Diz

If your '07 has the Vista roof, check the black ring around the rear roof unit. The velcro attachment can come loose. I just put new velcro around all 4 window sides. Fixed.

My '07 SEL AWD developed the leaking PTU problem in January of '08 at around 14k on the odometer. At that time, my local Ford guy said that they were seeing a number of '07s and new '08s coming in with leaking seals. I remembered him telling me that the repair was "process critical", i.e., if the service tech didn't follow procedures, there was a likelihood of repeat failure and leakage. In talking to some of my Ford powertrain engineering contacts, it appears that a high percentage of service techs either didn't follow procedure as detailed in the TSB, either because they didn't know or their dealership hadn't up-dated. Supposedly this is a Volvo designed PTU? I'm now at 39k on the odometer and the first seal repair is still holding.

I received the notorious letter 2 days after making an appointment at my local Ford dealer for an abnormally slow-to-warm-up temp gauge on my '07 SEL AWD. When I dropped it off the service tech told me about the heater core program letter before I could ask about it and he said that they would check out both the engine thermostat and cabin heater core. Problem - a malfunctioning engine thermostat. The cabin now heats up within 3/4 mile of driving and runs like a furnace. I've also noticed, the engine radiator cooling fan no longer runs after engine shut-off. All this along with 4 new tires and she purrs like a kitten. I love this car, err, cross-over.

I now have 5k ++ on the PTU since they replaced the notorious passenger side shaft seal. So far, so good (knock on wood). The dealer did say that Ford has modified the replacement procedure and process.

I've read and heard that correct seal replacement procedure is critical and that not all Techs are capable - Don't know if it's true. Also - The PTU is a Volvo design/mfr. and not Ford's? If anyone could design and build a PTU for an AWD/Cold weather application, you'd think it would be the Swedes.

CALLING ALL SERVICE TECHS/DEPARTMENT MANAGERS: Having just gone thru the passenger side/PTU seal replacement fiasco, can anyone address whether the seal replacement will last or is this a temporary patch until the next failure? I'm catching different stories as to whether dealer swaps last and that an entire PTU replacement will be necessary. Can anyone address as to why these seals have failed? I've heard stories that cold temps may be a factor. Are these not engineered/designed properly?