halfshaft from the intermediate shaft. Position aside and support the halfshaft.

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12. Remove and discard the circlip and O-Ring seal from the intermediate shaft.

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

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15. Remove the vent hose retainer.

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

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17. Remove the PTU bolts.

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18. 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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19. Remove and discard the PTU to transmission compression seal.

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

    Remove the PTU heat shield bolts and PTU heat shield.

    Torque: 10 Nm

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

    If equipped remove the PTU temperature sensor harness bracket.

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22. NOTE: This step is only necessary when installing a new component.
    NOTE: Be prepared to collect escaping fluid.

    If equipped remove the PTU oil temperature sensor.

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