Lincoln Corsair Manuals

Lincoln Corsair: Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4 / Diagnosis and Testing - Power Transfer Unit

Inspection and Verification

  1. Verify the customer concern.
  1. Visually inspect for obvious signs of mechanical damage.

  Visual Inspection Chart


Mechanical
  • Power transfer unit
  • Halfshafts and CV joints
  • Driveshaft and U-joints
  • Wheel/tire size and brand
  • Matching tire size and brand
  • Tire pressure
  1. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step
  1. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart.

Symptom Chart

Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices.
REFER to: Diagnostic Methods (100-00 General Information, Description and Operation).

In most circumstances the PCM sets a DTC to help guide with diagnostics. Refer to the DTC Chart before using the Symptom Chart. The Condition column lists the vehicle condition. The Possible Sources column lists a detailed vehicle condition. The Action column lists the action to be performed to determine the cause of the condition. Each action lists the components that can cause the system and the individual components in that system. The components are listed in order of disassembly. Use the list of components and the required action to focus on disassembly inspections for the root cause of the concern.

Symptom Possible Sources Action
  • PTU Bearing noise during Disconnected mode
  • Fluid level
  • PTU Input shaft support bearings
  • FILL with the correct type and amount of lubricant.
    REFER to: Power Transfer Unit Fluid Level Check (307-07B Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4, General Procedures).
  • REMOVE PTU, DISASSEMBLE and INSPECT input shaft bearings.
    REFER to: Power Transfer Unit Input Shaft Seal LH (307-07B Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
  • PTU Bearing noise during Connected Mode – Either with or without RDU activation.
  • Fluid level
  • PTU Ring gear shaft bearings
  • PTU pinion gear / output shaft bearings
  • FILL with the correct type and amount of lubricant.
    REFER to: Power Transfer Unit Fluid Level Check (307-07B Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4, General Procedures).
  • REMOVE PTU, DISASSEMBLE and INSPECT input shaft bearings.
    REFER to: Power Transfer Unit Input Shaft Seal LH (307-07B Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
  • Ratcheting or clicking type noise during Connecting or Disconnecting modes.
  • PTU input shaft dog clutch teeth worn or damaged
  • PTU dog clutch collar teeth worn or damaged
  • REMOVE PTU, DISASSEMBLE and INSPECT input shaft bearings.
    REFER to: Power Transfer Unit Input Shaft Seal LH (307-07B Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
  • No torque available at the rear drive shaft / Driveshaft does not rotate in Connected Mode
  • Shift fork worn or broken
  • Connecting sleeve to input shaft splines worn or damaged
  • Dog clutch worn or damaged
  • Ring and pinion teeth worn or broken
  • REMOVE and INSPECT PTU Actuator Motor.
    REFER to: Power Transfer Unit Actuator Motor (307-07B Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
  • REMOVE PTU and INPSECT connecting sleeve, dog clutch, and gears.
    REFER to: Power Transfer Unit Input Shaft Seal LH (307-07B Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
  • Leaking automatic transmission fluid from right hand side
  • Power transfer unit intermediate shaft seal
  • INSTALL a new intermediate shaft.
    REFER to: Intermediate Shaft (205-04 Front Drive Halfshafts, Removal and Installation).
  • Leaking automatic transmission fluid from left hand side
  • Transmission right hand differential seal and PTU to transmission compression seal
  • INSTALL new seals.
    REFER to: Halfshaft Seal RH - All-Wheel Drive (AWD) (307-01A Automatic Transmission - 8-Speed Automatic Transmission – 8F35/8F40, Removal and Installation).
  • Leaking gear lubricant from right hand side
  • Power transfer unit input shaft seal – RH & intermediate shaft bearing to PTU O-Ring
  • INSTALL new seals.
    REFER to: Power Transfer Unit Input Shaft Seal RH (307-07B Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
  • Leaking gear lubricant from left hand side
  • Power transfer unit input shaft seal – LH and PTU to transmission compression seal
  • INSTALL new seals.
    REFER to: Power Transfer Unit Input Shaft Seal LH (307-07B Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
  • Leaking gear lubricant from the seals
  • The power transfer unit vent is plugged (located on top of the power transfer unit)
  • Damaged seals
  • INSTALL a new power transfer unit vent
  • REPLACE the leaking seal. Refer Removal and Installation procedures in this section.
  • Automatic transmission fluid leaking into PTU or PTU gear lubricant leaking into transmission
  • Connecting sleeve to input shaft O-Ring
  • INSTALL new seals.
    REFER to: Power Transfer Unit Input Shaft Seal LH (307-07B Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).

Inspection of the seal's mating journal should be performed every time a seal is replaced. The mating part/journal should be replaced if it has any of the following conditions: Radial wear groove that is felt by running a finger nail across where the seal lip runs. Scratches, pitting, galling, nicks or other shaft damage under or near where the seal lip runs. Discoloration or coked oil on the shaft where the seal lip runs. Shaft corrosion under or near where the seal lip runs. Sharp edges or burrs on the shaft lead in chamfer. NEVER use emery cloth on journal finishes, replace the part.

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    General Procedures - Power Transfer Unit Draining and Filling

    Materials Name Specification Motorcraft® SAE 75W-85 Premium Synthetic Hypoid Gear LubricantXY-75W85-QL WSS-M2C942-A  Draining With the vehicle in NEUTRAL, position it on a hoist...

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