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

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

Special Tool(s) / General Equipment

	205-126 (T78P-4851-A) Holding Fixture, Drive Pinion Flange
	308-877 Installer, Pinion Output Seal TKIT-2012A-FL TKIT-2012A-ROW
Puller

Removal

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

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

Remove and discard the transfer case rear seal.

Installation

Using the special tool, install a new rear seal.
Use Special Service Tool: 308-877 Installer, Pinion Output Seal.

Align the marks, install the pinion flange.

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)

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

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...

Power Transfer Unit Vent. Removal and Installation

Removal With the vehicle in NUETRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation)...

Other information:

Ford Fusion 2013–2020 Service Manual: Rear Drive Axle and Differential. Diagnosis and Testing

Preliminary Inspection Visually inspect the housing, seals, and pinion flange for obvious signs of mechanical damage. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step If the cause is not visually evident, verify the symptom and REFER to Symptom Chart: NVH...

Ford Fusion 2013–2020 Service Manual: Forward Clutch Assembly. Diagnosis and Testing

Symptom Chart Forward Clutch For forward (1,2,3,4) clutch operation, REFER to: Transmission Description - System Operation and Component Description (307-01A Automatic Transmission - 6-Speed Automatic Transmission – 6F35, Description and Operation)...

Manual Climate Control

Ford Fusion. Manual Climate Control

Note: Depending on your vehicle option package, the controls may look different from what you see here.