Power Transfer Unit

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

Special Tool(s) / General Equipment 

1. Install the new PTU to transmission compression seal.

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2. Install the PTU and the PTU bolts.

   Torque: 66 lb.ft (90 Nm)

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3. Install a new RH halfshaft shaft seal. Refer to: Front Halfshaft RH .
4. Install the PTU support bracket and the PTU support bracket bolts.

   Torque: PTU support bracket to block: 35 lb.ft (48 Nm) PTU support bracket to PTU: 59 lb.ft (80 Nm)

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5. Connect the PTU vent hose.

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6. Install the PTU heat shield and the PTU heat shield bolts.

   Torque: 97 lb.in (11 Nm)

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7. Connect the PTU temperature sensor.

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8. Connect the PTU cooler lines.
   1. Connect the PTU cooler lines.
   2. Remove the hose clamp pliers form the PTU cooler lines. Use the General Equipment: Hose Clamp(s)

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9. Install the new converter gasket.

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10. Install the RH catalytic converter. Install the RH catalytic converter nuts.

    Torque: 30 lb.ft (40 Nm)

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11. NOTE: Loosely install the RH catalytic converter to transmission bracket through bolt before the RH catalytic converter bracket bolts are installed.

    Install the RH catalytic converter bracket through bolt.

    Torque: 35 lb.ft (48 Nm)

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12. Install the RH catalytic converter to transmission bracket bolts.

    Torque: 22 lb.ft (30 Nm)

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13. Connect the catalyst monitor sensor.

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14. Connect the HO2S sensor.

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15. Align the index-mark on driveshaft to the PTU pinion flange.

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16. Install the new driveshaft to PTU bolt and washer assemblies.

    Torque: 26 lb.ft (35 Nm)

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17. Install the RH halfshaft. Refer to: Front Halfshaft RH .
18. Install the front subframe. Refer to: Front Subframe .
19. Check the PTU fluid level. Refer to: Power Transfer Unit Fluid Level Check  .
20. If equipped with PTU cooling system, fill the cooling system. Refer to appropriate service information : ENGINE COOLING SYSTEM DRAINING, VACUUM FILLING AND BLEEDING - 2.0L / ENGINE COOLING SYSTEM DRAINING, VACUUM FILLING AND BLEEDING - 3.0L .
21. Check the exhaust system for leaks.