at8once Posted April 10, 2016 Share Posted April 10, 2016 I'm new to the forum and I'm hoping some of you with some mechanical experience can help. I have a 2007 Fusion 3.0L AWD with 118,000km's My car has been making a grinding and a whistling noise.. I brought it in and I was told I needed a new transfer case. The quote seemed ridiculously high but they told me it would need to be done asap (within next few months) to avoid future problems to the transmission. I was told the oil inside was VERY thick with metal shavings in it. They told me I could try to change the oil and extend the life of the transfer case. I've since done research online and some say that an oil change will renew the transfer case and will not cause any further damage to itself or to the transmission..Others say that an oil change will only grant it a little longer life(few months) but will eventually still fail and ruin the transmission. Id like to know what people on here think? thanks 0 Quote Link to comment Share on other sites More sharing options...
WWWPerfA_ZN0W Posted April 10, 2016 Share Posted April 10, 2016 Any idea how bad the metal shavings were? Since you say the PTU was grinding, I'd assume far more than normal. At least they said try a fluid R&R first, most people go straight with the replacement recommendation. It's worth trying at least once to flush out the old PTU fluid, put in Motorcraft or better fluid to the proper fill level. If it works, repeat that maintenance at least yearly, maybe sooner if you drive the car a lot. You could stave off replacement for quite some time by doing this. If the first flush does not bear results, then most likely you have to have the PTU replaced, probably a $700+labor US bill, not sure what the labor rates are in Canada. Dealers usually charge more than other service shops, so if you have a trusted mechanic, that would be the way to go to save money. 0 Quote Link to comment Share on other sites More sharing options...
at8once Posted April 11, 2016 Author Share Posted April 11, 2016 thanks this is great advice. Ill do a flush and refill to see if this helps at all. The garage quoted me at 600$ for a used part and 1200$ for a new one with labour charge of 600-700$. Does anyone know the recommended oil weight? and fill amount? thanks! 0 Quote Link to comment Share on other sites More sharing options...
WWWPerfA_ZN0W Posted April 11, 2016 Share Posted April 11, 2016 (edited) You can find the specs in the owner's manual here: http://www.fleet.ford.com/partsandservice/owner-manuals/ Specifically http://www.fordservicecontent.com/Ford_Content/catalog/owner_guides/07fsnog2e.pdf Pg 267 Power Transfer Unit (PTU) fluid (AWD) 12 ounces (0.35L) Motorcraft SAE 75W-140 Synthetic Rear Axle Lubricant XY-75W140-QL / WSL-M2C192-A You probably won't get 12 oz out of the case initially, and it will be very thick & slow to extract (& smelly). Only put in enough to get to the fill level, don't overfill or it will come out the vent, don't want that. If it starts to come out the drain/fill hole, that's more than enough, but ideally about a 1/4 inch below that level. Edited April 11, 2016 by WWWPerfA_ZN0W 0 Quote Link to comment Share on other sites More sharing options...
FernMTL Posted April 11, 2016 Share Posted April 11, 2016 Welcome to the forum neighbor!! Hope the oil change will help you. 0 Quote Link to comment Share on other sites More sharing options...
at8once Posted April 11, 2016 Author Share Posted April 11, 2016 thanks for all the great info guys! Once spring decides to show up ill be doing this and will let you know how it goes. 0 Quote Link to comment Share on other sites More sharing options...
FPD85 Posted April 11, 2016 Share Posted April 11, 2016 (edited) The best way is to make internal mods in the transfer case, in a way to implement new bearings and avoid the box from being damaged, ford engineers made a really poor box and it comes with a death date... :P Edited April 11, 2016 by FPD85 0 Quote Link to comment Share on other sites More sharing options...
akirby Posted April 11, 2016 Share Posted April 11, 2016 Always always always RTFM for fluid specs and other part numbers. Don't rely on what someone tells you. 0 Quote Link to comment Share on other sites More sharing options...
drolds1 Posted April 11, 2016 Share Posted April 11, 2016 This discussion has been moved to the AWD forum, a more appropriate area. You also may want to review the discussion on PTU fluid starting here. 0 Quote Link to comment Share on other sites More sharing options...
FPD85 Posted April 11, 2016 Share Posted April 11, 2016 Always always always RTFM for fluid specs and other part numbers. Don't rely on what someone tells you. Agreed, this was my case previously, now I know exactly what fluid to ask to be used, although my issue wasn't entirely fluid related, but ptu related as well which was fixed today this morning after a few more mods had been performed in the ptu. 0 Quote Link to comment Share on other sites More sharing options...
at8once Posted April 12, 2016 Author Share Posted April 12, 2016 So heres a question... where is the PtU actualy located? lol i kinda know what its suppose to look like but couldnt locate it. 0 Quote Link to comment Share on other sites More sharing options...
akirby Posted April 12, 2016 Share Posted April 12, 2016 It's the part attached to the transmission with the driveshaft sticking out of it. 0 Quote Link to comment Share on other sites More sharing options...
at8once Posted April 13, 2016 Author Share Posted April 13, 2016 thats the issue couldnt find anything on transmission that had drain/fill plugs. 0 Quote Link to comment Share on other sites More sharing options...
FPD85 Posted April 13, 2016 Share Posted April 13, 2016 thats the issue couldnt find anything on transmission that had drain/fill plugs. The fill plug is near the escape tube, almost not accessible, there is no drain plug, unless you add one. 0 Quote Link to comment Share on other sites More sharing options...
drolds1 Posted April 13, 2016 Share Posted April 13, 2016 See this. 0 Quote Link to comment Share on other sites More sharing options...
at8once Posted April 13, 2016 Author Share Posted April 13, 2016 The fill plug is near the escape tube, almost not accessible, there is no drain plug, unless you add one. Here you say there is no drain plug, but in the link with the other post it says there is only a drain hole.. Unless, in that post the guy was draining and filling from the fill hole? im very confused. 0 Quote Link to comment Share on other sites More sharing options...
WWWPerfA_ZN0W Posted April 13, 2016 Share Posted April 13, 2016 Yup, drain & fill are done through the same hole in the PTU. No problems. It might take a little time to figure out how to reach the lowest point inside the PTU case when draining out the fluid, but that's about it. 0 Quote Link to comment Share on other sites More sharing options...
at8once Posted April 13, 2016 Author Share Posted April 13, 2016 I managed to get the plug out...couldnt fit my hands anywhere neer the plug. now that its out... how on earth do i get the old stuff out. i got a siphon pump but thats not working 0 Quote Link to comment Share on other sites More sharing options...
at8once Posted April 13, 2016 Author Share Posted April 13, 2016 or is it possible there are 2 different plugs and i took off the wrong one? 0 Quote Link to comment Share on other sites More sharing options...
akirby Posted April 13, 2016 Share Posted April 13, 2016 the guy was draining and filling from the fill hole This. 0 Quote Link to comment Share on other sites More sharing options...
at8once Posted April 13, 2016 Author Share Posted April 13, 2016 (edited) Ok thanks. still not sure how i drain from the fill hole though lol. tried a few different things but nothing is coming out. Edited April 13, 2016 by at8once 0 Quote Link to comment Share on other sites More sharing options...
WWWPerfA_ZN0W Posted April 13, 2016 Share Posted April 13, 2016 Car is level (jackstands or lift)? Are you able to put in new fluid? If so, I would run it with the old/new fluid for a few days, then try draining/filling again. A service shop can add a thinner like kerosene or even ATF fluid to evacuate the old fluid if it is that thick, but I'd rather do a BG flush instead. 0 Quote Link to comment Share on other sites More sharing options...
akirby Posted April 13, 2016 Share Posted April 13, 2016 Ok thanks. still not sure how i drain from the fill hole though lol. tried a few different things but nothing is coming out. 0 Quote Link to comment Share on other sites More sharing options...
at8once Posted April 13, 2016 Author Share Posted April 13, 2016 Car is level, byt unable to put any new stuff in. not sure if its normal or not but the tube doesnt really go inside the hole. tried pumping new stuff in but just leaks right out. even if i had a large oil pump extractor.. theres no possible way to get the tube inside the unit. i called mr lube and they said they do it for 109$ which is an expensive experiment but sill cheaper then 2000$ for replacement. 0 Quote Link to comment Share on other sites More sharing options...
WWWPerfA_ZN0W Posted April 13, 2016 Share Posted April 13, 2016 Go to http://www.bgfindashop.com, put in your zip code and the maximum radius of 250 miles/km. See if there are shops relatively close to you that do driveline service ( symbol). For example: Precision AutomotiveDistance: 9 miles 385 Vantage Dr View map Orleans ON CAN K4A 3W2 2. Orleans Chrysler Dodge Jeep Distance: 10 miles 1465 Youville Drive View map OTTAWA ON CAN K1C 4R1 0 Quote Link to comment Share on other sites More sharing options...
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