PROBLEMS
2015 Ford Explorer AWD PTU Problems
Symptoms, diagnostics and maintenance considerations for the power transfer unit on AWD-equipped 2015 Ford Explorers.
Confirm the vehicle's engine, trim, drivetrain, market and equipment. The exact procedure may differ, even within the same model year.
Which versions this guide applies to
| Configuration | Important distinction |
|---|---|
| AWD with applicable 3.5L engine | PTU equipped; Ford SSM 47993 may be relevant depending on vehicle build details |
| Front-wheel drive | No AWD power transfer unit; diagnosis takes a different path |
| Other engines and AWD combinations | Confirm actual hardware and applicable Ford service bulletins by VIN |
A symptom is not a diagnosis. Verify engine and drivetrain using vehicle records, and check Ford service information for your VIN.
What the power transfer unit does
On AWD-equipped Explorers, the power transfer unit (PTU) routes transmission output toward the rear driveline. It is a separate component from the automatic transmission and rear differential. Front-wheel-drive versions do not use the same AWD PTU. Verify drivetrain before assuming a noise or leak is PTU-related.
Common warning signs
Possible symptoms include oily residue around the PTU, a gear-oil or burning smell after driving, whining or growling that changes with vehicle speed, and fluid venting. Similar noises can come from wheel bearings, tires, transmission components or the rear driveline. Smell and noise are reasons to investigate, not definitive proof of PTU failure.
A documented 2015-era Ford concern
Ford Special Service Message 47993 specifically includes 2015–2016 Explorer vehicles with certain 3.5L or 3.7L AWD powertrains, built on or before June 10, 2016, that may exhibit PTU venting, odor or noise. The document describes a possible rebuild path with an idler gear, shaft and bearing kit. Eligibility and repair choice depend on the exact vehicle and diagnosis.
Do not confuse model years or bulletins
A frequently shared Ford bulletin numbered 15-0056 addresses PTU vent-hose leakage on 2013–2014 Explorer and related models built by December 2013. That bulletin is not automatically applicable to a 2015 Explorer. Ask a repair shop to check the correct VIN-specific Ford service information rather than relying on internet lists.
What should be inspected first
A technician can inspect the unit and surrounding surfaces for the source of leaks, assess venting, check adjacent axle seals, listen to noises on a road test and look for drivetrain-related diagnostic faults. Fluid from a different engine or transmission component may run across the PTU case, so identifying the origin matters before authorizing replacement.
Fluid service questions
The PTU has its own lubricant, distinct from transmission fluid. Some Ford service schedules do not call for routine PTU changes under normal private-vehicle use; that does not mean suspected leaks or abnormal operation should be ignored. Service accessibility, fluid specifications and fill procedure differ by design. Check the exact Ford workshop procedure instead of treating a generic internet capacity as a drain-and-refill amount.
When driving should stop
If the vehicle produces a severe mechanical grinding noise, suddenly loses propulsion, has a heavy leak or displays an urgent drivetrain warning, safely stop and seek assistance. Continued driving with low lubricant can cause greater damage. A slight smell without other symptoms still warrants timely inspection, especially when it recurs.
Repair versus replacement
Depending on the failure and available components, a technician may propose a seal repair, PTU rebuild or complete replacement. Ask what failed, whether the proposed work addresses the root cause, which components are reused, how fluid is filled and checked, and whether related drivetrain seals will be examined. Get a written estimate and a warranty explanation.
Buying and maintaining an AWD Explorer
Check whether the Explorer is AWD, review records for PTU leaks or repairs, and listen for noise at several speeds. Avoid assuming a noise is normal because the SUV still drives. If your XLT is front-wheel drive, this article is background only; other causes of front-end noises should be investigated instead.
Separating PTU sounds from other driveline noises
Note if the noise changes with vehicle speed, accelerator position or cornering. Wheel bearings, tires, exhaust shields and transmission components can also make humming or grinding sounds. A technician can inspect fluid evidence, mounted components and the driveline before concluding the PTU has failed.
After repair or replacement
Ask what caused the original problem, whether adjacent seals or vent components were addressed, and whether there is any follow-up inspection required. Record the work performed and parts used. A replacement PTU does not eliminate the need to investigate tire size mismatches or other AWD operating concerns.
Use the correct model-year manual and current service information. Stop if instructions or safety precautions are unclear, and use a qualified technician for work you cannot verify.
References and further reading
This independent guide is not endorsed by the vehicle manufacturer. Let us know if you spot an error.