Ford Fusion: Power Transfer Unit - 6-Speed Automatic Transmission – 6F35 / Intermediate Shaft Bushing. Removal and Installation

Ford Fusion 2013–2020 Service Manual / Powertrain / Four-Wheel Drive Systems / Power Transfer Unit - 6-Speed Automatic Transmission – 6F35 / Intermediate Shaft Bushing. Removal and Installation

Special Tool(s) / General Equipment

	308-125 Remover, Transfer Case Bearing TKIT-1987-LM TKIT-1987-FLM
Slide Hammer

Removal

Remove the intermediate shaft seal.
Refer to: Intermediate Shaft Seal (308-07B Power Transfer Unit - 6-Speed Automatic Transmission – 6F35, Removal and Installation).

Using the special tool and a slide hammer, remove and discard the intermediate shaft bushing.
Use Special Service Tool: 308-125 Remover, Transfer Case Bearing.
Use the General Equipment: Slide Hammer

Installation

Clean the PTU input shaft.

NOTICE: The bushing can be easily damaged when using a driver that is too small. Use light force and monitor installation progress frequently to avoid bushing damage.
Using general shop equipment, install the new intermediate shaft bushing until it is seated against the machined recess in the PTU input shaft.

Install a new intermediate shaft seal.
Refer to: Intermediate Shaft Seal (308-07B Power Transfer Unit - 6-Speed Automatic Transmission – 6F35, Removal and Installation).

Power Transfer Unit Fluid Level Check. General Procedures

Materials Name Specification Motorcraft® SAE 75W-140 Synthetic Rear Axle LubricantXY-75W140-QL WSL-M2C192-A Check With the vehicle in NEUTRAL, position it on a hoist...

Intermediate Shaft Seal. Removal and Installation

Special Tool(s) / General Equipment 205-907Handle, 32 DriverTKIT-2008DH-FLM 307-256 (T92P-77000-FH) Installer, Differential Fluid SealTKIT-1992-FLMH/LMH Puller Removal Remove the RH halfshaft...

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