Ford Fusion Manuals

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

Special Tool(s) / General Equipment

Ford Fusion. Power Transfer Unit Input Shaft Seal. Removal and Installation 205-153 (T80T-4000-W)
Handle
Ford Fusion. Power Transfer Unit Input Shaft Seal. Removal and Installation 308-875
Installer, Inboard Cover Seal
TKIT-2012A-FL
TKIT-2012A-ROW
Ford Fusion. Power Transfer Unit Input Shaft Seal. Removal and Installation 308-878
Installer, Input Seal
TKIT-2012A-FL
TKIT-2012A-ROW

Removal

  1. Remove the PTU/transfer case.
    Refer to: Power Transfer Unit (308-07B Power Transfer Unit - 6-Speed Automatic Transmission – 6F35, Removal).
  1. Remove and discard the PTU cover bolts and remove the PTU cover.
Ford Fusion. Power Transfer Unit Input Shaft Seal. Removal and Installation
  1. Remove and discard the PTU cover O-ring seal.
Ford Fusion. Power Transfer Unit Input Shaft Seal. Removal and Installation
  1. Remove and discard the RH input shaft seal.
Ford Fusion. Power Transfer Unit Input Shaft Seal. Removal and Installation
  1. Remove the input shaft.
Ford Fusion. Power Transfer Unit Input Shaft Seal. Removal and Installation
  1. Remove and discard the LH input shaft seal.
Ford Fusion. Power Transfer Unit Input Shaft Seal. Removal and Installation

Installation

  1. Using the special tools, install a new LH input shaft seal.
    Use Special Service Tool: 308-878  Installer, Input Seal. , 205-153 (T80T-4000-W)  Handle.
Ford Fusion. Power Transfer Unit Input Shaft Seal. Removal and Installation
  1. Install the input shaft.
Ford Fusion. Power Transfer Unit Input Shaft Seal. Removal and Installation
  1. NOTE: The seal is correctly installed if it is flush with the transfer case cover.

    Using the special tools, install a new RH input shaft seal.
    Use Special Service Tool: 308-875  Installer, Inboard Cover Seal. , 205-153 (T80T-4000-W)  Handle.
Ford Fusion. Power Transfer Unit Input Shaft Seal. Removal and Installation
  1. Install a new PTU cover O-ring seal.
Ford Fusion. Power Transfer Unit Input Shaft Seal. Removal and Installation
  1. Install the PTU cover and the new PTU cover bolts.
    Torque:
      Stage 1:  115 lb.in (13 Nm)
      Stage 2:  45°
Ford Fusion. Power Transfer Unit Input Shaft Seal. Removal and Installation

NOTICE: Hand start bolts for the first three threads to ensure cross-threading does not occur.

  1. Install the PTU/transfer case.
    Refer to: Power Transfer Unit (308-07B Power Transfer Unit - 6-Speed Automatic Transmission – 6F35, Installation).

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