SECTION 308-07B: Transfer Case — Power Transfer Unit (PTU)
2014 Flex Workshop Manual
GENERAL PROCEDURES
Procedure revision date: 05/02/2013

Power Transfer Unit (PTU) Draining and Filling


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
Silicone Gasket and Sealant
TA-30 		WSE-M4G323-A4

NOTICE: A new PTU must be installed any time the PTU has been submerged in water.

NOTE: The PTU is not to be drained unless contamination is suspected. To drain the PTU lubricant, the PTU must be removed from the vehicle for PTU s without a drain plug. PTU s with a drain plug do not have to be removed from the vehicle. The lubricant that is drained may appear black and have a pungent odor. Do not mistake this for contaminated lubricant. Refer to Power Transfer Unit (PTU) — 3.5L or Power Transfer Unit (PTU) — 3.5L GTDI .

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

All vehicles

  1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02 .

  1. NOTE: Clean the area around the filler plug before removing.

    Remove the filler plug.

PTUs without a drain plug

NOTE: The lubricant capacity of the PTU is 0.53L (18 oz).

  1. With the PTU lubricant level even with the bottom of the fill opening, remove as much lubricant as possible from the PTU using an Oil Suction Gun 303-D104 (D94T-9000-A).
  1. Refill the PTU lubricant level even with the bottom of the fill opening and 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 lubricant as possible from the PTU .
  1. Refill the PTU lubricant level even with the bottom of the fill opening and 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 lubricant as possible from the PTU .

PTUs with a drain plug

NOTE: The lubricant capacity of the PTU is 0.53L (18 oz).

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

All vehicles

  1. With the vehicle on a flat, level surface, fill the PTU with lubricant. The lubricant must be even with the bottom of the fill opening.
  1. Apply silicone sealant to the filler plug threads and install the plug.