Anyone have an AWD with PTU problems?

 

Explorers PTUs have issues, haven't seen many Fusion PTU issues, what is your issue?

 

I have a bit of a propane smell now and then if the car has been driven a while. Looking for that I found a fair amount of info about the overheating and early failure due to lube breakdown from the heat. I plan to change the fluid very soon but was just looking for others. I have found a guy, on Youtube, who drilled and tapped his edge PTU to make changes easier. Failures seem to happen as soon as 50,000 miles but I have seen 90,000 stated as well.
Luckily I have no leaks anywhere and the oil in there is not sludge, yet.

 

Honestly I have not had to deal with any fusion PTU issues, though its also pretty rare for my dealer to see AWD fusions, we dont even see that many AWD escapes, I imagine these sell better in the north with snow and ice are a concern.
The explorer PTU issue we generally have is a misbuilt gear so we disassemble and replace internals the parts.
If you would like to specify which year I would be happy to check the drain/fill procedure for the PTU.
Also specify which engine you have as there could be some issue with certain engines differently effecting the PTU, just a thought.

 

I have an 08. Since there is no drain plug I have a laboratory suction container with a few holes for different hoses. I will warm up the PTU with a short drive and suction it out.
If you have a better method I am open to it.

 

Crazy but yeah theres no drain plug, I dont know what a laboratory suction container is but I assume its version of a pneumatic fluid evacuator which will work just fine.

 

Well I warmed up the car and did as planned. The work area is cramped but you can stuff a small (like ⅛" ID hose into the PTU. After two hours I had removed about 13 fl oz. Lots more attempts to stuff it further in or down but no luck.
To keep the hose from bending too much I stuck a straight pc of tie wire (just under 1/16" thick by 7" long) up the hose end. Worked well but didn't get me more than an extra fl oz.
I filled it till it came out the fill hole. Will do this again in about 5000 mi to get the leftovers that will mix together with the fresh fluid.
I looked at the unit and where it is positioned leaves no options if one wants to drill and tap a drain plug in place. There is a guy on Youtube that did just that on his Edge. He has a couple of videos about it. Search "Edge PTU drill & tap".