Output Shaft Seal and Flange: Removal

All vehicles 

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to JACKING & LIFTING .

   All vehicles except GTDI 

2. Remove the 2 exhaust Y-pipe-to-muffler and tail pipe flange nuts.
   • Discard the nuts and gasket.
NOTE: The resonator must be supported to prevent damage to the flexible pipe.
3. Using a length of mechanic's wire, support the resonator.

   GTDI vehicles 

4. Remove the 4 LH and RH exhaust flexible pipes-to-underbody catalytic converter nuts.
   • Discard the nuts and gasket.

   All vehicles 

NOTE: Index-mark both the driveshaft flanges for installation.
5. Remove the 4 driveshaft-to-PTU output flange bolts. Disconnect the driveshaft from the PTU and position it aside.
   • Using mechanic's wire, support the driveshaft.
NOTE: Rotational torque of the PTU rear output shaft flange must be measured and recorded using a Nm (lb-in) torque wrench for correct pinion bearing preload when reassembled. This will be the torque-to-turn measurement.
Fig 1: Measuring Rotational Torque Of PTU Output Shaft Using Suitable Torque Wrench
Courtesy of FORD MOTOR CO.
6. Using a suitable torque wrench, measure and record the rotational torque of the PTU output shaft.
7. Using the Drive Pinion Flange Holding Fixture, hold the output pinion flange. Remove and discard the pinion nut.
   Fig 2: Holding Output Pinion Flange Using Drive Pinion Flange Holding Fixture

   Courtesy of FORD MOTOR CO.
NOTE: Index-mark the output pinion flange to the pinion shaft.
Fig 3: Removing Output Pinion Flange Using Output Flange Remover (307-523)
Courtesy of FORD MOTOR CO.
8. Using the Output Flange Remover, remove the output pinion flange.
9. Remove and discard the output shaft seal.
10. Remove the bearing from the output shaft.
11. Remove and discard the collapsible spacer.