Ford Fusion Manuals

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

Special Tool(s) / General Equipment

Ford Fusion. Power Transfer Unit Rear Seal. Removal and Installation 205-126 (T78P-4851-A)
Holding Fixture, Drive Pinion Flange
Ford Fusion. Power Transfer Unit Rear Seal. Removal and Installation 308-877
Installer, Pinion Output Seal
TKIT-2012A-FL
TKIT-2012A-ROW
Puller

Removal

  1. Remove the PTU/transfer case.
    Refer to: Power Transfer Unit (308-07B Power Transfer Unit - 6-Speed Automatic Transmission – 6F35, Removal).
  1. Using the special tool, remove and discard the pinion flange nut.
    Use Special Service Tool: 205-126 (T78P-4851-A)  Holding Fixture, Drive Pinion Flange.
Ford Fusion. Power Transfer Unit Rear Seal. Removal and Installation
    1. Mark the pinion flange and the transfer case for reassembly.
    1. Using the puller, remove the pinion flange.
      Use the General Equipment: Puller
Ford Fusion. Power Transfer Unit Rear Seal. Removal and Installation
  1. Remove and discard the transfer case rear seal.
Ford Fusion. Power Transfer Unit Rear Seal. Removal and Installation

Installation

  1. Using the special tool, install a new rear seal.
    Use Special Service Tool: 308-877  Installer, Pinion Output Seal.
Ford Fusion. Power Transfer Unit Rear Seal. Removal and Installation
  1. Align the marks, install the pinion flange.
Ford Fusion. Power Transfer Unit Rear Seal. Removal and Installation
  1. Using the special tool, install a new pinion flange nut.
    Use Special Service Tool: 205-126 (T78P-4851-A)  Holding Fixture, Drive Pinion Flange.
    Torque: 173 lb.ft (235 Nm)
Ford Fusion. Power Transfer Unit Rear Seal. Removal and Installation
  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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