Ford Fusion: 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

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.

1. 1. Mark the pinion flange and the transfer case for reassembly.
      
   2. Using the puller, remove the pinion flange.
      Use the General Equipment: Puller

1. Remove and discard the transfer case rear seal.
   

Installation

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

1. Align the marks, install the pinion flange.
   

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)

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