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. Disconnect the HO2S electrical connector.

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3. Disconnect the catalyst monitor electrical connector.

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4. Remove and discard the driveshaft to PTU bolts and retaining straps.

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5. 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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6. Remove the RH catalytic converter to transmission bracket bolts.

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7. Remove the RH catalytic converter bracket through bolt and bracket.

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8. Remove and discard the RH catalytic converter nuts. Remove the RH catalytic converter.

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9. Remove and discard the converter gasket.

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10. Remove the PTU heat shield bolts and PTU heat shield.

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11. NOTE: This step is only necessary when installing a new PTU or replacing a PTU seal.

    Drain the PTU. Refer to: Power Transfer Unit Draining and Filling .

12. Disconnect the auxiliary pump connector and retainers.

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13. Disconnect the PTU motor connectors.

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14. If equipped, disconnect the PTU temperature sensor and retainers.

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15. Clamp the hoses.

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16. Release the hose clamps and position aside the PTU cooling system hoses.

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17. Remove the pump mounting nuts and position aside coolant pump along with hoses.

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

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20. Remove the vent hose retainer.

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

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22. Remove the PTU bolts and the PTU.

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23. Remove and discard the PTU to transmission compression seal.

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24. NOTE: This step is only necessary when installing a new PTU or replacing a PTU seal.

    If equipped, remove the PTU temperature sensor harness bracket.

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