Finisher42 Posted January 13, 2022 Report Share Posted January 13, 2022 (edited) My 2008 ford edge limited was leaking transmission fluid and spraying all over the engine compartment. I finally believe I found the root cause, a bad output shaft seal. The original seal was still in there and thus stuck after 13 yrs. So I tried every conventional method and ended up just breaking it out in pieces. Well me not being too bright thought there was a 2nd seal in there, and that really took a toll. I ended up drilling a small hole and inserting a screw to grab ahold of and thus pull the rest of the seal out?♂️?♂️. Little did I know the seal was already out and I just created a hole in the wall rite where the seal goes in. So, im leaking gear fluid and feel like a D.A. My question is can something like this be fixed, or is a new PTU in order for this kind of damage?? ( for some reason its not letting me post pictures of this. I will follow up and get some pictures uploaded. Thank you for any and all of your help. https://linksharing.samsungcloud.com/V5CbH3b9W7AN https://linksharing.samsungcloud.com/YiI0BNjRkIBN Edited January 13, 2022 by Finisher42 To add url for pictures Quote Link to comment Share on other sites More sharing options...
Finisher42 Posted January 13, 2022 Author Report Share Posted January 13, 2022 Long story short. I drilled a hole and inserted a screw in to what I thought was the output shaft seal on my 2008 edge limited. As it happens, the seal was already out, (broken out in pieces by me because it was stuck) I was replacing the front passenger side because of a leak. So now its leaking gear oil. Is there any way to plug something like this, or will the PTU have to be replaced?? Thank you. https://linksharing.samsungcloud.com/YiI0BNjRkIBN https://linksharing.samsungcloud.com/3gqqH1TWPZTN 1 Quote Link to comment Share on other sites More sharing options...
Cerberus Posted January 13, 2022 Report Share Posted January 13, 2022 can't say for 100% certain but it definitely looks like the screw is into a seal.. so be sure, find reference materials find images of the part and see if it matches what you are seeing. My guess, pop that puppy out and have a new one handy to install 2 Quote Link to comment Share on other sites More sharing options...
Finisher42 Posted January 15, 2022 Author Report Share Posted January 15, 2022 So, to you it looks like there is another seal in there that needs to comeout...? Thank you Quote Link to comment Share on other sites More sharing options...
Cerberus Posted January 19, 2022 Report Share Posted January 19, 2022 On 1/15/2022 at 3:26 PM, Finisher42 said: So, to you it looks like there is another seal in there that needs to comeout...? Thank you to me, it looks like the screw in into a seal. I dont think what came out first that broke into pieces was a seal. based on very little information.. Quote Link to comment Share on other sites More sharing options...
1004ron Posted January 19, 2022 Report Share Posted January 19, 2022 I cant comment because I haven't seen the images - if you post them direct to the forum I'd take a look. Quote Link to comment Share on other sites More sharing options...
dfreeman332 Posted January 20, 2022 Report Share Posted January 20, 2022 (edited) As KING of Ford Edge, Flex, Fusion, Taurus and Mercury MKX AWD PTU repairs; I have pulled out, upgraded, replaced or fixed these units as Ford dealerships refuse to service them on cars more than 10 years old/100,000+ miles. I was tired of hearing it costs $1,800+ as this is a non-serviceable unit. New/rebuilt units can be purchased for less than $700 and installed in 4 - 5 hours if you have hand tools, 2 hours was removing the exhaust pipe and the rear catalytic converter. Upon reassembly you will need the exhaust gaskets and one catalytic converter metal ring. If I replace a PTU I take the case apart drill a 1/2" hole and weld a threaded bung for a drain. I have also retrofitted a transaxle oil pump to a cooler in front of the AC condenser to prolong the life of the PTU; this was an additional $400 in parts and I question if was worth it as a tapped 1/8" NPT drain hole and changing the fluid every 20,000 miles should be sufficient till the Edge dies. Leaking "black/brown" fluid on the passenger side you need a PTU Cover seal and the dust cover seal kit; this is PTU fluid: ($68 in parts) Leaking "red" it is Mercon transmission fluid you will need the dust cover seal kit, ($40 in parts) also you need to inspect the "jack shaft" to make sure the race that rides in the inner oil seal is not pitted; passenger side "jack shaft" driveshaft to the CV joint on the passenger side is about $120 from online OEM sellers, which is less than advanceauto , oreillys etc. Repairing PTU both red/brown passenger side shaft seal leaks is relatively simple, and can be performed in about 2 hours; if you do not have lots of corrosion on nuts and suspension components. It is important to have the specialty tools to seat the oil seals properly and re-install the plastic dust shield otherwise the leak will stop for a few weeks or month and reappear. After learning this I purchased the FORD specialty tools and since performed 5 different repairs on these PTU's I may be enticed to rent out the tools to off-set my investment as the I have over $1,000 in the PTU seal tools and they sit on the shelf a lot; here are some repair sheets RH half shaft seal.pdf Halfshaft Seal - LH (Seals and Gaskets) - ALLDATA Repair.pdf Input Shaft Seal Installation (Seals and Gaskets) - ALLDATA Repair.pdf Here is a video to help you: Another great document RH PTU.pdf Edited January 21, 2022 by dfreeman332 Added document 1 2 Quote Link to comment Share on other sites More sharing options...
dfreeman332 Posted January 21, 2022 Report Share Posted January 21, 2022 (edited) Here are the tools to do the left hand side AWD replacement; I fabricated the extension 205-907 to be 39" is needed for all repairs; RH PTU - Brown/clear gear oil leaks - Heat Gun; 308-001 with 27" extension, 205-907, 308-777 required replacing right PTU cover seal, 205-882 to press back the plastic dust cover RH PTU - Red/Dexron leaks - tools needed: Heat Gun; 308-001 with 27" extension, 305-907, 205-882, 205-883 To remove the plastic cover seal use heat gun high for 10 minutes to soften, I stuff aluminum foil in the hole to prevent heat from damaging the jack shaft seals; use 308-001 to pull once HOT 200+ degrees Edited January 21, 2022 by dfreeman332 correction 1 1 Quote Link to comment Share on other sites More sharing options...
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