A/T - Fluid Leak From R/H Differential Seal
TSB 12-4-1204/30/12
6F35 AWD TRANSMISSION FLUID LEAK BUILT
10/4/2010 THROUGH 5/31/2011
FORD:
2011 Escape
MERCURY:
2011 Mariner
ISSUE
Some 2011 Escape and Mariner vehicles equipped with a 6F35 all-wheel drive (AWD) 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.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
1. Remove and discard the PTU deflector and suitable
cover seal. Refer to Workshop Manual (WSM), Section 308-07B.
2. Remove the PTU. Refer to WSM, Section 308-07B.
3. Remove the transmission halfshaft seal right hand (RH), AWD. Refer to WSM, Section 307-01A.
4. Measure the transmission halfshaft seal bore to determine the correct seal press-depth and installer. (Figure 1)
^ Face to bore chamfer greater than 25 mm (1"); use installation tool OTC 308-382.
^ Face to bore chamfer near 15 mm (0.6"); use installation tool OTC 307-428.
5. Install a new transmission halfshaft seal RH, AWD using appropriate installation tool. Refer to WSM, Section 307-01A.
6. Replace the PTU input shaft seal. Refer to WSM, Section 308-07B. Do not reassemble 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(R) supplied in the service kit on top of the journal. (Figure 3)
10. Place Speedi-Sleeve(R) press tool over the Speedi-Sleeve(R) and press down until tool bottoms out on the spacers and journal. (Figure 3)
11. Lift the Speedi-Sleeve(R) press tool, add two additional spacers supplied in service kit on top of the journal. (Figure 4)
12. Place the Speedi-Sleeve(R) press tool back on journal to protect the Speedi-Sleeve(R) surface while removing the flange.
13. Cut the Speedi-Sleeve(R) flange for removal with diagonal cutters. (Figure 5)
14. Use the 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(R) press tool as a support surface for the pliers. The Speedi-Sleeve(R) flange will break loose along the tear-off groove. (Figure 7)
16. Remove the Speedi-Sleeve(R) press tool and spacers.
17. Inspect for any burrs at the Speedi-Sleeve(R) flange tear-off location that could damage the seals and carefully file or stone them down as required. Tape off the two journals as shown to avoid file or stone contact with either journal surface. (Figure 8)
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 WSM, Section 308-07B.
20. Continue with input shaft seal installation to reassemble PTU.
21. Replace PTU cover seal and deflector. Refer to WSM, Section 308-07B.
22. Install PTU and add Motorcraft(R) SAE 75W-140 Synthetic Rear Axle Lubricant. Refer to WSM, Section 308-07B.
23. Check and adjust the transmission fluid level. Refer to WSM, Section 307-01A.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited
Warranty Coverage Warranty/ESP coverage limits/policies/prior approvals
are not altered by a TSB. Warranty/ESP coverage limits are determined by the identified causal part and verified using the OASIS part coverage tool.
OPERATION DESCRIPTION TIME
120412A 2011 Escape And Mariner 2.8 Hrs.
2.5L Engine: Follow
Service Procedure Steps
To Correct Condition (Do
Not Use With Any Other
Labor Operations)
120412A 2011 Escape And Mariner 3.1 Hrs.
3.0L Engine: Follow
Labor Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7251 D8
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