Drivetrain - PTU R/H Intermediate Shaft Leaks Svc. Tips
TSB 09-25-712/28/09
SERVICE TIP - POWER TRANSFER UNIT (PTU) -
RIGHT HAND INTERMEDIATE SHAFT SEAL LEAKS
FORD:
2008-2009 Taurus X
2008-2010 Taurus
2007-2010 Edge
2009-2010 Flex
LINCOLN:
2009-2010 MKS
2007-2010 MKX
2010 MKT
MERCURY:
2008-2009 Sable
This article supersedes TSB 09-8-10 to update the vehicle model years, vehicle line application and Part List.
ISSUE
Some 2007-2010 Edge, MKX, 2008-2009 Taurus-X, Sable 2008-2010 Taurus, 2009-2010 Flex and MKS and 2010 MKT vehicles may experience a fluid leak at the power transfer unit (PTU) right hand (RH) intermediate shaft seal. The online Workshop Manual (WSM), Section 308-07B has been updated with new tools and service procedures to assist with resolving leaks in this area. In addition, two (2) new seal kits were developed and depending on the location of the leak must be used to prevent repeat repairs.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
This service information is intended to improve diagnosis and repair of PTU leaks. It is still necessary to use the updated version of the online WSM, Section 308-07B to perform the actual repair.
FLUID COLOR AND DIAGNOSIS:
Automatic Transmission Fluid
Red automatic transmission fluid (ATF) is not used in the PTU itself. The RH intermediate shaft passes from the transaxle through the input hub of the PTU, where the intermediate shaft seal is located. A red ATF leak indicates fluid from the transaxle is leaking past this intermediate shaft seal contained in the PTU. Use the seal kit, which contains four pieces: the intermediate shaft seal, alignment washer, deflector, and seal protector tool. The intermediate shaft seal, alignment washer, and deflector need to be installed individually and before the seal protector tool is used.
Brown/Black Fluid Indicates a True PTU Seal Leak
Use the seal kit, which contains five pieces: the PTU cover seal, intermediate shaft seal, alignment washer, deflector and seal protector tool. The intermediate shaft seal, alignment washer, cover seal, and deflector need to be installed individually and before the seal protector tool is used. Use seal kit, which contains the PTU cover seal, intermediate shaft seal, alignment washer, and deflector. All four parts need to be installed individually.
NOTE
REFER TO (FIGURES 1 AND 2) THAT IDENTIFIES THE LOCATION OF THE PTU LEAKS.
Service Kit Contents/Function:
^ Cover Seal - Retains brown/black gear lube used in the PTU.
NOTE
THE PTU COVER SEAL ONLY NEEDS TO BE REPLACED WHEN THERE IS BROWN/BLACK GEAR LUBE LEAKING FROM BETWEEN THE BOTTOM EDGE OF THE DEFLECTOR AND THE PTU COVER.
^ Intermediate Shaft Seal - Retains red ATF used in the transaxle.
^ Alignment Washer - Supports and centers the intermediate shaft in the seal.
^ Deflector - Keeps dust and dirt away from the intermediate shaft and PTU input shaft seals.
^ Seal Protector Tool - which is a one time use, keeps the shaft splines from contacting intermediate shaft seal during installation to prevent the seal from being damaged. It is very important to remove the seal protector off the intermediate shaft during the installation at the proper distance to prevent seal damage. (Figure 3)
Performing Repair
It is necessary to use the updated version of the online WSM, Section 308-07B to perform the actual repair. The service procedure has been updated with new and improved service tools specified. Failing to follow the WSM to perform this repair will result in repeat PTU leaks. Never remove the deflector by use of a pry bar or chisel this will result in damage to the input shaft PTU hub and/or PTU housing. It is very important to properly heat the new deflector to the desired temperature specifications called out in the WSM, prior to installation. Never attempt to heat the deflector on the PTU assembly to seat it, seal damage will result. When the new deflector is properly seated it will be recessed 1/8" - 3/16" (3-5 mm) into the PTU pocket. (Figure 4)
NOTE
MAKE SURE LINKSHAFT SEAL INSTALLER (205-883) IS CLEAN OF DEBRIS AND THERE ARE NO BURRS THAT COULD DAMAGED THE SEAL PRIOR TO INSTALLATION.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
092507A 2007-2010 Edge, MKX, 1.6 Hrs.
2008-2010 Taurus,
2008-2009 Taurus X
Sable, 2009-2010 Flex,
MKS, 2010 MKT: Replace
The PTU Intermediate
Shaft Seal, Includes Time
To Replace The
Passenger Side PTU
Intermediate Shaft Seal
And Deflector In Vehicle
(Do Not Use With Any
Other Labor Operations)
092507B 2007-2010 Edge, MKX, 1.9 Hrs.
2008-2010 Taurus,
2008-2009 Taurus X
Sable, 2009-2010 Flex,
MKS, 2010 MKT: Replace
The PTU Cover Seal,
Passenger Side PTU
Intermediate Shaft Seal
And, Deflector In Vehicle
(Do Not Use With Any
Other Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7275 D8
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