Ford Taurus Service Manual: Transfer Case - Power Transfer Unit (PTU)

SPECIFICATIONS

Material

Ford Taurus. Manual Transmission, Clutch and Transfer Case

Torque Specifications

Ford Taurus. Manual Transmission, Clutch and Transfer Case

Refer to the procedure in this section.

DESCRIPTION AND OPERATION

Power Transfer Unit (PTU)

The AWD system consists of the following:

  • PTU
  • Rear driveshaft
  • AWD module
  • Rear axle with coupling device

The PTU is a mechanical device attached to the transmission. The PTU supplies torque to the rear axle through the rear driveshaft. The AWD module is an electronic device that sends an electronic signal to the active torque control coupling solenoid which controls the rear axle coupling to apply the torque generated from the PTU to the rear wheels when required.

DIAGNOSIS AND TESTING

Power Transfer Unit (PTU)

Principles of Operation

The PTU is a gearbox that attaches to the transmission. The RH intermediate shaft passes through the PTU and engages the differential side gear as in normal FWD applications. The PTU directs power to the rear driveshaft through a helical gear spline coupled to the transmission differential case, a helical gear drop (idler gear) and hypoid/helical ring gear assembly and pinion set. The PTU is sealed from the transmission 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, input shaft seal, cover seal and the PTU -transmission 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 AWD system utilizes a heat protection mode to protect the 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.
  1. Inspect for obvious signs of mechanical damage.

Visual Inspection Chart

Mechanical

  • PTU
  • Halfshafts and CV joints
  • Driveshaft and U-joints
  • Wheel/tire size and brand
  • Matching tire size and brand
  • Tire pressure
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
  1. If the cause is not visually evident, verify the symptom and GO to Symptom Chart.

Symptom Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. Refer to Diagnostic Methods in Section 100-00 for information about these practices.

Ford Taurus. Manual Transmission, Clutch and Transfer Case

Ford Taurus. Manual Transmission, Clutch and Transfer Case

Analysis of Leakage

NOTE: Inspection of the seal's mating journal should be performed every time a seal is replaced. The mating part/journal should be replaced if it has any of the following conditions: Radial wear groove that can be felt by running a finger nail across where the seal lip runs. Scratches, pitting, galling, nicks or other shaft damage under or near where the seal lip runs. Discoloration or coked oil on the shaft where the seal lip runs. Shaft corrosion under or near where the seal lip runs. Sharp edges or burrs on the shaft lead in chamfer. NEVER use emery cloth on journal finishes, replace the part.

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. Its important to note the color fluid that 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. The specified tools called out in this procedure will allow seal replacement without causing damage to the PTU casing/drive gear.

If the leak is red automatic transmission fluid, 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.

If the leak is brown/black gear lube, the PTU larger cover seal needs replacement. This is located on the PTU cover behind the deflector. REFER to Cover Seal.

Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Intermediate shaft seal (part of kit 7275)
  2. Alignment washer (part of kit 7275)
  3. Cover seal (part of kit 7275)
  4. Seal deflector (part of kit 7275)

PTU Leaks From the LH Side

If the leak is red automatic transmission fluid, the compression seal needs replacement. This is between the PTU and transmission. REFER to Power Transfer Unit (PTU) - 3.5L Ti-VCT or Power Transfer Unit (PTU) - 3.5L GTDI.

If the leak is brown/black and venting fluid from the top of the PTU , the PTU is overfilled due to the input shaft seals leaking red automatic transmission fluid into the PTU. Replace the input shaft seals, REFER to Input Shaft Seal.

Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. PTU -to-transmission compression seal (7086)
  2. Transfer case driver gear seal (7H469)
  3. Transfer case driver gear seal (7H469

GENERAL PROCEDURES

Power Transfer Unit (PTU) Draining and Filling

Special Tool(s)

Ford Taurus. Manual Transmission, Clutch and Transfer Case

Material

Ford Taurus. Manual Transmission, Clutch and Transfer Case

NOTICE: Install a new PTU any time the PTU has been submerged in water.

NOTE: Do not drain the PTU unless contamination is suspected. The fluid that is drained may appear black and have a pungent odor. Do not mistake this for contaminated fluid.

NOTE: Fill level checks are done in-vehicle only. Let the vehicle sit 10 minutes after the road test before checking the fluid level.

All vehicles

  1. With the vehicle in NEUTRAL, position it on a hoist. REFER to Section 100-02, Jacking and Lifting , Lifting Points.

Vehicles with a PTU cooler

NOTE: All vehicles with a PTU cooler will have a drain plug.

  1. Remove the drain plug and drain the PTU.
    • Torque to 20 Nm (177 lb-in).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Remove the PTU temperature sensor heat shield bolts and the heat shield.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Disconnect the PTU temperature sensor electrical connector.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Unclip the PTU temperature sensor wiring harness from the retainer clip and position aside.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTE: Clean the area around the PTU temperature sensor before removing.

    Remove the PTU temperature sensor.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. With the vehicle on a flat, level surface, fill the PTU. The fluid must be even with the bottom of the PTU temperature sensor opening.
    • Fluid capacity is 0.53 L (0.56 qt.).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTE: Replace the O-ring before Installing the PTU temperature sensor.

    Replace the O-ring and install the PTU temperature sensor.

    • Tighten to 12 Nm (106 lb-in).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Clip the PTU temperature sensor wiring harness back into position.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Connect the PTU temperature sensor electrical connector.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Instal the PTU temperature sensor heat shield and heat shield bolts.
    • Tighten to 12 Nm (106 lb-in).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

Vehicles without a PTU cooler

  1. Remove the filler plug.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

Vehicles without a drain plug

  1. With the PTU fluid level even with the bottom of the fill opening, remove as much fluid as possible from the PTU using an Oil Suction Gun 303-D104 (D94T-9000-A).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Refill the PTU fluid level even with the bottom of the fill opening.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Install the filler plug hand-tight.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. With the aid of an assistant, rotate the front tires a minimal of 3 times in the same direction.
  1. Remove the filler plug. Using an Oil Suction Gun 303-D104 (D94T-9000-A), remove as much fluid as possible from the PTU.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Refill the PTU fluid level even with the bottom of the fill opening.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Install the filler plug hand-tight.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. With the aid of an assistant, rotate the front tires a minimal of 3 times in the same direction.
  1. Remove the filler plug. Using an Oil Suction Gun 303-D104 (D94T-9000-A), remove as much fluid as possible from the PTU.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

Vehicles with a drain plug.

  1. Remove the drain plug.
  1. Apply silicone sealant to the drain plug threads and install the plug.
    • Tighten to 20 Nm (177 lb-in).

All vehicles

  1. Fill the PTU with lubricant. The fluid must be even with the bottom of the fill opening.
  1. Apply silicone sealant to the filler plug threads and install the plug.
    • Tighten to 20 Nm (177 lb-in).

REMOVAL AND INSTALLATION

Cover Seal

Special Tool(s)

Ford Taurus. Manual Transmission, Clutch and Transfer Case

Removal

NOTE: The 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. 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 seal and deflector. Refer to Intermediate Shaft Seal and Deflector.
  1. NOTE: There is a bearing inside the PTU directly behind the cover seal. The bearing is not serviced.

    Special Tool(s): Handle from Remover, Halfshaft 205-241, Slide Hammer 100-01 (T50T-100-A).
    General equipment: Seal puller.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

Installation

  1. Special Tool(s): Handle, Driver (32 in) 205-907, Installer, Halfshaft Oil Seal 308-431, Installer, Shaft Bearing Cup 308-221 (T94P-7025-BH).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. New 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).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Install the intermediate shaft seal and deflector. Refer to Intermediate Shaft Seal and Deflector.
  1. Fill the PTU as necessary. Refer to Power Transfer Unit (PTU) Draining and Filling.

Output Shaft Seal

Special Tool(s)

Ford Taurus. Manual Transmission, Clutch and Transfer Case

Removal

All vehicles

  1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02.

All vehicles except GTDI

  1. Remove the 2 exhaust Y-pipe-to-muffler and tail pipe flange nuts.
    • Discard the nuts and gasket.
  1. 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

  1. Remove the 4 LH and RH exhaust flexible pipes-to-underbody catalytic converter nuts.
    • Discard the nuts and gasket.

All vehicles

  1. Index-mark the driveshaft.
    Marker. Discard the specified component. Follow local disposal regulations.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. 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.

    General equipment: Torque wrench.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Special Tool(s): Holding Fixture, Drive Pinion Flange 205-126 (T78P-4851-A).
    Discard the specified component. Follow local disposal regulations.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTE: Index-mark the output pinion flange to the pinion shaft.

    Marker.
    Special Tool(s): Remover, Output Flange 307-523.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Remove and discard the output shaft seal.
  1. Remove and discard the collapsible spacer.

Installation

All vehicles

  1. Install the new collapsible spacer.
  1. Special Tool(s): Installer, PTO Drive Gear Outer Oil Seal 308-430.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Visual check.
    Align the index-mark made during removal.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. 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.

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

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTE: Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal.
    • Tighten to 70 Nm (52 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

GTDI vehicles

  1. 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

  1. Install the new exhaust Y-pipe-to-muffler and tail pipe flange gasket and nuts.
    • Tighten to 40 Nm (30 lb-ft).

All vehicles

  1. Fill the PTU as necessary. Refer to Power Transfer Unit (PTU) Draining and Filling.

Intermediate Shaft Seal and Deflector

Special Tool(s)

Ford Taurus. Manual Transmission, Clutch and Transfer Case

General Equipment

Ford Taurus. Manual Transmission, Clutch and Transfer Case

Material

Ford Taurus. Manual Transmission, Clutch and Transfer Case

Removal

NOTE: For high resolution: 

 Click here to view a video version of this procedure.

NOTE: For low resolution: 

 Click here to view a video version of this procedure.

NOTE: The 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. Refer to Analysis of Leakage under Power Transfer Unit (PTU).

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. Refer to Section 100-02.
  1. Remove the RH front wheel and tire. Refer to Section 204-04.
  1. Remove the RH brake disc. Refer to Section 206-03.
  1. Remove the RH intermediate shaft. Refer to Section 205-04.
  1. NOTE: The following instruction will prevent the Remover, Transfer Case Bearing Cup 308-125 (T87P-7120-D) from opening too far which would make removing the intermediate shaft seal deflector difficult.

    Special Tool(s): Remover, Transfer Case Bearing Cup 308-125 (T87P-7120-D).
    Place a 16 mm (5/8 in) washer between the components as shown.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

NOTICE: Failure to utilize the recommended tools may result in serious damage to the PTU.

  1. Special Tool(s): Remover, Transfer Case Bearing Cup 308-125 (T87P-7120-D), handle from Remover, Halfshaft 205-241, Slide Hammer Master Set 100-D112.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Special Tool(s): Remover, Transfer Case Bearing Cup 308-125 (T87P-7120-D), handle from Remover, Halfshaft 205-241, Slide Hammer Master Set 100-D112.
    • The seal deflector will be damaged during removal. Remove all foreign material from the PTU before continuing with the repair.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Special Tool(s): Remover, Transfer Case Bearing Cup 308-125 (T87P-7120-D), handle from Remover, Halfshaft 205-241, Slide Hammer Master Set 100-D112.
    Remove the intermediate shaft seal, and if equipped, the alignment washer.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

Installation

NOTE: The following illustration shows the correct orientation of the seal components when installed in the vehicle.

Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Intermediate shaft seal (part of 7275 kit) - retains red automatic transmission fluid used in the transmission
  2. Alignment washer (part of 7275 kit) - supports and centers the intermediate shaft in the seal
  3. Cover Seal (part of 7275 kit) - keeps dust/dirt away from the intermediate shaft seal
  4. Seal deflector (part of 7275 kit) - keeps dust/dirt away from the PTU input shaft seal
  5. 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. Special Tool(s): Installer, PTU Linkshaft Seal 205-883, Handle, Driver 812.8 mm (32 in) 205-907.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Special Tool(s): Installer, PTU Linkshaft Seal 205-883, Handle, Driver 812.8 mm (32 in) 205-907.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Special Tool(s): Installer, PTU Linkshaft Seal 205-883, Handle, Driver 812.8 mm (32 in) 205-907.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTICE: Do not use force when installing the alignment washer or damage to the washer can occur.

    Special Tool(s): Installer, PTU Linkshaft Seal 205-883, Handle, Driver 812.8 mm (32 in) 205-907.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTICE: Do not overheat (melt) the seal deflector. Monitor the temperature of the deflector with a temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating. Do not allow the temperature to exceed 100ºC (212ºF). Overheating 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.

    Hot air gun.
    Special Tool(s): Installer, Front Axle Bushing 205-346, Handle, Driver 812.8 mm (32 in) 205-907.
    Position the deflector on the Installer, Front Axle Bushing 205-346 using silicone brake caliper grease and dielectric compound to retain it to the Installer, Front Axle Bushing 205-346. Using a hot air gun, heat the back of the tool to a minimum of 71ºC (160ºF) and a maximum of 93ºC (200ºF) 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 93ºC (200ºF) to a maximum of 100ºC (212ºF).
    • 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.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. General Equipment: 5-Pound Dead Blow Hammer
    Special tool(s): Installer, Front Axle Bushing 205-346, Handle, Driver 812.8 mm (32 in) 205-907.
    Install the seal deflector immediately after heating.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. 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 (0.12-0.20 in) into the pocket all the way around.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. 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 metal brake parts cleaner, thoroughly clean the deflector and intermediate shaft area of any residual fluid that may have accumulated during the repair.

  1. Install the RH intermediate shaft. Refer to Section 205-04.
  1. Install the RH brake disc. Refer to Section 206-03.
  1. Install the RH front wheel and tire. Refer to Section 204-04.
  1. Fill the transmission as necessary. Refer to Section 307-01A.

Input Shaft Seal

Special Tool(s)

Ford Taurus. Manual Transmission, Clutch and Transfer Case

Removal

  1. Remove the PTU. Refer to Power Transfer Unit (PTU) - 3.5L Ti-VCT or Power Transfer Unit (PTU) - 3.5L GTDI.
  1. Special Tool(s): Holding Fixture, Transmission 307-003 (T57L-500-B).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Discard the specified component. Follow local disposal regulations.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

NOTICE: Do not press the seals lower than specified. Excessive force will damage the bearing below the seals.

NOTE: Both seals will need to be pressed lower into the PTU input shaft opening to break the seals outer sealant loose from the PTU.

NOTE: There is approximately a 5 mm (0.196 in) air gap between both seals and approximately 1 mm (0.039 in) air gap between the inner seal and the bearing race.

  1. Special Tool(s): Installer, Parking Brake Bearing 206-040 (T88T-2598-F).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Special Tool(s): Remover/Installer, PTU Input Shaft Seal 308-777/1.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Special Tool(s): Remover/Installer, PTU Input Shaft Seal 308-777/1, Remover/Installer, PTU Input Shaft Seal 308-777/2.
    Press the Remover/Installer, PTU Input Shaft Seal 308-777/2 (punch) downward until the shoulder of the Remover/Installer, PTU Input Shaft Seal 308-777/2 (punch) touches the Remover/Installer, PTU Input Shaft Seal 308-777/1.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTE: Do not overtighten the Remover/Installer, PTU Input Shaft Seal 308-777/3 (screws). Turn the Remover/Installer, PTU Input Shaft Seal 308-777/3 (screws) until they are seated into the Remover/Installer, PTU Input Shaft Seal 308-777/1 holes.

    Special Tool(s): Remover/Installer, PTU Input Shaft Seal 308-777/1, Remover/Installer, PTU Input Shaft Seal 308-777/3 (screws).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Special Tool(s): Remover/Installer, PTU Input Shaft Seal 308-777/1, Remover/Installer, PTU Input Shaft Seal 308-777/2.
    Press the Remover/Installer, PTU Input Shaft Seal 308-777/2 (punch) downward until the shoulder of the Remover/Installer, PTU Input Shaft Seal 308-777/2 (punch) touches the Remover/Installer, PTU Input Shaft Seal 308-777/1.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTE: Do not overtighten the Remover/Installer, PTU Input Shaft Seal 308-777/3 (screws). Turn the Remover/Installer, PTU Input Shaft Seal 308-777/3 (screws) until they are seated into the Remover/Installer, PTU Input Shaft Seal 308-777/1 holes.

    Special Tool(s): Remover/Installer, PTU Input Shaft Seal 308-777/1, Remover/Installer, PTU Input Shaft Seal 308-777/3 (screws).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Special Tool(s): Slide Hammer 100-001 (T50T-100-A), Remover/Installer, PTU Input Shaft Seal 308-777/1.
    Discard the specified component. Follow local disposal regulations.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Drain the PTU.
    • Position the PTU output flange upward and tilt the PTU approximately 30 degrees toward the LH seal bore to allow the fluid to drain from the PTU input shaft opening.

Installation

  1. Clean the specified component with the special material. Visual check.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Visual check.
    Special Tool(s): Remover/Installer, PTU Input Shaft Seal 308-777/4, Handle 205-153 (T80T-4000-W).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Visual check.
    Special Tool(s): Remover/Installer, PTU Input Shaft Seal 308-777/5, Handle 205-153 (T80T-4000-W).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. New compression seal.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Install the PTU. Refer to Power Transfer Unit (PTU) - 3.5L Ti-VCT or Power Transfer Unit (PTU) - 3.5L GTDI.
  1. Fill the PTU as necessary. Refer to Power Transfer Unit (PTU) Draining and Filling.

Power Transfer Unit (PTU) - 3.5L Ti-VCT

Removal

  1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. If equipped with PTU cooling, drain the cooling system. Refer to Section 303-03.
  1. Remove the intermediate shaft. Refer to Section 205-04.
  1. Remove the RH catalytic converter. Refer to Section 309-00.
  1. Index-mark the driveshaft. Marker. Discard the specified component. Follow local disposal regulations.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. If equipped with PTU cooling system.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. If equipped with PTU cooling system.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Discard the specified component. Follow local disposal regulations.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

Installation

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    • Tighten to 90 Nm (66 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTE: Inspect the O-ring seals and replace as necessary.

    If equipped, install the PTU coolant tubes and the bolt.

    • Tighten to 25 Nm (18 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. If equipped, connect the PTU cooling system temperature sensor electrical connector.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    • Tighten to 70 Nm (52 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    • Tighten the roll restrictor-to-transmission bracket bolts to 90 Nm (66 lb-ft).
    • Tighten the roll restrictor through bolt to 103 Nm (76 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    • Tighten to 9 Nm (80 lb-in).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Tighten to 48 Nm (35 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Line up the index marks. Visual check.
    • Tighten to 70 Nm (52 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Install the RH catalytic converter. Refer to Section 309-00.
  1. NOTE: A new PTU intermediate shaft seal must be installed whenever the intermediate shaft or PTU is removed from the vehicle. Refer to Intermediate Shaft Seal and Deflector.

    Install the intermediate shaft. Refer to Section 205-04.

  1. Clean the specified component with the specified material.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Fill the PTU , if necessary. The fluid must be even with the bottom of the fill opening.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    • Tighten to 20 Nm (177 lb-in).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. If equipped with PTU cooling, fill the cooling system. Refer to Section 303-03.

Power Transfer Unit (PTU) - 3.5L GTDI

Removal

  1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02.
  1. General equipment: Steering wheel holder.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. If equipped with PTU cooling, drain the cooling system. Refer to Section 303-03.
  1. Remove the intermediate shaft. Refer to Section 205-04.
  1. Remove the RH catalytic converter. Refer to Section 309-00.
  1. Index-mark the driveshaft. Marker. Discard the specified component. Follow local disposal regulations.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTICE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. Refer to Section 501-20B.

    Discard the specified component. Follow local disposal regulations.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. General equipment: Jackstand.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTE: RH shown, LH similar.

    Discard the specified component. Follow local disposal regulations.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTE: RH shown, LH similar.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. General equipment: Jackstand.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. If equipped with PTU cooling system.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. If equipped with PTU cooling system.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Discard the specified component. Follow local disposal regulations.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

Installation

  1. New compression seal.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    • Tighten to 90 Nm (66 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTE: Inspect the O-ring seals and replace as necessary.

    If equipped, install the PTU coolant tubes and the bolt.

    • Tighten to 25 Nm (18 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. If equipped, connect the PTU cooling system temperature sensor electrical connector.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTE: RH shown, LH similar.

    Tighten to 55 Nm (41 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTE: RH shown, LH similar.
    • Tighten to 150 Nm (111 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    • Tighten the roll restrictor bracket bolts to 90 Nm (66 lb-ft).
    • Tighten the roll restrictor through bolt to 103 Nm (76 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    • Tighten the roll restrictor bracket bolts to 90 Nm (66 lb-ft).
    • Tighten the roll restrictor through bolt to 103 Nm (76 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    • Tighten the 2 bolts to 70 Nm (52 lb-ft).
    • Tighten the bolt to 48 Nm (35 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    • Tighten the 2 bolts to 48 Nm (35 lb-ft).
    • Tighten the bolt to 19 Nm (168 lb-in).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Tighten to 9 Nm (80 lb-in).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Tighten to 9 Nm (80 lb-in).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTICE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. Refer to Section 501-20B.
    • Tighten to 20 Nm (177 lb-in).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Line up the index marks. Visual check.
    • Tighten to 70 Nm (52 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Install the RH catalytic converter. Refer to Section 309-00.
  1. NOTE: A new PTU intermediate shaft seal must be installed whenever the intermediate shaft or PTU is removed from the vehicle. Refer to Intermediate Shaft Seal and Deflector.

    Install the intermediate shaft. Refer to Section 205-04.

  1. Clean the specified component with the specified material.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Fill the PTU , if necessary. The fluid must be even with the bottom of the fill opening.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    • Tighten to 20 Nm (177 lb-in).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. If equipped with PTU cooling, fill the cooling system. Refer to Section 303-03.

Power Transfer Unit (PTU) - 3.7L Ti-VCT

Removal

  1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. If equipped with PTU cooling, drain the cooling system. Refer to Section 303-03.
  1. Remove the intermediate shaft. Refer to Section 205-04.
  1. Remove the RH catalytic converter. Refer to Section 309-00.
  1. Index-mark the driveshaft. Marker. Discard the specified component. Follow local disposal regulations.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. If equipped with PTU cooling system.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. If equipped with PTU cooling system.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Discard the specified component. Follow local disposal regulations.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

Installation

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    • Tighten to 90 Nm (66 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. NOTE: Inspect the O-ring seals and replace as necessary.

    If equipped, install the PTU coolant tubes and the bolt.

    • Tighten to 25 Nm (18 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. If equipped, connect the PTU cooling system temperature sensor electrical connector.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    • Tighten to 70 Nm (52 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    • Tighten the roll restrictor-to-transmission bracket bolts to 90 Nm (66 lb-ft).
    • Tighten the roll restrictor through bolt to 103 Nm (76 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    • Tighten to 9 Nm (80 lb-in).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Tighten to 48 Nm (35 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Line up the index marks. Visual check.
    • Tighten to 70 Nm (52 lb-ft).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Install the RH catalytic converter. Refer to Section 309-00.
  1. NOTE: A new PTU intermediate shaft seal must be installed whenever the intermediate shaft or PTU is removed from the vehicle. Refer to Intermediate Shaft Seal and Deflector.

    Install the intermediate shaft. Refer to Section 205-04.

  1. Clean the specified component with the specified material.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. Fill the PTU , if necessary. The fluid must be even with the bottom of the fill opening.

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    • Tighten to 20 Nm (177 lb-in).

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

    Ford Taurus. Manual Transmission, Clutch and Transfer Case

  1. If equipped with PTU cooling, fill the cooling system. Refer to Section 303-03.
    Four Wheel Drive (4WD) Systems
    DESCRIPTION AND OPERATION All Wheel Drive (AWD) Systems The AWD system consists of the following: PTU Rear driveshaft AWD relay module Rear axle with ATC solenoid Torque ...

    Exhaust System
    SPECIFICATIONS Torque Specifications a Refer to the procedure in this section. DESCRIPTION AND OPERATION Exhaust System Component Location The 2.0L Gasoline Turbocharged Direct Injection (GTDI) ...

    Other materials:

    Manual heating and air conditioning
    A. Fan speed control: Controls the volume of air circulated in your vehicle. Turn to select the desired fan speed or switch off. If you switch the fan off, the windshield may fog up. B. Defrost: Distributes air through the windshield defroster vents and demister vents. This setting can also ...

    Audio System
    GENERAL INFORMATION Radio Frequencies and Reception Factors AM and FM frequencies are established by the Federal Communications Commission (FCC) and the Canadian Radio and Telecommunications Commission (CRTC). Those frequencies are: AM: 530, 540–1700, 1710 kHz FM: 87.9–107.7, 107.9 MHz ...

    Appendices
    GENERAL INFORMATION SYNC® End User License Agreement (EULA) • You have acquired a device (“DEVICE”) that includes software licensed by Ford Motor Company and its affiliates (“FORD MOTOR COMPANY”) from an affiliate of Microsoft Corporation (“MS”). Those installed software products ...