So in the past couple of months I have had a burning oil smell coming in through the vents. Put the car on ramps, saw some oil coming from what looked to be the fitting on the bottom of the rear turbo (the on closest to the firewall). Took it to the dealer, told them what I found, and to fix it. So a week went by, I get the car back (With an extra wrench they left under the hood) and all seems well. Take the car to work, and down the strip a few times. Smell comes back. Put the car back up on the ramps, see more oil.

OK, maybe they fixed the leak, and just neglected to clean the oil. I cleaned it off, and sure enough the oil returned. Since the leak was small, I figured I would drive it and strip it a few more times. So last Saturday, I took the car in to fix the leak, and now to fix the defroster on the passenger side (which did not work during our last storm) and still no heat on the passenger side. My service adviser calls me on Monday to ask why my car was being worked on in the trans shop (like I would know). I said I did not know, I did not put it there.   

I drop off the rental they gave me (2014 Explorer Limited 4wd---Gas hog) and pick up my car. While reading the receipt here is what they wrote "PTU unit fail condition, Code D01 7003B. Ck for trans leaks, found massive black fluid leaking from PTU unit, inspect oil in PTU unit, found excessive metal contamination in PTU. Removed and replaced PRU unit.......'

They also replaced the door actuator door that was clicking when starting and when I switch to recirc/fresh air. But now not only does my wifes side of the car not have heat, I don't either, unless I crank it up to 90. Looks like another service call.

Man, that stinks.  I hope you get your heat back!  I wonder what that metal contamination in PTU is.  gear grindings?  I hope that leak problem is over with. 

Yeah I am going to hold off on racing for a couple weeks to make sure the leak is gone. I would assume they are the gears also. I don't know what is inside the PTU that would cause it. But I had no indication of anything wrong with the PTU, none whatsoever. But they also did some reprogramming and my Strategy code changed, so I am waiting on updates from Livernois.

Kinda wondering if the racing contributed/caused this.

I'm sure it didn't help.    Interesting about them changing codes on you.  I wonder why and what the change will mean.  Too bad you have to wait for tunes again!

It is running pretty good. Almost didnt notice it was not tuned, almost. But is way better than that 6200# 3.5l Explorer.

Did you check your coolant level by any chance?  Topping it off might fix the low/no heat condition.  But yeah, probably a good idea to let the dealer "handle" it.

Possible your SHO had one of the weaker PTU units installed.  You had no shifting issues whatsoever before they replaced the PTU?  Normal to have fluid leak out of the overflow vent when it is hot.  But, PTU should not get that hot if the PTU fluid is in primo condition (and you are not trying to run 600 AWHP ).  It may have been venting for some time, till it got low enough to start disintegrating.

This is taken from an older incomplete service tip document, but ...  09-8-10 SERVICE TIP - POWER TAKE-OFF UNIT (PTU) - RIGHT HAND
http://www.fordflex.net/forums/viewtopic.php?f=3&t=1752

FORD: 2008-2009 Taurus X, Taurus, 2009-2008 Edge, 2009 Flex
LINCOLN: 2009 MKS, 2007-2009 MKX, MERCURY: 2008-2009 Sable


This article supersedes TSB 08-12-3 to update the vehicle model years, vehicle line application Service Procedure and Part List.

FLUID COLOR AND DIAGNOSIS:

Automatic Transmission Fluid

Red automatic transmission fluid (ATF) is not used in the PTU itself. The RH intermediate shaft passes from the transaxle through the input hub of the PTU, where the intermediate shaft seal is located. A red ATF leak indicates fluid from the transaxle is leaking past this intermediate shaft seal contained in the PTU. Use the seal kit, which contains four pieces: the intermediate shaft seal, alignment washer, deflector, and seal protector tool. The intermediate shaft seal, alignment washer, and deflector need to be installed individually and before the seal protector tool is used.

Brown/Black Fluid Indicates a True PTU Seal Leak

Use the seal kit, which contains five pieces: the PTU cover seal, intermediate shaft seal, alignment washer, deflector and seal protector tool. The intermediate shaft seal, alignment washer, cover seal, and deflector need to be installed individually and before the seal protector tool is used. Use seal kit, which contains the PTU cover seal, intermediate shaft seal, alignment washer, and deflector. All four parts need to be installed individually.

Was it factory fill in the PTU? If so, how many miles on it?

It appears time and time again that the recommended service interval on the fluid, especially for more severe driving habits, should be considerably more frequent than Ford suggests.

Sent from my SM-N900V using Tapatalk

I Am At Work, But 61000. OEM Fluid.

Quote from: SoCalSHO on March 13, 2014, 12:44:59 AM
Kinda wondering if the racing contributed/caused this.

Uh, this post was sarcasm right?? You have how many dragstrip launches on a drivetrain making 35% more torque than stock?? There's no free lunch, racing stresses componants, componants fail when they are over their design limits OR are repetatively taken to the limit. Why ya think Mike (4drHtRd) dumped his much stressed project car...

No matter the cause, I truly think keeping the fluid fresh would have prevented or prolonged it.

Still can't fathom the sparse fluid capacity though. Makes no sense.

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Regardless of over-stress from racing, etc... it seems that sometimes these hold up and sometimes they don't... when they fail it seems like it's 50K - 60K miles.  Gotta wonder, given the 100K service interval rec,  if Ford is doing a little beta testing with us on what appears to be the weak link in the drive train.

Quote from: QuickSilver on March 13, 2014, 06:25:18 PM

Quote from: SoCalSHO on March 13, 2014, 12:44:59 AMKinda wondering if the racing contributed/caused this.

Uh, this post was sarcasm right??

You have how many dragstrip launches on a drive train making 35% more torque than stock??

There's no free lunch.

Racing stresses components.

Components fail when they are over their design limits OR are repetitively taken to the limit.

Why 'ya think Mike (4DRHTRD) dumped his much stressed project car...

Quote of the year right there good people.......

Gotta pay to play, that's for sure.....

The piper will come for each of us at some point.

But until then, may we all enjoy good times in our EB based vehicles!

Sent from my DROID RAZR HD using Tapatalk

Quote from: BiGMaC on March 13, 2014, 07:30:14 PM
Gotta wonder, given the 100K service interval rec,  if Ford is doing a little beta testing with us on what appears to be the weak link in the drive train.

Well, if this is true, then they have been beta testing since the PTU design was first introduced what, a decade ago? 

http://www.fordtaurus.net/forums/viewtopic.php?t=4180
TSB 06-4-11 OIL LEAK FROM POWER TRANSFER UNIT

DIY Intermediate Shaft Repair:
http://www.myfordfreestyle.com/forums/viewtopic.php?f=12&t=5140

Simply hasn't been fixed over the years.

Quote from: SHOdded on March 13, 2014, 09:53:13 PM

Quote from: BiGMaC on March 13, 2014, 07:30:14 PM
Gotta wonder, given the 100K service interval rec,  if Ford is doing a little beta testing with us on what appears to be the weak link in the drive train.

Well, if this is true, then they have been beta testing since the PTU design was first introduced what, a decade ago? 

http://www.fordtaurus.net/forums/viewtopic.php?t=4180
TSB 06-4-11 OIL LEAK FROM POWER TRANSFER UNIT

DIY Intermediate Shaft Repair:
http://www.myfordfreestyle.com/forums/viewtopic.php?f=12&t=5140

Simply hasn't been fixed over the years.

OK ... let me get this clear , it is the same basic design  ... I hope like hell its not the same unit .