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

Special Tool(s) / General Equipment

	205-153 (T80T-4000-W) Handle
	308-875 Installer, Inboard Cover Seal TKIT-2012A-FL TKIT-2012A-ROW
	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.
   

1. Remove and discard the PTU cover O-ring seal.
   

1. Remove and discard the RH input shaft seal.
   

1. Remove the input shaft.
   

1. Remove and discard the LH input shaft seal.
   

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.

1. Install the input shaft.
   

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.

1. Install a new PTU cover O-ring seal.
   

1. Install the PTU cover and the new PTU cover bolts.
   Torque:
     Stage 1:  115 lb.in (13 Nm)
     Stage 2:  45°

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).