Drivetrain - Power Transfer Unit Fluid Leaks
TSB 06-9-605/15/06
OIL LEAK FROM POWER TRANSFER UNIT
FORD:
2005 Five Hundred, Freestyle
MERCURY:
2005 Montego
This article supersedes TSB 06-4-11 to update the parts list.
ISSUE
Some 2005 Freestyle, Five Hundred, and Montego vehicles equipped with All Wheel Drive may exhibit an oil leak from the power transfer unit (PTU) input seal.
ACTION
Replace the input shaft seal following the Service Procedure.
SERVICE PROCEDURE
1. Remove the PTU from the vehicle following Workshop Manual, Section 308-07.
2. Position the PTU on the bench with input shaft upward. (Figure 1)
3. Remove the deflector (7H459) from the PTU input shaft. (Figure 2)
4. Remove the input shaft seal (7H429).
5. Use Loctite(R) 7070 or equivalent cleaner to clean PTU seal area of dirt/oil.
6. Verify that no residual cleaner remains on the PTU seal area.
7. Install a new seal with the seal installer (205-815) per the Workshop Manual, Section 308-07.
8. Apply a bead of Loctite(R) 410 to seal/PTU interface, 360° around the seal. (Figure 3)
NOTE
DO NOT OVER APPLY.
9. Allow Loctite(R) to cure for at least 1 minute.
10. Reinstall deflector. (Figure 4)
11. Rotate the PTU and remove the oil fill plug.
NOTE
ALWAYS HANDLE THE PTU SO THE VENT IS IN THE UPWARD POSITION TO KEEP OIL AWAY FROM THE VENT AREA.
12. Drain all of the oil out of the PTU.
13. Remove the black plastic filter (4022) from the brass vent (7034) by carefully prying out with a small blade screwdriver.
14. Wipe off any excess oil from the inside of the brass vent and verify that no parts of the filter are left inside vent opening.
15. Install a new filter
16. Reinstall the PTU into the vehicle following the Workshop Manual, Section 308-07.
17. Fill the PTU with oil per the Workshop Manual, Section 308-07.
18. Reinstall the oil fill plug.
NOTE
ALWAYS HANDLE THE PTU SO THE VENT IS IN THE UPWARD POSITION TO KEEP OIL AWAY FROM THE VENT AREA.
NOTE
TO LOCATE A LOCTITE(R) DISTRIBUTOR GO TO SELECT YOUR COUNTRY, THEN SELECT "DISTRIBUTORS" OR "CONTACT US" TO SEARCH FOR A LOCAL DISTRIBUTOR.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
060906A 2005 Five Hundred AWD, 2.6 Hrs.
Freestyle AWD, Montego
AWD: Replace The Input
Shaft Seal, And Vent
Includes Time To Remove
And Install Power Transfer
Unit (Do Not Use With
7003B, 7003B1)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7H424 D8
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