LEMON Manuals: Even more car manuals for everyone
Home >> Mercury >> 2008 >> Milan Base, 2.3 Z, Automatic >> Repair and Diagnosis >> External Pages >> Different car >> Section 1360 (Transfer Case - Power Transfer Unit (PTU)) >> In-Vehicle Servicing >> Intermediate Shaft Seal and Deflector >> Removal

Intermediate Shaft Seal and Deflector: Removal

WARNING: This page is about a different car, the 2009 Mercury Milan, 2009 Lincoln MKZ, and 2009 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: The Power Transfer Unit (PTU) may leak different color fluids, red oil leak for automatic transmission fluid and brown/black gear lube for PTU fluid. The PTU seals prevent these types of fluids from leaking. It is important to note which color fluid is leaking to conduct the most appropriate service procedure. This procedure will correct a red oil leak (automatic transmission fluid) from the intermediate shaft seal on the RH side of the PTU. If the leak is red automatic transmission fluid, this indicates that the differential seals in the transaxle are also leaking and need to be replaced along with the intermediate shaft seal. Refer to AUTOMATIC TRANSAXLE/TRANSMISSION - AISIN AW21 article to replace the differential seals before replacing the intermediate shaft seal. For additional information, refer to Analysis of Leakage .
NOTE: This procedure is to be performed through the RH wheel opening. It is not necessary to remove the exhaust components to complete this repair.
  1. Remove the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
    2. NOTE: The following instruction will prevent the Bearing Cup Remover from opening too far which would make removing the intermediate shaft seal deflector difficult.
  2. Place a 16 mm (5/8 in) washer between the components of the Bearing Cup Remover as shown.
    3. Fig 1: Placing Washer Between Components Of Bearing Cup Remover
    GF0041494Courtesy of FORD MOTOR CO.
    NOTE: Using a 5-pound or larger slide hammer eases the removal of the seal deflector.
  3. Using the Bearing Cup Remover, the extension from the Halfshaft Remover, and a suitable slide hammer, remove the seal deflector.
    • The seal deflector will have been damaged during removal. Remove all foreign material from the PTU before continuing with the repair.
    4. Fig 2: Removing Seal Deflector
    GF0041495Courtesy of FORD MOTOR CO.
  4. Using the Bearing Cup Remover, the extension from the Halfshaft Remover, and a suitable slide hammer, remove the intermediate shaft seal, and if equipped, the alignment washer.
    5. Fig 3: Removing Intermediate Shaft Seal
    GF0041496Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals