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hello, 2007 ford fusion 3.0L AWD Automatic trans 115k miles. I've got gear lube puking out of the top vent cap on the AWD PTO. I'ts blowing down the underside of the vehicle. The fluid is black as tar. I pulled the fill plug off, no fluid came out. the magnet had typical pasty collection from noraml wear, no metal chunks or shiny particles. Ive also got a whirring bearing noise that sounds like a wheel bearing (checked them and they are ok). the noise sounds faster than wheel bearing like it could be a bearing out of the pto on center driveshaft pinion bearing etc. I hear noise at the right driveshaft bearing (could be the bearing or resonating from the pto?) Is the pto junk or what? Im thinking there could have been a seal leak and transfer of fluid from trans to pto? Any common problems with these?
Country: United StatesMake: FordModel: Fusion SELYear: 2007Engine: 3.0L Already Tried: hello, 2007 ford fusion 3.0L AWD Automatic trans 115k miles. I've got gear lube puking out of the top vent cap on the AWD PTO. I'ts blowing down the underside of the vehicle. The fluid is black as tar. I pulled the fill plug off, no fluid came out. the magnet had typical pasty collection from noraml wear, no metal chunks or shiny particles. Ive also got a whirring bearing noise that sounds like a wheel bearing (checked them and they are ok). the noise sounds faster than wheel bearing like it co
Hello and welcome. My name is James.
The fluid in the PTU should look like normal gear lube. We see these all the time at the dealer for noise accompanied by leaks and nasty fluid like you describe. Most often the bearings inside the PTU fail and cause a chain reaction.
In this case, we replace the unit.
The internal components are not serviceable for this unit. There is no drain for the unit either to really get a good fluid sample, although it can be disassembled once removed.
The best diagnosis without disassembly is to use a stethescope on it while the engine is running and the transaxle is in drive range with an assistant to operate the accelerator.
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Please let me know if I can clarify any of this or if you have additional questions.
James.
Ok, so its safe to say its junk? I figured that much with the black fluid. Can you give me some details on replacing it? It looks like the rear cat has to come out, does the subframe need to be loosened? does it simply unbolt from trans and pull off? thanks.
Basically, yes.
The right bank cat needs to be removed, which is simpler than it first looks, along with the right halfshaft.
The subframe can stay fastened, however you'll want to remove the transaxle roll restricter that connects the bottom of it to the subframe. This will allow you to rotate the powertrain forward to allow clearance for the PTU to be removed once unbolted.
Experience: Ford senior master tech, 18 years experience.