TSB 09-25-7

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TSB 09-25-7	SERVICE TIP - POWER TRANSFER UNIT (PTU) - RIGHT HAND INTERMEDIATE SHAFT SEAL LEAKS
Publication Date: December 15, 2009

FORD:	2008-2009 Taurus X 2008-2010 Taurus 2007-2010 Edge 2009-2010 Flex
LINCOLN:	2009-2010 MKS 2007-2010 MKX 2010 MKT
MERCURY:	2008-2009 Sable

This article supersedes TSB 09-8-10 to update the vehicle model years, vehicle line application and Part List.

ISSUE:

Some 2007-2010 Edge, MKX, 2008-2009 Taurus-X, Sable 2008-2010 Taurus, 2009-2010 Flex and MKS and 2010 MKT vehicles may experience a fluid leak at the power transfer unit (PTU) right hand (RH) intermediate shaft seal. The online Workshop Manual (WSM), Section 308-07B has been updated with new tools and service procedures to assist with resolving leaks in this area. In addition, two (2) new seal kits were developed and depending on the location of the leak must be used to prevent repeat repairs.

ACTION:

Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

This service information is intended to improve diagnosis and repair of PTU leaks. It is still necessary to use the updated version of the online WSM, Section 308-07B to perform the actual repair.

FLUID COLOR AND DIAGNOSIS:

Automatic Transmission Fluid

Red automatic transmission fluid (ATF) is not used in the PTU itself. The RH intermediate shaft passes from the transaxle through the input hub of the PTU, where the intermediate shaft seal is located. A red ATF leak indicates fluid from the transaxle is leaking past this intermediate shaft seal contained in the PTU. Use the seal kit, which contains four pieces: the intermediate shaft seal, alignment washer, deflector, and seal protector tool. The intermediate shaft seal, alignment washer, and deflector need to be installed individually and before the seal protector tool is used.

Brown/Black Fluid Indicates a True PTU Seal Leak

Use the seal kit, which contains five pieces: the PTU cover seal, intermediate shaft seal, alignment washer, deflector and seal protector tool. The intermediate shaft seal, alignment washer, cover seal, and deflector need to be installed individually and before the seal protector tool is used. Use seal kit, which contains the PTU cover seal, intermediate shaft seal, alignment washer, and deflector. All four parts need to be installed individually.

NOTE: REFER TO (FIGURES 1 AND 2) THAT IDENTIFIES THE LOCATION OF THE PTU LEAKS.

Figure 1 - Article 09-25-7

Figure 2 - Article 09-25-7

Service Kit Contents/Function:

Cover Seal - Retains brown/black gear lube used in the PTU.

NOTE: THE PTU COVER SEAL ONLY NEEDS TO BE REPLACED WHEN THERE IS BROWN/BLACK GEAR LUBE LEAKING FROM BETWEEN THE BOTTOM EDGE OF THE DEFLECTOR AND THE PTU COVER.

Intermediate Shaft Seal - Retains red ATF used in the transaxle.
Alignment Washer - Supports and centers the intermediate shaft in the seal.
Deflector - Keeps dust and dirt away from the intermediate shaft and PTU input shaft seals.
Seal Protector Tool - which is a one time use, keeps the shaft splines from contacting intermediate shaft seal during installation to prevent the seal from being damaged. It is very important to remove the seal protector off the intermediate shaft during the installation at the proper distance to prevent seal damage. (Figure 3)

Figure 3 - Article 09-25-7

Performing Repair

It is necessary to use the updated version of the online WSM, Section 308-07B to perform the actual repair. The service procedure has been updated with new and improved service tools specified. Failing to follow the WSM to perform this repair will result in repeat PTU leaks. Never remove the deflector by use of a pry bar or chisel this will result in damage to the input shaft PTU hub and/or PTU housing. It is very important to properly heat the new deflector to the desired temperature specifications called out in the WSM, prior to installation. Never attempt to heat the deflector on the PTU assembly to seat it, seal damage will result. When the new deflector is properly seated it will be recessed 1/8" - 3/16" (3-5 mm) into the PTU pocket. (Figure 4)

NOTE: MAKE SURE LINKSHAFT SEAL INSTALLER (205-883) IS CLEAN OF DEBRIS AND THERE ARE NO BURRS THAT COULD DAMAGED THE SEAL PRIOR TO INSTALLATION.

Figure 4 - Article 09-25-7

PART NUMBER PART NAME

8T4Z-7275-DC Seal Kit (Excludes PTU Cover Seal)

8T4Z-7275-CC Seal Kit (Includes PTU Cover Seal)

PART NUMBER	PART NAME
8T4Z-7275-DC	Seal Kit (Excludes PTU Cover Seal)
8T4Z-7275-CC	Seal Kit (Includes PTU Cover Seal)

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

OPERATION	DESCRIPTION	TIME
092507A	2007-2010 Edge, MKX, 2008-2010 Taurus, 2008-2009 Taurus X , Sable, 2009-2010 Flex, MKS, 2010 MKT: Replace The PTU Intermediate Shaft Seal, Includes Time To Replace The Passenger Side PTU Intermediate Shaft Seal And Deflector In Vehicle (Do Not Use With Any Other Labor Operations)	1.6 Hrs.
092507B	2007-2010 Edge, MKX, 2008-2010 Taurus, 2008-2009 Taurus X , Sable, 2009-2010 Flex, MKS, 2010 MKT: Replace The PTU Cover Seal, Passenger Side PTU Intermediate Shaft Seal And, Deflector In Vehicle (Do Not Use With Any Other Labor Operations)	1.9 Hrs.

DEALER CODING

BASIC PART NO.	CONDITION CODE
7275	d8

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.