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Power Transfer Unit (PTU) - Automatic Transaxle

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
Material

Item Specification
Motorcraft SAE 75W-140 Synthetic Rear Axle Lubricant
XY-75W140-QL (US); CXY-75W140-1L (Canada) (vehicles with the trailer towing option or 4:10 ratio)		 WSL-M2C192-A
Fig 1: Exploded View Of Power Transfer Unit PTU - Automatic Transaxle With Torque Specifications
GF0025483Courtesy of FORD MOTOR CO.
Item Part Number Description
1 W500210-S Power transfer unit (PTU) heat shield bolts (3 required)
2 7F496 PTU heat shield
3 7251 PTU
4 W706822-S PTU-to-transaxle bolts (3 required)
5 W500121-S PTU-to-transaxle bolt (M10)
6 7034 Vent tube
7 - PTU-to-engine bracket bolt (4 cylinder engine) (6 required)
8 3K305 PTU-to-engine bracket (4 cylinder bracket)
9 - PTU-to-engine bracket bolts (6 cylinder engines) (6 required)
10 3K305 PTU-to-engine bracket (6 cylinder engines)

All vehicles 

    CAUTION: A new power transfer unit (PTU) intermediate shaft seal must be installed whenever the intermediate shaft or PTU is removed from the vehicle.
    NOTE: If necessary, install a new RH differential fluid seal. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - CD4E article or AUTOMATIC TRANSAXLE/TRANSMISSION - ELECTRONICALLY CONTROLLED CONTINUOUSLY VARIABLE TRANSMISSION (ECVT) article.
  1. Position the power transfer unit (PTU) to the transaxle.
  2. Install the PTU-to-engine bracket and the 6 bracket bolts.
    • Tighten to 48 Nm (35 lb-ft).
  3. Connect the PTU vent tube.
  4. Install the 3 PTU-to-transaxle bolts.
    • Tighten to 70 Nm (52 lb-ft).
  5. Install the PTU-to-transaxle bolt (M10).
    • Tighten to 47 Nm (35 lb-ft).
  6. Install the PTU heat shield and the 3 PTU heat shield bolts.
    • Tighten to 11 Nm (8 lb-ft).

    7. Vehicles equipped with 3.0L 

  7. Install the catalytic converter - 3.0L RH manifold. For additional information, refer to EXHAUST SYSTEM article.

    8. All vehicles 

  8. Install the crossmember brace and the 4 bolts.
    • Tighten to 40 Nm (30 lb-ft).
    9. Fig 2: Crossmember Brace Bolts
    GF0025471Courtesy of FORD MOTOR CO.
  9. Install the driveshaft. For additional information, refer to DRIVESHAFT article.
  10. Install the front RH intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS article.
  11. Install the exhaust as required. For additional information, refer to EXHAUST SYSTEM article.
  12. Fill the PTU. For additional information, refer to Power Transfer Unit (PTU) Draining and Filling - Automatic Transaxle .
  13. Check the transaxle fluid level. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - CD4E article or AUTOMATIC TRANSAXLE/TRANSMISSION - ELECTRONICALLY CONTROLLED CONTINUOUSLY VARIABLE TRANSMISSION (ECVT) article.
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