Escaping transmission fluid

Some 2011 Ford Escape and Mercury Mariner vehicles equipped with a 6F35 all-wheel-drive transmission may exhibit a transmission fluid leak from the right side transmission differential seal at the interface with the power transfer unit (PTU) input gear journal.

1. Remove and discard the PTU deflector and cover seal. Refer to workshop manual Section 308-07B.
2. Remove the PTU.
3. Remove the transmission halfshaft seal right hand (RH). Refer to workshop manual Section 307-01A.
4. Measure the transmission halfshaft seal bore to determine the correct seal press-depth and installer (see Figure 1).

-          Face-to-bore chamfer greater than 1.00” (25mm) requires installation tool OTC 308-382.

-          Face-to-bore chamfer approx. 0.60” (15mm) requires installation tool OTC 307-428.

5. Install a new transmission halfshaft RH AWD seal using the appropriate installation tool. Refer to workshop manual Section 307-01A.
6. Replace the PTU input shaft seal. Refer to workshop manual Section 308-07B. Do not reassemble the PTU at this point.
7. Position the drive gear assembly onto a suitable press.
8. Place one green and one white spacer from the service kit on the end of the journal as a stop for the press tool (Figure 2).
9. Place Speedi-Sleeve supplied in the service kit on top of the journal (Figure 3).
10. Place the Speedi-Sleeve press tool over the Speedi-Sleeve and press down until the tool bottoms out on the spacers and journal (Figure 3).
11. Lift the Speedi-Sleeve press tool and add two additional spacers from the service kit on top of the journal (Figure 4).
12. Place the Speedi-Sleeve press tool back on the journal to protect the Speedi-Sleeve surface while removing the flange.
13. Cut the Speedi-Sleeve flange for removal with diagonal cutters (Figure 5).
14. Use diagonal cutters to grab the flange near the cut and tear it down to the tear-off groove in the sleeve (Figure 6).
15. Using long needle nose pliers, grasp the flange and twist it into a coil, using the Speedi-Sleeve press tool as a support surface for the pliers. The Speedi-Sleeve flange will break loose along the tear-off groove.
16. Remove the Speedi-Sleeve press tool and spacers.
17. Inspect for any burrs at the Speedi-Sleeve flange tear-off location that could damage the seals, and carefully file them down as required. Tape off the two journals as shown to avoid file or stone contact with either journal surface (Figure 7).
18. Clean the gear and bearing assembly to remove any filings from the journals and bearings.
19. Replace the PTU intermediate shaft seal. Refer to workshop manual Section 308-07B.
20. Continue with input shaft seal installation to reassemble the PTU.
21. Replace the PTU cover seal and deflector.
22. Install the PTU and add Motorcraft SAE 75W-140 Synthetic Rear Axle Lubricant.
23. Check and adjust the transmission fluid level.

REQUIRED PARTS

PTU input seal kit………………...BL8Z-1177-A

CV bolt and washer……………...YL8Z-4529-AA

U-joint strap (2)………………..….E3TZ-4A254-A

U-joint bolt…………………………YL8Z-4N272-AA

Wheel hub nut……………….……W705967-S440

Ball joint bolt………………………W709618-S439

Ball joint nut……………………….W520213-S440

Nut – 3.0L………………………….W5204414-S441

Nut – 3.0L…………………....…….W520413-S441

RH cat. conv. exhaust gasket 3.0L………………..7E5Z-5F263-AA

Exh. Manifold to Y-pipe gasket 3.0L……9L8Z-9450-A

Y-pipe exhaust gasket 3.0L……………..9L8Z-5E241-A

Spring nut 3.0L (2)……………….………9L8Z-5G215-A

75W-140 synth. gear lube………………XY-75W140-QL