Ford Escape: Power Transfer Unit / Installation - Power Transfer Unit

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

   Install the 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, install the PTU temperature sensor harness bracket.
   Torque: 97 lb.in (11 Nm)

1. NOTE: Make sure that a new gasket is installed.

   Install a new gasket.
   

1. Install the new PTU to transmission compression seal.
   

1. Install the PTU and mounting bolts.
   Torque: 76 lb.ft (103 Nm)

1. Install the new PTU bolts and hand tighten at this stage.
   Torque: 76 lb.ft (103 Nm)

1. Tighten in the sequence shown.
   Torque: 81 lb.ft (110 Nm)

1. Install the PTU support bracket and bolts.
   Torque: 35 lb.ft (48 Nm)

1. Position the catalytic converter in the vehicle.
   

1. Install the catalytic converter mounting bracket hand tighten at this stage.
   

1. NOTE: Make sure that the new exhaust manifold nuts are installed.

   Install the exhaust manifold nuts.
   Torque: 41 lb.ft (55 Nm)

1. 1. Tighten the lower bracket nut.
      Torque: 35 lb.ft (47.5 Nm)
   2. Tighten the PIA nut.
      Torque: 35 lb.ft (47.5 Nm)

1. Install the heat shield.
   Torque: 93 lb.in (10.5 Nm)

1. Install the EGR cooler inlet tube.
   Refer to: Exhaust Gas Recirculation (EGR) Cooler Inlet Tube (303-08C Engine Emission Control, Removal and Installation).
   

1. • Connect the catalyst monitor sensor connector and harness retainers.
     
   • Connect the HO2S connector and harness retainer.
     

1. If equipped, position back the wiring harness and connect retainer.
   

1. If equipped, connect the PTU temperature sensor. Connect the motor connectors and retainers.
   

1. Install the vent hose retainer.
   

1. NOTE: The PTU vent hose should be replaced whenever a new PTU is installed.

   Connect the PTU vent hose.
   

1. NOTE: Make sure that the installation marks are aligned.

1. Install new PTU flange bolts.
   Torque: 26 lb.ft (35 Nm)

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

1. Fill the PTU.
   Refer to: Power Transfer Unit Draining and Filling (308-07D) .
   

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

1. 1. If the engine appearance cover stud bolt is loosened or removed, it must be installed/tightened into the valve cover.
      Torque: 62 lb.in (7 Nm)
   2. Position the engine appearance cover onto the engine with the grommets aligned with the studs.
      
   3. Press down on the engine appearance cover at each grommet location to attach the grommets onto the studs.
      
   4. Install the engine appearance cover nut.
      Torque: 44 lb.in (5 Nm)

1. Check the exhaust system for leaks.