How to Replace Transfer Case Power Transfer Unit?

The details are for 2008 and 2009 Ford Taurus car models.


Power Transfer Unit
REMOVAL & INSTALLATION

Instructions are as follows :----

NOTE

The PTU is a mechanical device attached to the transaxle. It supplies torque to the rear axle through the rear driveshaft. The 4X4 control module is an electronic device which controls the rear axle coupling to apply the torque generated from the PTU to the rear wheels when required.

Removal & Installation

1. Raise the vehicle on a hoist.
2. Remove the right front halfshaft.
3. Remove the right catalytic converter.
4. Index mark the driveshaft flange to the output flange.
5. Remove the 4 bolts from the driveshaft flange.
6. Remove the upper PTU bracket bolts and the bracket.
7. Remove 5 PTU support bracket bolts and the bracket.
8. Position the engine roll restrictor aside.
   1. Remove the 2 engine roll restrictor-to-transaxle bolts.
   2. Loosen the rear engine roll restrictor bolt and pivot the roll restrictor downward.
      
      NOTE

      Position a drain pan under the vehicle.
9. Remove the 5 PTU bolts. Pull the PTU outward and separate it from the transaxle. Rotate the output flange upward, then turn it and remove the PTU from the vehicle.
10. Inspect the compression seal for wear or damage. Install a new seal as necessary. Using a small screwdriver, remove and discard the compression seal.

To install:

NOTE

A new compression seal must be installed whenever the Power Transfer Unit (PTU) is removed from the vehicle.

1. Using a suitable tool, install the new compression seal.
2. Position the PTU in place and install the 5 PTU bolts. Tighten to 66 ft. lbs. (90 Nm).
3. Position the PTU support bracket in place and install the 3 PTU support bracket-to-engine bolts. Tighten to 52 ft. lbs. (70 Nm).
4. Install the 2 PTU support bracket-to-transaxle bolts. Tighten to 52 ft. lbs. (70 Nm).
5. Position the engine roll restrictor to the transaxle and install the 2 bolts. Tighten the engine roll restrictor-to-transaxle bolts to 76 ft. lbs. (103 Nm). Tighten the rear engine roll restrictor bolt to 66 ft. lbs. (90 Nm).
   
   NOTE

   Line up the index marks made during removal.
6. Install the 4 driveshaft-to-output flange bolts. Tighten the bolts in a star-pattern. Tighten to 52 ft. lbs. (70 Nm).
7. Install the RH catalytic converter.
8. Install the RH front halfshaft.
9. Top off fluids as necessary.

This will help.

Thanks.

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Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html