SECTION 308-07B Transfer Case — Power Transfer Unit (PTU)

CONTENTS PAGE

IN-VEHICLE REPAIRIntermediate Shaft Seal and Deflector ............................................................................................................................. 308-07B-2

308-07B-i Transfer Case — Power Transfer Unit (PTU) 308-07B-i

2007 Edge, MKX, 2/2007

IN-VEHICLE REPAIRIntermediate Shaft Seal and DeflectorSpecial Tool(s)

Bearing Cup Remover308-125 (T87P-7120-D)

Handle, Driver 32 in205-907

Installer, PTU Linkshaft Seal205-883

Installer, PTU Linkshaft Seal Dust Shield205-882

Remover, Front Wheel Hub205-D070 (D93P-1175-B) or equivalent

Remover, Halfshaft205-241

General Equipment

16 mm (5/8 in) washer (used with 308-125)

308-07B-2 Transfer Case — Power Transfer Unit (PTU) 308-07B-2

2007 Edge, MKX, 2/2007

Material

Item Specification

Metal Brake Parts CleanerPM-4-A or PM-4-B (US); CPM-4 (Canada)

—

MERCON® V Automatic Transmission FluidXT-5-QM (or XT-5-QMC) (US); CXT-5-LM12 (Canada)

MERCON® V

Silicone Brake Caliper Grease and Dielectric CompoundXG-3-A

ESE-M1C171-A

Removal

NOTE: For High Resolution: A video version of this procedure is available on-line.

NOTE: For Low Resolution: A video version of this procedure is available on-line.

NOTE: The Power Transfer Unit (PTU) may leak different color fluids, red oil leak for automatic transmission fluid and brown/black gear lube for PTU fluid. ThePTU seals prevent these types of fluids from leaking. It is important to note which color fluid is leaking to determine the most appropriate service procedure.This procedure will correct a red oil leak (automatic transmission fluid) from the intermediate shaft seal on the RH side of the PTU. For additionalinformation, refer to Analysis of Leakage in this section.

NOTE: This procedure is to be performed through the RH wheel opening. It is not necessary to remove the exhaust components to complete this repair.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.

2. Remove the RH front wheel and tire. For additional information, refer to Section 204-04.

3. Apply the brake to keep the halfshaft from rotating and remove the front wheel hub nut.

• Do not discard the nut at this time.

4. Remove the brake flexible hose bracket bolt and disconnect the hose from the shock absorber.

5. Disconnect the wheel speed sensor harness from the shock absorber bracket.

308-07B-3 Transfer Case — Power Transfer Unit (PTU) 308-07B-3IN-VEHICLE REPAIR (Continued)

2007 Edge, MKX, 2/2007

6. Remove the RH brake disc. For additional information, refer to Section 206-03.

7. NOTICE: Suspension fasteners are critical parts because they affect performance of vital components and systems and their failure may result in majorservice expense. New parts must be installed with the same part numbers or equivalent part, if replacement is necessary. Do not use areplacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to make sure of correctretention of these parts.

Remove and discard the upper stabilizer bar link nut.

• Position the stabilizer bar link aside.

8. Remove and discard the ball joint-to-knuckle bolt and nut.

• Separate the lower control arm from the knuckle.

9. Using the Front Wheel Hub Remover, separate the halfshaft from the wheel hub.

308-07B-4 Transfer Case — Power Transfer Unit (PTU) 308-07B-4IN-VEHICLE REPAIR (Continued)

2007 Edge, MKX, 2/2007

10. Pull the knuckle outboard and rotate it toward the rear of the vehicle.

• Secure the knuckle assembly.

11. NOTE: It is not necessary to separate the halfshaft from the intermediate shaft for this repair.

Remove the 2 intermediate shaft bracket bolts and the intermediate and halfshaft assembly.

• Inspect the intermediate shaft for pitting or damage in the seal contact area. Replace if necessary.

12. NOTE: The following instruction will prevent the Bearing Cup Remover from opening too far which would make removing the intermediate shaft sealdeflector difficult.

Place a 16 mm (5/8 in) washer between the components of the Bearing Cup Remover as shown.

308-07B-5 Transfer Case — Power Transfer Unit (PTU) 308-07B-5IN-VEHICLE REPAIR (Continued)

2007 Edge, MKX, 2/2007

NOTICE: Failure to utilize the recommend tools may result in serious damage to the Power Transfer Unit (PTU).

13. Assemble the special tools as indicated in the following table and illustration:

Item Description

1 308-125

2 Extension for 205-241

3 5-pound or larger slide hammer

14. NOTE: Using a 5-pound or larger slide hammer eases the removal of the seal deflector.

Using the Bearing Cup Remover, the extension from the Halfshaft Remover, and a suitable slide hammer, remove the seal deflector.

• The seal deflector will have been damaged during removal. Remove all foreign material from the PTU before continuing with the repair.

15. Using the Bearing Cup Remover, the extension from the Halfshaft Remover, and a suitable slide hammer, remove the intermediate shaft seal, and ifequipped, the alignment washer.

308-07B-6 Transfer Case — Power Transfer Unit (PTU) 308-07B-6IN-VEHICLE REPAIR (Continued)

2007 Edge, MKX, 2/2007

Installation

NOTE: The following illustration shows the correct orientation of the seal components when installed in the vehicle.

Item Description

1 Intermediate shaft seal (part of 7275 kit) — retains red ATF used in the transaxle

2 Alignment washer (part of 7275 kit) — supports and centers the intermediate shaft in the seal

3 Seal deflector (part of 7275 kit) — keeps dust/dirt away from the intermediate shaft seal and Power Transfer Unit(PTU) input shaft seal

4 Seal protector (part of 7275 kit) — protects intermediate shaft seal from damage by the intermediate shaft splinesduring installation. Must be removed before shaft is fully installed

1. Place the intermediate shaft seal on the PTU Linkshaft Seal Installer and Driver Handle with the spring side facing away from the tool.

308-07B-7 Transfer Case — Power Transfer Unit (PTU) 308-07B-7IN-VEHICLE REPAIR (Continued)

2007 Edge, MKX, 2/2007

2. Using the PTU Linkshaft Seal Installer and Driver Handle, install the intermediate shaft seal.

3. Place the alignment washer on the PTU Linkshaft Seal Installer and Driver Handle with the beveled edge (white-striped side) facing towards the tool.

4. NOTICE: Do not use force when installing the alignment washer or damage to the washer can occur.

Using the PTU Linkshaft Seal Installer and Driver Handle, install the alignment washer by hand, pushing it in until it bottoms against the seal.

• When installed, the white-striped side should be facing out.

5. NOTICE:

308-07B-8 Transfer Case — Power Transfer Unit (PTU) 308-07B-8IN-VEHICLE REPAIR (Continued)

2007 Edge, MKX, 2/2007

Do not overheat (melt) the seal deflector. Monitor the temperature of the deflector with a suitable temperature measuring device, such as adigital temperature laser or infrared thermometer, while heating. Do not allow the temperature to exceed 100°C (212°F). Overheating willdamage the deflector. If the deflector is damaged, a new deflector must be used.

NOTE: Apply a small amount of silicone brake caliper grease and dielectric compound to the inner lip of the deflector where it installs on the tube inside thePTU before heating. This will ease the installation of the deflector.

Position the deflector on the PTU Linkshaft Seal Dust Shield Installer using silicone brake caliper grease and dielectric compound to retain it to theinstaller. Using a suitable heat gun, heat the back of the tool to a minimum of 71°C (160°F) and a maximum of 93°C (200°F) by concentrating theheat across the back of the installer while rotating the tool. Once the optimum temperature is achieved on the tool, move the heat gun to the front ofthe tool and heat the inside of the deflector where it snaps onto the PTU shaft until the temperature of the deflector is a minimum of 93°C (200°F) to amaximum of 100°C (212°F).

• As an alternative method to heating the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry off the deflector and install.

6. Using a 5-pound or larger dead blow hammer, install the seal deflector immediately after heating using the PTU Linkshaft Seal Dust Shield Installerand Driver Handle.

7. Make sure the deflector is completely seated all the way around and there are no cracks on the face. The deflector is correctly installed when the faceof the deflector is recessed 3-5 mm (0.12-0.20 in) into the pocket all the way around.

8. Once the deflector is fully seated, insert the seal protector into the PTU deflector ID.

308-07B-9 Transfer Case — Power Transfer Unit (PTU) 308-07B-9IN-VEHICLE REPAIR (Continued)

2007 Edge, MKX, 2/2007

9. Apply a thin coat of silicone brake caliper grease and dielectric compound to the intermediate shaft seal journal.

10. NOTE: A slight effort may be required to fully seat the intermediate and halfshaft assembly as it passes through the alignment washer.

Partially install the intermediate and halfshaft assembly through the PTU deflector until the splines have cleared the seal protector. Pull the sealprotector out of the deflector and off of the intermediate and halfshaft assembly.

• Tighten to 40 Nm (30 lb-ft).

11. Fully install the intermediate and halfshaft assembly and the 2 bolts.

• Tighten to 40 Nm (30 lb-ft).

308-07B-10 Transfer Case — Power Transfer Unit (PTU) 308-07B-10IN-VEHICLE REPAIR (Continued)

2007 Edge, MKX, 2/2007

12. NOTE: A significant amount of residual fluid will collect between the seal and deflector during this repair. This is a normal condition and should not bemisinterpreted as a leak after the repair is complete.

Using brake parts cleaner, thoroughly clean the deflector and intermediate shaft area of any residual fluid that may have accumulated during therepair.

13. Position the halfshaft and ball joint into the wheel knuckle. Install the new ball joint bolt and nut.

• Tighten to 55 Nm (41 lb-ft).

14. Position the stabilizer bar link and install the new nut.

• Tighten to 90 Nm (66 lb-ft).

15. Install the RH brake disc. For additional information, refer to Section 206-03.

16. Position the brake flexible hose bracket to the shock absorber and install the bolt.

• Tighten to 20 Nm (177 lb-in).

308-07B-11 Transfer Case — Power Transfer Unit (PTU) 308-07B-11IN-VEHICLE REPAIR (Continued)

2007 Edge, MKX, 2/2007

17. Connect the wheel speed sensor harness to the shock absorber bracket.

18. NOTICE: Do not tighten the halfshaft nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered ontothe wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.

Apply the brake to keep the halfshaft from rotating. Using the previously removed wheel hub nut, seat the halfshaft into the front wheel hub.

• Tighten to 350 Nm (258 lb-ft).

• Remove and discard the wheel hub nut.

19. NOTICE: The wheel hub nut contains a one-time locking chemical that is activated by the heat created when it is tightened. Install and tighten the newwheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when nottightened within the specified time or damage to the components can occur.

Apply the brake to keep the halfshaft from rotating and install a new wheel hub nut.

• Tighten to 350 Nm (258 lb-ft).

20. Install the RH front wheel and tire. For additional information, refer to Section 204-04.

21. Inspect the transmission fluid level and add clean, specified fluid as necessary.

308-07B-12 Transfer Case — Power Transfer Unit (PTU) 308-07B-12IN-VEHICLE REPAIR (Continued)

2007 Edge, MKX, 2/2007