At the time I dropped the car off I told their service advisor about the recent oil change and that I didn’t think the recent trouble was a coincidence. He brushed me off saying it was likely caused by the recent cold weather. The next day when he phoned me about my car he admitted they have had the same problem with the Ford Edge.
Being suspicious, a little searching on Google found this TSB:
Some 2007 Edge and MKX AWD vehicles may exhibit a PTU oil leak from the vent which is located on the top surface of the PTU. The oil leak could also be mistaken as coming from the interface seal between PTU and transaxle.
The Ford Edge Forum has a topic about failed PTU seals where people have had their PTU replaced 5 times:
The Dec 17th vehicle report card from the dealer showed no leaks (checked ok). I think they overfilled my PTU. The above TSB says some PTU’s should be filled level with the plug, and some below. Overfilling would explain my problem, and could mean many people have had unnecessary replacements of their PTU’s. If the oil change technician is overfilling PTU’s, won’t all those cars eventually come back as warranty repairs to the same dealership? And won't the problem keep coming back no matter how many times the PTU is replaced if they continue to be overfilled?
I have attached a photo of my leaking PTU. You can see the fluid dripping onto the exhaust pipe causing the burning smell. I couldn't tell where the leak was originating, so I'm not sure how the mechanic was so confident a seal had failed.
Edited by mazda626, 11 January 2009 - 11:53 PM.