Power Transfer Unit (PTU) Draining and Filling

SPECIAL TOOL(S)

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Oil Suction Gun 303-D104 (D94T-9000-A)

MATERIAL

Item	Specification
Motorcraft® SAE 75W-140 Synthetic Rear Axle Lubricant XY-75W140-QL (US); CXY-75W140-1L (Canada)	WSL-M2C192-A and GL-5
Motorcraft® Silicone Gasket and Sealant TA-30	WSE-M4G323-A4

NOTE: 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 Jacking and Lifting , Lifting Points.

Vehicles with a PTU cooler

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

2.

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

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3.

Remove the RH catalytic converter. Refer to REFER to Exhaust System - 3.5L GTDI.

4.

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

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5.

Disconnect the PTU temperature sensor electrical connector.

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6.

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

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7.

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

NOTE: The PTU temperature sensor can be removed using a 15mm crows foot and extension.

Remove the PTU temperature sensor.

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8.

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.).

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9.

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).

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10.

Clip the PTU temperature sensor wiring harness back into position.

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11.

Connect the PTU temperature sensor electrical connector.

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12.

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

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13.

Install the RH catalytic converter. REFER to Exhaust System - 3.5L GTDI.

Vehicles without a PTU cooler

14.

Remove the filler plug.

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Vehicles without a drain plug

15.

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).

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16.

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

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17.

Install the filler plug hand-tight.

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18.

With the aid of an assistant, rotate the front tires a minimal of 3 times in the same direction.

19.

Remove the filler plug. Using an Oil Suction Gun 303-D104 (D94T-9000-A), remove as much fluid as possible from the PTU.

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20.

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

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21.

Install the filler plug hand-tight.

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22.

With the aid of an assistant, rotate the front tires a minimal of 3 times in the same direction.

23.

Remove the filler plug. Using an Oil Suction Gun 303-D104 (D94T-9000-A), remove as much fluid as possible from the PTU.

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Vehicles with a drain plug.

24.

Remove the drain plug.

25.

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

All vehicles

26.

Fill the PTU with lubricant. The fluid must be even with the bottom of the fill opening.

27.

Apply silicone sealant to the filler plug threads and install the plug.
- Tighten to 20 Nm (177 lb-in).