Lincoln Corsair Manuals

Lincoln Corsair: Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4 / Removal and Installation - Power Transfer Unit Input Shaft Seal LH

Special Tool(s) / General Equipment

204-069 (T81P-1104-C)
Remover/Installer, Front Wheel Hub
205-153 (T80T-4000-W)
Handle
307-557
Installer, Ball Bearing
TKIT-2005U-FLM
TKIT-2005U-LM
TKIT-2006U-FLM/LM
TKIT-2006UF/FM
308-968
Installer, Input Shaft Seal
308-971
Remover, Input Sleeve
308-972
Installer, Input Sleeve
308-973
Remover, PTU Input Sleeve
Hydraulic Press
Bearing Separator

Removal

  1. Remove the PTU actuator motor.
    Refer to: Power Transfer Unit Actuator Motor (307-07B Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
  1. Remove the PTU cooler.
    Refer to: Power Transfer Unit Cooler - Vehicles With: Power Transfer Unit Oil-to-Coolant Cooler (307-07B Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
  1. Remove and discard PTU case bolts.
  1. Intstall the special tools. Remove the casing.
    Use Special Service Tool: 308-971  Remover, Input Sleeve. , 308-972  Installer, Input Sleeve. , 204-069 (T81P-1104-C)  Remover/Installer, Front Wheel Hub. , 308-973  Remover, PTU Input Sleeve.
  1. NOTE: The bearing race and shim may come out when the seal is removed.

    Using the special tools, remove and discard the LH seal.
    Use Special Service Tool: 205-153 (T80T-4000-W)  Handle. , 307-557  Installer, Ball Bearing.
  1. Remove and dicard the O ring.
  1. Position the internal components and side cover in the press. Using the tool, push the input sleeve to neutral position to release any pressure on the snap ring.
    Use Special Service Tool: 308-972  Installer, Input Sleeve. , 308-973  Remover, PTU Input Sleeve.
    Use the General Equipment: Hydraulic Press
  1. Check whether snap ring rotates freely in the groove.
    • Install the tool in the connecting sleeve.
      Use Special Service Tool: 308-971  Remover, Input Sleeve.
    • Rotate the tool until the teeth or fingers drop into the snap ring end gap.
  1. NOTE: The bearing separator should be installed loosely under the connecting sleeve. Tightening the bearing separator against the PTU input shaft will cause damage to the input shaft splines as the connecting sleeve is removed.

    If the snap ring does not rotate freely, use the tools as per the graphic to pull the input sleeve up till it’s tight on the snap ring.
    Use Special Service Tool: 308-971  Remover, Input Sleeve. , 204-069 (T81P-1104-C)  Remover/Installer, Front Wheel Hub.
    Use the General Equipment: Bearing Separator
    1. NOTE: The bearing remover should be loosely installed under the sleeve.

      Install the tools as per the graphic.
      Use the General Equipment: Bearing Separator
    1. Remove the input sleeve.
  1. Remove and discard the snap ring.
  1. Remove the discard the O ring.

Installation

  1. Lubricate and install the new O ring.
  1. Lubricate and install the new O ring.
  1. Install new PTU case bolts.
    Torque:
      Stage 1:  22 lb.ft (30 Nm)
      Stage 2:  50°
  1. Using the special tool, install the LH seal.
    Use Special Service Tool: 205-153 (T80T-4000-W)  Handle. , 308-968  Installer, Input Shaft Seal.
  1. Install the new snap ring.
    1. Inspect outer sealing surfaces for wear or damage. Install a new sleeve as necessary.
    1. Lubricate and install the new snap ring.
    1. Position the snap ring with the end gaps as close to the center as possible, push down/outward on the snap ring opposite the end gap.
    1. Set snap ring to proper depth.
    1. Install the connecting sleeve on the input shaft.
    1. Install sleeve installer tool in the connecting sleeve. Place AUTO side down for 8F35/40 applications. Place MANUAL side down for MMT6
      Use Special Service Tool: 308-972  Installer, Input Sleeve. , 308-973  Remover, PTU Input Sleeve.
    1. Place PTU in a press and press until tool bottoms out. A click sound may be heard when snap ring fits on the groove.
      Use the General Equipment: Hydraulic Press
  1. Install the PTU cooler.
    Refer to: Power Transfer Unit Cooler - Vehicles With: Power Transfer Unit Oil-to-Coolant Cooler (307-07B Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
  1. Install the PTU actuator motor.
    Refer to: Power Transfer Unit Actuator Motor (307-07B Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).

    Removal and Installation - Power Transfer Unit Cooler - Vehicles With: Power Transfer Unit Oil-to-Coolant Cooler

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