MajorCommonTransmission

Ford Explorer: Power Transfer Unit (PTU) overheating & failure on AWD

Power Transfer Unit (PTU) overheating & failure on AWD is a common transmission fault on the Ford Explorer on the 2011–2019 cars, and we rate it major. Putting it right costs $1,800 to $3,500 at New Zealand independent workshop rates. Below is what goes wrong, the symptoms to notice on a test drive, where to look, and what to ask the seller before you hand over any money. It is one of 11 documented faults on the Ford Explorer.

Vehicle: Ford Explorer
Years: 2011–2019
Fuel: petrol
Gearbox: auto
System: Transmission

This page covers the Ford Explorer as a model. Some faults only affect particular engines or build years — enter a plate below to narrow the list to one car.

All Ford Explorer faults11 documented faults on this model

What you are looking at

No photograph available

We do not hold a verified photograph of the Transfer case yet. We would rather show none than show a picture of a different part.

What goes wrong

AWD fifth-generation (U502) Explorers use a compact Power Transfer Unit bolted to the transaxle to send drive to the rear. It holds only a small amount of 'lifetime' gear oil with no factory change interval, sits next to the exhaust, and cooks that fluid until the bearings and gears wear out. Owners report a burnt or propane-like smell, whine or grinding, shudder on take-off and fluid leaks; a badly failed PTU can seize and take the transaxle case with it. Because there is no service schedule, damage often sets in from around 120,000-160,000 km on units whose fluid was never changed. Draining and refilling with synthetic 75W-140 every ~50,000 km greatly extends life.

What you would notice

Burnt oil or propane-like smell, especially after driving
Whine, hum or grinding that changes with speed
Shudder or clunk on take-off
Oil weeping/leaking around the PTU or a low PTU fluid level
Vibration through the floor at highway speed

How to check it

Where to look. Power Transfer Unit, mounted to the transaxle on the passenger side, near the exhaust (AWD models)

Parts involved: Transfer case.

What it costs to put right

$1,800 to $3,500 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

Ask the seller

“Is this an AWD model, and has the PTU fluid ever been changed?”
“Do you notice any whine or a burnt smell after driving?”
“Has the PTU or transfer unit been replaced?”

Now check the Ford Explorer you are actually looking at

Everything above is true of the model, and it is free. What it does not tell you is whether THIS car has been looked after: its odometer history and whether the reading has ever gone backwards, whether there is still money owing on it, whether it has been reported stolen, how many owners it has had and what it is really worth today. That comes from the official records for that plate. Enter the plate for the free details, or get the full history and a market valuation from $13.49.

Not sure what you would be paying for? See what a full KickTyres check includes.

Where this comes from

The failure described above is documented in the sources below. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them.

explorerforum.com Serious Explorations threads 'PTU gone bad', 'Signs the Power Transfer Unit (PTU) is failing' and 'PTU Leak'
go-parts.com - 'Ford Explorer, Taurus, Flex & More (2013-2019) PTU Failure: The Burnt Smell, Whine, and Definitive Fix'

Ford Explorer buyer questions

Is power transfer unit (ptu) overheating & failure on awd serious on a Ford Explorer?

We rate it major and common on the Ford Explorer. AWD fifth-generation (U502) Explorers use a compact Power Transfer Unit bolted to the transaxle to send drive to the rear. It holds only a small amount of 'lifetime' gear oil with no factory change interval, sits next to the exhaust, and cooks that fluid until the bearings and gears wear out. Owners report a burnt or propane-like smell, whine or grinding, shudder on take-off and fluid leaks; a badly failed PTU can seize and take the transaxle case with it. Because there is no service schedule, damage often sets in from around 120,000-160,000 km on units whose fluid was never changed. Draining and refilling with synthetic 75W-140 every ~50,000 km greatly extends life.

How much does it cost to fix on a Ford Explorer?

$1,800 to $3,500 at New Zealand independent workshop rates. That figure is for this job on its own. A car showing the symptoms on this page is usually worth either walking away from or negotiating down by at least the repair figure.

Which Ford Explorer years are affected?

Our research records this fault on the 2011–2019 Ford Explorer. Build dates move around, especially on imported cars, so treat the range as the years to look hardest at rather than a guarantee either way. The official records tell you the exact build and first registration date for the car in front of you.

How do I check for it before I buy?

On an AWD car, sniff for a hot burnt-oil smell after a drive and listen for a rising whine or grinding on acceleration; look underneath for fluid seepage around the PTU where it meets the transaxle; ask whether the PTU fluid has ever been changed. Look here: Power Transfer Unit, mounted to the transaxle on the passenger side, near the exhaust (AWD models)