Taurus X PTU Section Servman

2008 Taurus/Taurus X/Sable Workshop Manual
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SECTION 308-07B: Transfer Case Power Transfer Unit (PTU) SPECIFICATIONS

Procedure revision date: 05/22/2009
Material Item MERCON V Automatic Transmission Fluid XT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 (Canada) Motorcraft MERCON LV Automatic Transmission Fluid XT-10-QLV Metal Brake Parts Cleaner PM-4-A or PM-4-B (US); CPM-4 (Canada) Motorcraft SAE 75W-140 Synthetic Rear Axle Lubricant XY-75W140-QL (US); CXY75W140-1L (Canada) Silicone Brake Caliper Grease and Dielectric Compound XG-3-A Specification MERCON V Fill Capacity
MERCON LV
WSL-M2C192-A and GL-5
0.53L (18 oz)
ESE-M1C171-A
Description Ball joint nut Driveshaft-to-output flange bolts Engine roll restrictor-to-transaxle bolts Fill plug Power Transfer Unit (PTU) bolts PTU support bracket bolts Rear engine roll restrictor bolt Wheel hub nut
a Refer a
Nm lb-ft lb-in 150 111 70 20 90 70 90 52 18 66 52 66 103 76 177
Intermediate and halfshaft assembly nuts 25
to the procedure in this section.
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SECTION 308-07B: Transfer Case Power Transfer Unit (PTU) DESCRIPTION AND OPERATION

Power Transfer Unit (PTU)

The All-Wheel Drive (AWD) system consists of the following: Power Transfer Unit (PTU) Rear driveshaft 4X4 control module Rear axle with coupling device The PTU is a mechanical device attached to the transaxle. It supplies torque to the rear axle through the rear driveshaft. The 4X4 control module is an electronic device which controls the rear axle coupling to apply the torque generated from the PTU to the rear wheels when required.
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SECTION 308-07B: Transfer Case Power Transfer Unit (PTU) DIAGNOSIS AND TESTING

Principles of Operation The Power Transfer Unit (PTU) is a gearbox that attaches to the transaxle. The RH intermediate shaft passes through the PTU and engages the differential side gear as in normal Front Wheel Drive (FWD) applications. The PTU directs power to the rear driveshaft through a helical gear spline coupled to the transaxle differential case, a helical gear drop (idler gear) and hypoid/helical ring gear assembly and pinion set. The PTU is sealed from the transaxle and has its own oil sump. Serviceable components of the PTU are limited to the output shaft seal and flange, intermediate shaft seal and deflector, the cover seal and the PTU -transaxle compression seal. The internal components are not serviced. Do not remove the cover of the PTU . If any of the geared components, bearings, case cover or internal shafts are worn or damaged, a new PTU must be installed. Heat Protection Mode During very extreme off-road operation, the All-Wheel Drive (AWD) system utilizes a heat protection mode to protect the Active Torque Coupling (ATC) solenoid (part of rear axle) from damage. If the system detects an overheat condition, it enters a locked mode. If the heat in the system continues to rise once in the locked mode, the 4X4 control module disables the ATC solenoid. Allow the system to cool down at least 10 minutes with the ignition switch in the ON position. For concerns with the 4X4 control module or ATC , refer to Section 308-07A .
Inspection and Verification 1. Verify the customer concern. 2. Inspect for obvious signs of mechanical damage.
Mechanical Power Transfer Unit (PTU) Halfshafts and CV joints Driveshaft and U-joints Wheel/tire size and brand Matching tire size and brand Tire pressure 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
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4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart - Power Transfer Unit (PTU) .
Symptom Chart
Symptom Chart Power Transfer Unit (PTU) Condition The Power Transfer Unit (PTU) makes noise Possible Sources Tire inflation pressure Tire and wheel size Fluid level Action MAKE SURE all tires and wheels are the same size and brand and the inflation pressures are correct. FILL with the correct type and amount of lubricant. REFER to Power Transfer Unit (PTU) Draining and Filling in this section. OPERATE the vehicle in all gears. If there is noise in the transaxle in NEUTRAL, or in some gears and not in others, REMOVE and REPAIR the transaxle. Refer to the appropriate section in Group 307 for the procedure. If there is noise in all gears, INSTALL a new PTU . REFER to Power Transfer Unit (PTU) in this section. REFER to Analysis of Leakage in this section. REFER to Analysis of Leakage in this section.
Internal components
Leaking fluid from the PTU vent Leaking automatic transmission fluid
PTU over filled PTU intermediate shaft seal PTU compression seal The PTU vent is plugged (located on top of the PTU ) Damaged seals
Leaking gear lubricant from the seals
INSTALL a new PTU . REFER to Power Transfer Unit (PTU) in this section. REFER to Analysis of Leakage in this section. REFER to Section 205-02 .
Vehicle has no or inadequate torque at rear wheels
Rear axle
PTU mechanical failure Vehicle binds in a turn or resists turning/pulsates or shudders in a straight line Wheels/tires
REFER to Power Transfer Unit (PTU) in this section. REFER to Section 204-04 .
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Brake system Wheel bearings Halfshafts Wheel speed sensor(s) ABS module
REFER to Section 206-00 . REFER to Section 204-00 . REFER to Section 205-00 . REFER to Section 206-09 . REFER to Section 206-09 .
Analysis of Leakage The PTU may leak different color fluids, red oil leak for an 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 of fluid is leaking to determine the most appropriate service procedure. PTU Leaks From the RH Side NOTICE: Remove and replace leaking seals using the information found in the Intermediate Shaft Seal and Deflector or Cover Seal replacement procedure in this section. The specified tools called out in this procedure will allow seal replacement without causing damage to the Power Transfer Unit (PTU) casing/drive gear. If the leak is red automatic transmission fluid, then the PTU intermediate shaft seal needs replacement. This is inside the bore of the PTU shaft behind the deflector. Refer to the Intermediate Shaft Seal and Deflector procedure in this section. If the leak is brown/black gear lube, then the PTU larger cover seal needs replacement. This is located on the PTU cover behind the deflector. Refer to Cover Seal procedure in this section. NOTE: The following figure is for reference only. The kit also includes a special tool (not pictured) that is used during seal installation only and is not intended to be left in the PTU as a sealing device.
Item 1 2 3 4
Description Intermediate shaft seal (part of kit 7275) Alignment washer (part of kit 7275) Cover seal (part of kit 7275) Seal deflector (part of kit 7275)
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PTU Leaks From the LH Side If the leak is the red automatic transmission fluid, the compression seal needs replacement. This is between the PTU and transmission. Refer to Power Transfer Unit (PTU) in the Removal portion of this section. If the leak is brown/black, the PTU is overfilled and venting fluid from the top of the PTU . Flush and fill the PTU . Refer to Power Transfer Unit (PTU) Draining and Filling in this section.
Item 1 2 3
Description Power Transfer Unit (PTU)-to-transaxle compression seal (7086) Transfer case driver gear seal (not serviceable) Transfer case driver gear seal (not serviceable)
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SECTION 308-07B: Transfer Case Power Transfer Unit (PTU) GENERAL PROCEDURES

Power Transfer Unit (PTU) Draining and Filling
Material Item Motorcraft SAE 75W-140 Synthetic Rear Axle Lubricant XY-75W140-QL (US); CXY75W140-1L (Canada) Specification WSL-M2C192-A and GL-5
NOTICE: A new Power Transfer Unit (PTU) must be installed any time the PTU has been submerged in water. NOTE: The Power Transfer Unit (PTU) is not to be drained unless contamination is suspected. To drain the PTU fluid, the PTU must be removed from the vehicle. The fluid that is drained may appear black and have a pungent odor. Do not mistake this for contaminated fluid. For additional information, refer to Power Transfer Unit (PTU) in the Removal portion of this section. NOTE: Fill level checks are done in-vehicle only. Let the vehicle sit 10 minutes after the road test before checking the fluid level. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 10002 . 2. Clean the area around the filler plug before removing.
3. Remove and discard the filler plug. 4. With the vehicle on a flat, level surface, fill the PTU with lubricant. The fluid must be even with the bottom of the fill opening. Fluid capacity is 0.53L (18 oz). 5. Install a new filler plug. Tighten to 20 Nm (177 lb-in).
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SECTION 308-07B: Transfer Case Power Transfer Unit (PTU) IN-VEHICLE REPAIR

Cover Seal
Special Tool(s) Handle, Driver (32 in) 205-907
Installer, Halfshaft Oil Seal 308-431
Installer, Shaft Bearing Cup 308-221 (T94P-7025-BH)
Remover, Halfshaft 205-241
Slide Hammer 100-01 (T50T-100-A)
Removal 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 determine the most appropriate service procedure. This procedure will correct a brown/black (gear lube) leak from the RH side of the PTU . For additional information, refer to Analysis of Leakage in this section. 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.
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1. Remove the intermediate shaft seal and deflector. For additional information, refer to Intermediate Shaft Seal and Deflector in this section. 2. NOTE: There is a bearing inside the PTU directly behind the cover seal. The bearing is not serviced. Remove the cover seal using the Slide Hammer, the extension from the Halfshaft Remover and a suitable seal puller inserted into the groove of the seal.
Installation 1. Assemble the Driver Handle, the Halfshaft Oil Seal Installer and the Shaft Bearing Cup Installer as shown.
2. Using the Driver Handle, the Halfshaft Oil Seal Installer and the Shaft Bearing Cup Installer, install the cover seal in the PTU .
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3. Install the intermediate shaft seal and deflector. For additional information, refer to Intermediate Shaft Seal and Deflector in this section. 4. Fill the PTU as necessary. For additional information, refer to Power Transfer Unit (PTU) Draining and Filling in this section.
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Output Shaft Seal
Special Tool(s) Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)
Installer, PTU Drive Gear Outer Oil Seal 308-430
Remover, Output Flange 307-523
Output Shaft Seal and Flange
Item 1 2 3 4
Description Collapsible spacer (part of 7275 kit) Output shaft seal (part of 7275 kit) Output shaft seal deflector (part of 7275 kit) Output pinion flange (part of 7275 kit)
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Pinion flange nut (part of 7275 kit)
Removal All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 10002 . All vehicles except Gasoline Turbocharged Direct Injection (GTDI) 2. Remove the 2 exhaust Y-pipe-to-muffler and tail pipe flange nuts. Discard the nuts and gasket. 3. NOTICE: The resonator must be supported to prevent damage to the flexible pipe. 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 5. NOTE: Index-mark both the driveshaft flanges for installation. Remove the 4 driveshaft-to-Power Transfer Unit (PTU) output flange bolts. Disconnect the driveshaft from the PTU and position it aside. Using mechanic's wire, support the driveshaft. 6. 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. 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.
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8. NOTE: Index-mark the output pinion flange to the pinion shaft. Using the Output Flange Remover, remove the output pinion flange.
9. Remove and discard the output shaft seal deflector. 10. Remove and discard the output shaft seal. 11. Remove and discard the collapsible spacer. Installation All vehicles 1. Install the new collapsible spacer. 2. Using the PTU Drive Gear Outer Oil Seal Installer, install the output shaft seal.
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3. Using the PTU Drive Gear Outer Oil Seal Installer, install the output shaft seal deflector.
4. NOTE: Install the output pinion flange to engage the spline as previously marked. Install the output pinion flange. 5. NOTICE: Refer to the rotational torque previously recorded with the Nm (lb-in) torque wrench. Tighten the pinion nut in small increments until it is within 0.3 Nm (3 lb-in) of the reference measurement. If 0.3 Nm (3 lb-in) is exceeded, then the collapsible spacer will be damaged and a new collapsible spacer will be required. Using the Drive Pinion Flange Holding Fixture to hold the output pinion flange, install and tighten the new pinion flange nut.
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6. Using the index mark, position the driveshaft and install the 4 driveshaft-to- PTU output flange bolts. Tighten to 70 Nm (52 lb-ft). GTDI vehicles 7. Install the new LH and RH exhaust flexible pipe-to-underbody catalytic converter gaskets and nuts. Tighten to 40 Nm (30 lb-ft). All vehicles except GTDI 8. Install the new exhaust Y-pipe-to-muffler and tail pipe flange gasket and nuts. Tighten to 40 Nm (30 lb-ft). All vehicles 9. Fill the PTU as necessary. For additional information, refer to Power Transfer Unit (PTU) Draining and Filling in this section.
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Intermediate Shaft Seal and Deflector
Special Tool(s) Bearing Cup Remover 308-125 (T87P-7120-D)
Handle, Driver (32 in) 205-907
Installer, PTU Linkshaft Seal 205-883
Installer, PTU Linkshaft Seal Dust Shield 205-882
Remover, Front Wheel Hub 205-D070 (D93P-1175-B) or equivalent
Remover, Halfshaft 205-241
General Equipment 16 mm (5/8 in) washer (used with 308-125) Material
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Item Metal Brake Parts Cleaner PM-4-A or PM-4-B (US); CPM-4 (Canada) MERCON V Automatic Transmission Fluid XT-5-QM (or XT-5-QMC) (US); CXT5-LM12 (Canada) Silicone Brake Caliper Grease and Dielectric Compound XG-3-A Removal NOTE: For High Resolution: NOTE: For Low Resolution:
! " # $
Specification
MERCON V
ESE-M1C171A
&
'
&
'
&
"
&
"
&
'
&
'
&
"
&
NOTE: The Power Transfer Unit (PTU) may leak different color fluids, red fluid 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 determine the most appropriate service procedure. This procedure will correct a red fluid leak (automatic transmission fluid) from the intermediate shaft seal on the RH side of the PTU . For additional information, refer to Analysis of Leakage in this section. 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. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 . 2. Remove the RH front wheel and tire. For additional information, refer to Section 204-04 . 3. Apply the brake to keep the halfshaft from rotating and remove the front wheel hub nut. Do not discard the nut at this time.
4. Remove the RH brake disc. For additional information, refer to Section 206-03 . 5. NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in major service expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as
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specified during reassembly to make sure of correct retention of these parts. Remove and discard the ball joint nut. Separate the lower control arm from the knuckle.
6. Using the Front Wheel Hub Remover, separate the halfshaft from the wheel hub.
7. Pull the knuckle outboard and rotate it toward the rear of the vehicle. Secure the knuckle assembly.
8. Remove the 2 intermediate shaft bracket nuts and the intermediate and halfshaft assembly. Inspect the intermediate shaft for pitting or damage in the seal contact area. Replace if necessary.
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9. NOTE: The following instruction will prevent the Bearing Cup Remover from opening too far which would make removing the intermediate shaft seal deflector difficult. Place a 16 mm (5/8 in) washer between the components of the Bearing Cup Remover as shown.
NOTICE: Failure to utilize the recommend tools may result in serious damage to the Power Transfer Unit (PTU). 10. Assemble the special tools as indicated in the following table and illustration: Item 1 2 3 308-125 Extension for 205-241 5-pound or larger slide hammer Description
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11. NOTE: Using a 5-pound or larger slide hammer eases the removal of the seal deflector. 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.
12. 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.
Installation NOTE: The following illustration shows the correct orientation of the seal components when installed in the
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vehicle.
Item 1 2 3 4
Description Intermediate shaft seal (part of 7275 kit) retains red transmission fluid used in the transaxle Alignment washer (part of 7275 kit) supports and centers the intermediate shaft in the seal Seal deflector (part of 7275 kit) keeps dust/dirt away from the intermediate shaft seal and Power Transfer Unit (PTU) input shaft seal Seal protector (part of 7275 kit) protects intermediate shaft seal from damage by the intermediate shaft splines during installation. Must be removed before shaft is fully installed
1. Place the intermediate shaft seal on the PTU Linkshaft Seal Installer and Driver Handle with the spring side facing away from the tool.
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2. Using the PTU Linkshaft Seal Installer and Driver Handle, install the intermediate shaft seal.
3. Place the alignment washer on the PTU Linkshaft Seal Installer and Driver Handle.
4. NOTICE: Do not use force when installing the alignment washer or damage to the washer can occur. Using the PTU Linkshaft Seal Installer and Driver Handle, install the alignment washer by hand, pushing it in until it bottoms against the seal.
5. NOTICE: Do not overheat (melt) the seal deflector. Monitor the temperature of the deflector with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating. Do not allow the temperature to exceed 100C (212F). Overheating
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will damage the deflector. If the deflector is damaged, a new deflector must be used. NOTE: Apply a small amount of silicone brake caliper grease and dielectric compound to the inner lip of the deflector where it installs on the tube inside the PTU before heating. This will ease the installation of the deflector. Position the deflector on the PTU Linkshaft Seal Dust Shield Installer using silicone brake caliper grease and dielectric compound to retain it to the installer. Using a suitable heat gun, heat the back of the tool to a minimum of 71C (160F) and a maximum of 93C (200F) by concentrating the heat across the back of the installer while rotating the tool. Once the optimum temperature is achieved on the tool, move the heat gun to the front of the tool and heat the inside of the deflector where it snaps onto the PTU shaft until the temperature of the deflector is a minimum of 93C (200F) to a maximum of 100C (212 F). As an alternative method to heating the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry off the deflector and install.
6. Using a 5-pound or larger dead blow hammer, install the seal deflector immediately after heating using the PTU Linkshaft Seal Dust Shield Installer and Driver Handle.
7. Make sure the deflector is completely seated all the way around and there are no cracks on the face. The deflector is correctly installed when the face of the deflector is recessed 3-5 mm (0.118-0.196 in) into the pocket all the way around.
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8. Once the deflector is fully seated, insert the seal protector into the PTU deflector inside diameter.
9. Apply a thin coat of silicone brake caliper grease and dielectric compound to the intermediate shaft seal journal. 10. NOTE: A slight effort may be required to fully seat the intermediate and halfshaft assembly as it passes through the alignment washer. Partially install the intermediate and halfshaft assembly through the PTU deflector until the splines have cleared the seal protector.
11. Pull the seal protector out of the deflector and off of the intermediate and halfshaft assembly.
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12. Fully install the intermediate and halfshaft assembly and the 2 nuts. Tighten to 25 Nm (18 lb-ft).
13. NOTE: A significant amount of residual fluid will collect between the seal and deflector during this repair. This is a normal condition and should not be misinterpreted as a leak after the repair is complete. Using brake parts cleaner, thoroughly clean the deflector and intermediate shaft area of any residual fluid that may have accumulated during the repair. 14. Position the halfshaft and ball joint into the wheel knuckle. Install the new ball joint nut. Tighten to 150 Nm (111 lb-ft).
15. Install the RH brake disc. For additional information, refer to Section 206-03 .
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16. NOTICE: Do not tighten the halfshaft nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied. Apply the brake to keep the halfshaft from rotating. Using the previously removed wheel hub nut, seat the halfshaft into the front wheel hub. Tighten to 350 Nm (258 lb-ft). Remove and discard the wheel hub nut.
17. NOTICE: The wheel hub nut contains a one-time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur. Apply the brake to keep the halfshaft from rotating and install a new wheel hub nut. Tighten to 350 Nm (258 lb-ft). 18. Install the RH front wheel and tire. For additional information, refer to Section 204-04 . 19. Check the transmission fluid level and add clean transmission fluid as necessary.
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SECTION 308-07B: Transfer Case Power Transfer Unit (PTU) REMOVAL

Page 2 of 5
Item Part Number 1 2 7251 W711918-S
Description Power Transfer Unit (PTU) Driveshaft-to-output flange bolt (4 required)
Page 3 of 5
3 4 5 6 7 8 9 10 11
4R602 W713156-S 6P082 W500724-S W500724-S 7A444 W500741-S W500741-S 7086
Driveshaft Engine roll restrictor-to-transaxle bolts (2 required) Engine roll restrictor PTU support bracket-to-PTU bolts (2 required) PTU support bracket-to-engine bolts (3 required) PTU support bracket Front PTU bolts (3 required) Rear PTU bolts (2 required) Compression seal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 . 2. Remove the RH halfshaft. For additional information, refer to Section 205-04 . 3. Remove the RH catalytic converter. For additional information, refer to Section 309-00 . 4. NOTE: To maintain the initial driveshaft balance, index-mark the driveshaft flange and the output flange. Remove the 4 driveshaft-to-output flange bolts, then disconnect the driveshaft from the output flange. Position the driveshaft aside.
5. Remove the 5 Power Transfer Unit (PTU) support bracket bolts and the support bracket.
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6. Position the engine roll restrictor aside. 1. Remove the 2 engine roll restrictor-to-transaxle bolts. 2. Loosen the rear engine roll restrictor bolt and pivot the roll restrictor downward.
7. NOTE: Position a drain pan under the vehicle. Remove the 5 PTU bolts. Pull the PTU outward and separate it from the transaxle. Rotate the output flange upward, then turn it and remove the PTU from the vehicle. 8. Inspect the compression seal for wear or damage. Install a new seal as necessary. Using a small screwdriver, remove and discard the compression seal.
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SECTION 308-07B: Transfer Case Power Transfer Unit (PTU) INSTALLATION

Page 2 of 4
Item Part Number 1 2 7086 7251 Compression seal
Description Power Transfer Unit (PTU)
Page 3 of 4
3 4 5 6 7 8 9 10 11
W711918-S 4R602 W713156-S 6P082 W500724-S W500724-S 7A444 W500741-S W500741-S
Driveshaft-to-output flange bolt (4 required) Driveshaft Engine roll restrictor-to-transaxle bolts (2 required) Engine roll restrictor PTU support bracket-to-PTU bolts (2 required) PTU support bracket-to-engine bolts (3 required) PTU support bracket Front PTU bolts (3 required) Rear PTU bolts (2 required)
1. NOTE: A new compression seal must be installed whenever the Power Transfer Unit (PTU) is removed from the vehicle. Using a suitable tool, install the new compression seal.
2. Position the PTU in place and install the 5 PTU bolts. Tighten to 90 Nm (66 lb-ft). 3. Position the PTU support bracket in place and install the 3 PTU support bracket-to-engine bolts. Tighten to 70 Nm (52 lb-ft).
4. Install the 2 PTU support bracket-to-transaxle bolts. Tighten to 70 Nm (52 lb-ft).
Page 4 of 4
5. Position the engine roll restrictor to the transaxle and install the 2 bolts. Tighten the engine roll restrictor-to-transaxle bolts to 103 Nm (76 lb-ft). Tighten the rear engine roll restrictor bolt to 90 Nm (66 lb-ft). 6. NOTE: Line up the index marks made during removal. Install the 4 driveshaft-to-output flange bolts. Tighten the bolts in a star-pattern. Tighten to 70 Nm (52 lb-ft). 7. Install the RH catalytic converter. For additional information, refer to Section 309-00 . 8. Install the RH front halfshaft. For additional information, refer to Section 205-04 . 9. Top off fluids as necessary.

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2008 Taurus/Taurus X/Sable Workshop Manual

SECTION 308-07B: Transfer Case Power Transfer Unit (PTU) SPECIFICATIONS

2008 Taurus/Taurus X/Sable Workshop Manual

WSL-M2C192-A and GL-5

0.53L (18 oz)

Nm lb-ft lb-in 150 111 70 20 90 70 90 52 18 66 52 66 103 76 177

Intermediate and halfshaft assembly nuts 25

to the procedure in this section.

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

Power Transfer Unit (PTU)

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

Power Transfer Unit (PTU)

2008 Taurus/Taurus X/Sable Workshop Manual

Leaking gear lubricant from the seals

Vehicle has no or inadequate torque at rear wheels

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

Power Transfer Unit (PTU) Draining and Filling

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

Special Tool(s) Handle, Driver (32 in) 205-907

Installer, Halfshaft Oil Seal 308-431

Installer, Shaft Bearing Cup 308-221 (T94P-7025-BH)

Remover, Halfshaft 205-241

Slide Hammer 100-01 (T50T-100-A)

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

Output Shaft Seal

Special Tool(s) Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A)

Installer, PTU Drive Gear Outer Oil Seal 308-430

Remover, Output Flange 307-523

Output Shaft Seal and Flange

2008 Taurus/Taurus X/Sable Workshop Manual

Pinion flange nut (part of 7275 kit)

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

Intermediate Shaft Seal and Deflector

Special Tool(s) Bearing Cup Remover 308-125 (T87P-7120-D)

Handle, Driver (32 in) 205-907

Installer, PTU Linkshaft Seal 205-883

Installer, PTU Linkshaft Seal Dust Shield 205-882

Remover, Front Wheel Hub 205-D070 (D93P-1175-B) or equivalent

Remover, Halfshaft 205-241

General Equipment 16 mm (5/8 in) washer (used with 308-125) Material

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual

2008 Taurus/Taurus X/Sable Workshop Manual