SECTION 308-07B: Transfer Case — Power Transfer Unit (PTU)
2014 Taurus Workshop Manual
GENERAL PROCEDURES
Procedure revision date: 06/28/2013

Power Transfer Unit (PTU) Draining and Filling


Special Tool(s)
Oil Suction Gun
303-D104 (D94T-9000-A)

Material
Item Specification
Motorcraft® SAE 75W-140 Synthetic Rear Axle Lubricant
XY-75W140-QL (US); CXY-75W140-1L (Canada)
WSL-M2C192-A and GL-5
Motorcraft® Silicone Gasket and Sealant
TA-30
WSE-M4G323-A4

NOTICE: Install a new PTU any time the PTU has been submerged in water.

NOTE: Do not drain the PTU unless contamination is suspected. The fluid that is drained may appear black and have a pungent odor. Do not mistake this for contaminated fluid.

NOTE: Fill level checks are done in-vehicle only. Let the vehicle sit 10 minutes after the road test before checking the fluid level.

All vehicles

  1. With the vehicle in NEUTRAL, position it on a hoist. REFER to Section 100-02, Jacking and Lifting , Lifting Points.

Vehicles with a PTU cooler

NOTE: All vehicles with a PTU cooler will have a drain plug.

  1. Remove the drain plug and drain the PTU .
  1. Remove the PTU temperature sensor heat shield bolts and the heat shield.
  1. Disconnect the PTU temperature sensor electrical connector.
  1. Unclip the PTU temperature sensor wiring harness from the retainer clip and position aside.
  1. NOTE: Clean the area around the PTU temperature sensor before removing.

    Remove the PTU temperature sensor.
  1. With the vehicle on a flat, level surface, fill the PTU . The fluid must be even with the bottom of the PTU temperature sensor opening.
  1. NOTE: Replace the O-ring before Installing the PTU temperature sensor.

    Replace the O-ring and install the PTU temperature sensor.
  1. Clip the PTU temperature sensor wiring harness back into position.
  1. Connect the PTU temperature sensor electrical connector.
  1. Instal the PTU temperature sensor heat shield and heat shield bolts.

Vehicles without a PTU cooler

  1. Remove the filler plug.

Vehicles without a drain plug

  1. With the PTU fluid level even with the bottom of the fill opening, remove as much fluid as possible from the PTU using an Oil Suction Gun 303-D104 (D94T-9000-A).
  1. Refill the PTU fluid level even with the bottom of the fill opening.
  1. Install the filler plug hand-tight.
  1. With the aid of an assistant, rotate the front tires a minimal of 3 times in the same direction.
  1. Remove the filler plug. Using an Oil Suction Gun 303-D104 (D94T-9000-A), remove as much fluid as possible from the PTU .
  1. Refill the PTU fluid level even with the bottom of the fill opening.
  1. Install the filler plug hand-tight.
  1. With the aid of an assistant, rotate the front tires a minimal of 3 times in the same direction.
  1. Remove the filler plug. Using an Oil Suction Gun 303-D104 (D94T-9000-A), remove as much fluid as possible from the PTU .

Vehicles with a drain plug.

  1. Remove the drain plug.
  1. Apply silicone sealant to the drain plug threads and install the plug.

All vehicles

  1. Fill the PTU with lubricant. The fluid must be even with the bottom of the fill opening.
  1. Apply silicone sealant to the filler plug threads and install the plug.