jlkansascity

I agree with the other comments about warranty. I think drilling a hole in the PTU case would be frowned upon, but I don't know. I can say for sure that Amsoil will not affect your warranty. As long as the lubricant meets Ford specifications for the application, you can use whatever brand you want. So, for the PTU Ford specs 75w-140 GL4 and Amsoil makes a product that fits that criteria exactly.

Those are ball park "normal" prices from what I've seen I was quoted $1,600.00. I've seen prices from the 1200 range to 1600

Here is another new article, with phone number to call if you are experiencing this problem. Although not an official recall, Ford has announced "customer satisfaction program 15B21" after owners complained about water seeping through the A-pillar areas. Ford discovered water could enter a metal joint behind the hood hinge and cause water damage in numerous areas, including the carpet, floorboard, dash and A-pillar areas. http://www.carcomplaints.com/news/2015/2015-ford-edge-water-leaks.shtml I'm a FORD fan; I've owned a lot of them in my life. 1989 Mustang GT, 2003 Mustang GT convertible, 2003 7.3 liter 1 ton 4x4 pickup, 2007 Edge among a few. I just think they could do better managing customer satisfaction and reputation by being proactive with issues. Like cv27 says above; reputation, reputation, reputation.

I agree a professional install of this product is great and looks awesome. My daughter just put it on her 2015 Mustang GT and I was very impressed with it.

I've wrestled with the same decision on my Gen 1 and what it came down to for me was the fact that other things are included with the factory option. Like on the older ones, I think you got receiver hitch, engine oil cooler, larger radiator, upgraded battery and cooling fans, wiring harness and 4-pin connector I looked up the 2014/2015 class ll tow package and this is what Ford says is included; Class II Trailer Tow Package includes hitch receiver, larger radiator, upgraded cooling fans, wiring harness with 4-pin connector, and trailer sway control (3,500 lbs. max.) To me, it ended up being more about enhanced cooling, etc. than the actual receiver. I also hate the small receiver as I have lot's of 2" stuff I can't use on it.

Does it sound like the rear of the car? that would possibly be fuel, but I've never experienced that. Does it sound like the front of the car? if so it could be the a-pillar leak reported by several sources. Check my post here for some links.

It looks like Ford is in denial about problems on the new Edge. Reports are they had an actual "stop sale" (quit selling these until we get the problem figured out) but Ford denies that claim. Here is the article reporting the STOP SALE. Here is the article where they DENY there was a stop sale. This is due to a leak where water leaks into the front a pillars, and then inside the cabin. Vehicles made after April 28, 2015 are not affected, due to a change in manufacturing plant used. To me this smacks of the Gen1 transfer case issues which were widely recognized and experienced, but Ford chose to totally ignore and not support.

Try this article http://www.automobilemag.com/features/news/1507-ford-refutes-reports-on-2015-edge-stop-sale/

I think that's a good approach if you're under warranty. I would be curious about their reaction. One of the frustrating things with this problem is that some dealers treat this as a known defect item and fix it no charge, and then some dealers won't do you any favors like Thoroughbred Ford (which is my local dealer). I have now run 8 months past when they wanted to charge me $1,600 for the replacement and after multiple oil changes I think it's fine now. Just pulled a trailer to and from Denver / KC a couple of weeks ago.

Wow, you got 175k miles on an Edge? That gives me some hope. I'm heading from KC to Denver (and back) pulling a 5x8 uhaul this upcoming weekend so we'll see how it goes. I've used the "suction, refill, repeat" option and after 6 changes it's getting a lot cleaner.

Yeah, unfortunately it is very difficult to get a drain hose or plastic tie fill level check into the fill plug. The suction line I used is very small hard plastic maybe 1/8" OD. You hit some gears or castings straight in, so you have to try to point it down, and a little towards the front of the vehicle. I finally got a little better at it after changing the oil 5 times now (this year) to get the sludge cleaned out. I'd like to see some photos and hear about what you find out from the old case when you get it! Good luck -JL

Coronan; what size drain plug did you go with? It looks pretty big...

Nice workbench in the photos. I see the jar of Hodgdon, and some very sizable rifle projectiles and some fat handgun rounds...

I did another oil change following WWWPerfA_ZN0W directions about how to create a dipstick. My strategy, after being told by Ford that they wanted $1,600 to replace the PDU, was just to repeatedly change the fluid to clean it out and free up the vent. This recent oil change was the 4th change in the last 10 months. I did one initial change/fill (it was essentially empty), then #2 in a week, then #3 in a month, then just did #4 after 6 months. Now the oil still looks pretty dirty but it's at least fluid and not some pasty black grease. Using the dipstick as described was pretty easy and kept me from overfilling it. Normally when filling to the fill plug, it would leak some blowing out the vent after filling it, but this time is has not. Probably due to not overfilling it, plus the vent probably getting cleaned up finally by clean oil. I've used Amsoil for the last few changes which I think will help clean up and dissolve the nasty grease. I'm doing it again in 6 months, then probably will go to an annual change. I think I barely caught mine just before physical damage to the unit and it seems to operate fine now. I also counted the pumps on the new oil pump I am using to push the new oil into the transfer case. On the pump I'm using, 12 strokes/pumps is nearly the exact amount of oil needed. Then I double check with the dipstick and add more if needed. I've also been using the same plug, cleaned and taped with Teflon tape with no issues. JL

Yes there are a few good ones online. I have gathered some of the links; here you go; This is a gathering of notes related to my issues with our Ford Edge, 2007. Particularly the PTO (transfer case) issues. If any of you out there drive an all-wheel-drive Ford Edge, Flex, or 500 or Lincoln MKS be aware these have a time-bomb transfer case issue. When this fails (and it will) it will cost you $1600.00 more or less at a dealer. It’s due to a very poor design on the PTO unit, so that the fluid in the unit cannot be changed. So, it gets sludged up, blows oil out the vent, and fails. What the PTO looks like after the oil dries up and turns into sludge, right before failure; PTO Photos The new part, being sold on eBAY by the hundreds, by Ford Dealers; http://bit.ly/FordPTO The authoritative forum thread on this issue; read the whole thing, especially NATRIX posts; http://bit.ly/FordEdgePTOFailures Great forum post on the Ford Flex forum; http://bit.ly/FordFlexPTOFailure Ford Edge (Flex) axle shaft problem / replacement with custom tools (this is a related problem and in the same area, with good photos) http://bit.ly/FordEdgeAxleShaft These are just pasted from my collection here; http://jonathanlackman.com/blog/ford-edge-pdu-pto-transfer-case-issues-flex-500-mkx/

Mine was starting to puke/leak, but did not actually fail. No whine either. From what I've read online, I would suspect that by the time you have your amount of miles on it, the case is practically empty, having little or no oil left in it. That's the state mine was in. With low or no oil, I would think failure would be pretty quick. To your point though; dealers want to replace them all the time just because of the leak. They wanted to replace mine for $1600.00. There are HUNDREDs of these transfer cases being sold online through ebay, amazon, etc. (some by Ford dealers) , so there are a lot of them getting replaced.

Thanks for the great post with all the detail and the photos. I was in the same boat; nearly empty transfer case. My strategy was to change it several times to get it cleaned up. I filled it (after getting nothing out), then changed it in a week, then changed it again in a month. It started getting cleaner and leaking less. I was filling to the fill plug, as I hadn't seen the process for using a zip tie until about a month ago when WWWPerfA_ZN0W first posted the zip tie measurement process (THANKS!). So, it was probably leaking a bit out the vent due to overfilling. But that probably also helped clear out the vent. After 3 changes now, my next one is 6 months out, and it has almost stopped leaking. I get 1,2,3 drops about every three weeks, probably due to overfilling. Of course, this Edge is a 2007 with 140k miles on it so it has lasted a while. Sad thing is, the dealer here said unequivocally that it needed to be replaced for $1600.00. That was 6 months ago. I think they're ripping people off left and right on this situation. Jonathan

on that 5th photo, the top of the photo is towards the front of the car, and the bottom of the photo is the rear of the car. The shaft going horizontally at the top of the photo is the passenger side front axle; going to the right front wheel of the car. The actual driveshaft going to the rear of the car isn't really visible on this photo but would be down at the bottom of the photo towards the rear of the car.

There is also a photo / drawing on this thread that has an orange arrow pointing at the drain plug; http://www.fordedgeforum.com/topic/15488-ptu-seal-replacement-timeline/

Ironpeddler; what kind of car is this, an Edge? I didn't bother to take the wheel off. I put the car up on ramps, and then slid under there and looked up on the passenger side of the PTO / transfer case. Here it is marked in kind of a blue/green on a new case; http://www.ebay.com/itm/2007-2014-Ford-Edge-Lincoln-MKX-transfer-case-power-take-off-unit-OEM-/291017684141 Here you can see it on the top right about the 1:00 or 2:00 position on a used case; http://s159.photobucket.com/user/the_natrix/media/Ford%20Edge%20PTU/KICX5244_zps584a0dfb.jpg.html?sort=3&o=5 Here is a image of it http://www.justanswer.com/ford/6y51f-ford-fusion-sport-awd-drain-interval-ptu-transfer.html Probably the best link to see what it looks like on the car from the bottom is the 5th photo in this post, http://www.ecoboostperformanceforum.com/index.php?topic=1706.0

The first time I did it, after the "puking" leak started, the car had 140k miles on it. The transfer case was nearly empty. I probably got 1-2 tablespoons of thick nasty grease out of it. After filling it, the car sounded quieter, and seemed to be smoother. I think it was very near catastrophic failure...

I have followed this thread since noticing my 2007 doing the "puking" leaking. I took it to Ford and they said oh yeah it's shot, give us $1600 and we'll replace it. They also wanted $1400 to replace the steering rack. So, after reading this thread I decided to take the least invasive option. I took a suction pump (link below) which I already had in the shop, and sucked out as much oil as I could, which was hardly any. I think the xfer case was just about empty, but I sucked out what I could and filled it with gear oil. I drove this a week, and it blew oil out the vent like crazy (maybe because the case was finally full). Then I changed it again, and I got more nasty oil out of it, and refilled it with Amsoil. Then, I drove that for a month. Now I just changed it again, and got all the oil sucked out and filled again with Amsoil. It's now only puking a very little, like 2-3 drips a week. So, I think it's getting cleaned up just from the frequent changes which was my goal. I'm going to drive it 3 months now and do the change again. I was about ready to drill the drain plug, with the xfer case on the car, but I decided to just change the oil until it got cleaned up and it appears to be working out. The oil suction tool I used; http://www.liquivac.com/ The oil pump i used to put oil back IN the case; http://www.autozone.com/test-scan-and-specialty-tools/fluid-pump/oem-fluid-transfer-pump/94647_0_0/ I tried the oil pumps that screw on the top of a oil jug, but they do not suck to the bottom of the bottle so that's a pain. The one above from Autozone works good, it sucks in one hose and pushes it out the other hose, but it's a mess to clean up because it's all full of oil then. I got a lot of help on this forum, I hope this helps someone else out also.

Do you have any photos of how the drain plug looks and where it is located? I presume you did this while it was on the vehicle? I have drained (suction hose) and refilled mine once, and it's still puking so I may have to resort to the drain plug drilling and install. Jonathan

Natrix, I really appreciate your posts on this topic it really helped me figure out what's going on. What is the EASY way you're referring to for checking if the PTU is fine? Jonathan

I have read online that the 2013 still has this same problem. Does anyone know if the 2014 has the same problem with the same PTO unit? I'm guessing the entirely redesigned 2015 has s different drivetrain. This situation reminds me of the Porsche Intermediate Shaft Failure (IMS). Porsche denied it for years (since 2001) but last fall it was granted Class Action status. would think this PTO problem would get some similar traction.