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

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

Special Tool(s) / General Equipment

	205-907 Handle, 32 Driver TKIT-2008DH-FLM
	307-256 (T92P-77000-FH) Installer, Differential Fluid Seal TKIT-1992-FLMH/LMH
Puller

Removal

Remove the RH halfshaft.
Refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation).

Using the puller, remove and discard the intermediate shaft seal.
Use the General Equipment: Puller

Ford Fusion. Intermediate Shaft Seal. Removal and Installation

Inspect the intermediate shaft bushing. Replace if necessary.
Refer to: Intermediate Shaft Bushing (308-07B Power Transfer Unit - 6-Speed Automatic Transmission – 6F35, Removal and Installation).

Installation

NOTE: The seal is correctly installed if it is flush with the transfer case cover.
Using the special tools, install a new intermediate shaft seal.
Use Special Service Tool: 307-256 (T92P-77000-FH) Installer, Differential Fluid Seal. , 205-907 Handle, 32 Driver.

Install the RH halfshaft.
Refer to: Front Halfshaft RH (205-04 Front Drive Halfshafts, Removal and Installation).

Intermediate Shaft Bushing. Removal and Installation

Special Tool(s) / General Equipment 308-125Remover, Transfer Case BearingTKIT-1987-LMTKIT-1987-FLM Slide Hammer Removal Remove the intermediate shaft seal...

Power Transfer Unit Input Shaft Seal. Removal and Installation

Special Tool(s) / General Equipment 205-153 (T80T-4000-W) Handle 308-875Installer, Inboard Cover SealTKIT-2012A-FLTKIT-2012A-ROW 308-878Installer, Input SealTKIT-2012A-FLTKIT-2012A-ROW Removal Remove the PTU/transfer case...

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Ford Fusion 2013–2020 Owners Manual: End User License Agreement

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