Lincoln Corsair: Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4 / Removal - Power Transfer Unit - Vehicles Without: Power Transfer Unit Oil-to-Coolant Cooler

Special Tool(s) / General Equipment

1. Remove the front subframe.
   Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting System, Removal and Installation).
   

1. Remove the catalytic converter.
   Refer to: Catalytic Converter (309-00A Exhaust System - 2.0L EcoBoost (177kW/240PS) – MI4, Removal and Installation).
   

1. Remove and discard the driveshaft to PTU bolts and retaining straps.
   

1. 
   Separate the driveshaft from the PTU flange.
   

   1. NOTE: Make sure that the component aligns with the installation mark.

      Index-mark the driveshaft and PTU flange.
      

   2. NOTICE: Do not remove driveshaft from the PTU flange by pulling on the driveshaft tube. Damage to the CV-joint can result.

      Using general equipment, separate the driveshaft from the PTU flange.
      Use the General Equipment: Punch
      Use the General Equipment: Copper Hammer
   3. Position aside and support the driveshaft.
      

1. Drain the PTU.
   Refer to: Power Transfer Unit Draining and Filling (307-07B Power Transfer Unit - 2.0L EcoBoost (177kW/240PS) – MI4, General Procedures).
   

1. Remove the intermediate shaft.
   Refer to: Intermediate Shaft (205-04 Front Drive Halfshafts, Removal and Installation).
   

1. If equipped, disconnect the PTU temperature sensor electrical connector. Disconnect the motor connectors and the retainers.
   

1. If equipped, disconnect retainer and position aside the wiring harness.
   

1. Disconnect and position aside the PTU vent hose.
   

1. Remove the vent hose retainer.
   

1. Remove the PTU support bracket bolts and the PTU support bracket.
   

1. Remove the PTU bolts.
   

1. NOTICE: This is a tight fit, use care to not damage the transmission and PTU mating surfaces.

   Remove the PTU bolts and the PTU.
   

1. Remove and discard the PTU to transmission compression seal.
   

1. NOTE: This step is only necessary when installing a new PTU or replacing a PTU seal.

   Remove the PTU heat shield bolts and PTU heat shield.
   Torque: 89 lb.in (10 Nm)

1. NOTE: This step is only necessary when installing a new PTU or replacing a PTU seal.

   If equipped, remove the PTU temperature sensor harness bracket.