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

WARNING: This page is about a different variant/trim than selected.

For information on Ford Color Coded Illustrations refer to OEM Color Coding .

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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Install the new PTU to transmission compression seal.

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Install the PTU and mounting bolts.
Torque: 76 lb.ft (103 Nm)

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Install the PTU support bracket and bolts.
Torque: 35 lb.ft (48 Nm)

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Install the intermediate shaft. Refer to: Intermediate Shaft
Install the vent hose retainer.

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

Connect the PTU vent hose.

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Install the coolant pump and hoses. Install the pump mounting nuts.
Torque: 80 lb.in (9 Nm)

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NOTE: Make sure to remove the hose clamp pliers.

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

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

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Connect the PTU motor connectors.

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Connect the auxiliary pump connector and retainers.

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Install the PTU heat shield and PTU heat shield bolts.
Torque: 97 lb.in (11 Nm)

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Install the new converter gasket.

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NOTE: Evenly tighten the fasteners during installation.

Install the RH catalytic converter and the new RH catalytic converter nuts.

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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.

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Install the RH catalytic converter to transmission bracket bolts.
Torque: 22 lb.ft (30 Nm)

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NOTE: Make sure that the installation marks are aligned.

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Install new PTU flange bolts.
Torque: 26 lb.ft (35 Nm)

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Connect the catalyst monitor sensor.

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Connect the HO2S.

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Install the intermediate shaft. Refer to: Intermediate Shaft
Fill the PTU. Refer to: Power Transfer Unit Draining and Filling .
Install the front subframe. Refer to: Front Subframe