Dorman 600-257 Power Take Off Unit (PTU) Yoke Instruction Manual

1. Product Overview

The Dorman 600-257 Power Take Off Unit (PTU) Yoke is a direct replacement component designed to securely connect the output shaft of a vehicle's power take off unit to the drive shaft. This part is engineered to restore functionality when the original yoke is worn, damaged, or has failed, ensuring proper power transfer within the drivetrain system.

Image 1.1: The Dorman 600-257 PTU Yoke kit, including the yoke, nut, crush washer, and oil seal.

2. Compatibility

This PTU yoke is compatible with the following vehicle models. Always verify fitment using your vehicle's make, model, and trim level before installation.

• Ford Edge: 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015
• Ford Explorer: 2011, 2012, 2013, 2014, 2015
• Ford Flex: 2009, 2010, 2011, 2012, 2013, 2014, 2015
• Ford Police Interceptor Sedan: 2013, 2014, 2015
• Ford Taurus X: 2008, 2009
• Ford Taurus: 2008, 2009, 2010, 2011, 2012, 2013, 2014, 2015
• Lincoln MKS: 2009, 2010, 2011, 2012, 2013, 2014, 2015
• Lincoln MKT: 2011, 2012
• Lincoln MKX: 2007, 2008, 2009, 2010
• Mercury Sable: 2008, 2009

3. What's in the Box

The Dorman 600-257 PTU Yoke package includes the following components:

• 1 x PTU Yoke
• 1 x Nut
• 1 x Crush Washer
• 1 x Oil Seal

Image 3.1: Close-up view of the included nut, crush washer, and oil seal.

4. Installation (Setup)

Installation of the Dorman 600-257 PTU Yoke requires specialized tools and automotive knowledge. It is highly recommended that installation be performed by a qualified professional technician to ensure proper fitment, function, and vehicle safety.

General Installation Guidelines (Professional Installation Recommended):

1. Safety First: Ensure the vehicle is properly supported on a lift or jack stands. Disconnect the battery.
2. Access PTU: Locate and gain access to the Power Take Off Unit (PTU) on your specific vehicle model. This may involve removing other components.
3. Remove Old Yoke: Carefully remove the drive shaft from the old yoke. Then, remove the retaining nut and the old yoke from the PTU output shaft. Note the orientation and any shims or spacers.
4. Inspect and Clean: Inspect the PTU output shaft for any damage or wear. Clean the mating surfaces thoroughly.
5. Install New Components: Install the new oil seal, crush washer, and then the Dorman 600-257 PTU Yoke onto the output shaft. Ensure proper seating.
6. Torque Nut: Install the new nut and torque it to the vehicle manufacturer's specifications using a torque wrench. Overtightening or undertightening can lead to premature failure.
7. Reattach Drive Shaft: Reattach the drive shaft to the new yoke, ensuring all fasteners are tightened to specification.
8. Final Checks: Reassemble any removed components. Check for proper clearance and ensure no leaks are present after initial operation.

Image 4.1: Top view of the PTU Yoke, highlighting the splined interior for shaft connection.

Image 4.2: Bottom view of the PTU Yoke, showing the mounting points.

5. Operation and Function

Once properly installed, the Dorman 600-257 PTU Yoke functions as a critical link in the vehicle's all-wheel drive (AWD) or four-wheel drive (4WD) system. It connects the Power Take Off Unit (PTU), which receives power from the transmission, to the drive shaft that transmits this power to the rear differential. This connection allows for the distribution of power to the rear wheels, enabling the AWD/4WD capability of the vehicle.

The yoke is designed for a precise fit, ensuring efficient and reliable power transfer while minimizing vibration and wear on connected components.

Image 5.1: Side profile of the PTU Yoke, illustrating its robust construction.

6. Maintenance

The Dorman 600-257 PTU Yoke is designed for durability and long-term performance. As a component within the drivetrain, its longevity is influenced by the overall health and maintenance of the vehicle's PTU and drive shaft system.

• Regular Inspections: During routine vehicle maintenance, have a qualified technician inspect the PTU yoke and surrounding components for signs of wear, damage, or leaks from the oil seal.
• Fluid Levels: Ensure the PTU fluid levels are maintained according to the vehicle manufacturer's specifications. Low or contaminated fluid can lead to increased wear on internal components, including the yoke.
• Address Vibrations: If unusual vibrations or noises are detected from the drivetrain, have the vehicle inspected promptly. These symptoms could indicate issues with the yoke, drive shaft, or PTU.

7. Troubleshooting

If issues arise after installation or during the lifespan of the PTU yoke, consider the following general troubleshooting points. For complex issues, professional diagnosis is essential.

• Vibrations: If vibrations occur, especially during acceleration, it could indicate improper installation, an unbalanced drive shaft, or issues with the PTU itself. Re-check torque specifications and balance.
• Fluid Leaks: Leaks around the yoke area often point to a damaged or improperly installed oil seal. Ensure the seal is correctly seated and not pinched.
• Unusual Noises: Clunking, grinding, or whining noises can suggest wear in the PTU, drive shaft, or an issue with the yoke's connection. Professional inspection is required.
• Loss of AWD/4WD: If the vehicle's all-wheel drive or four-wheel drive system is not engaging, the PTU or its connections, including the yoke, may be at fault. This requires diagnostic scanning and expert evaluation.

8. Specifications

9. Warranty and Support

Dorman products are backed by a commitment to quality and customer satisfaction. For specific warranty information regarding the Dorman 600-257 PTU Yoke, please refer to the official Dorman warranty policy available on their website or contact Dorman customer support directly.

For technical assistance, installation questions, or to report an issue, please visit the official Dorman website or contact their customer service department. When contacting support, please have your product model number (600-257) and vehicle information readily available.

Dorman Website: www.dormanproducts.com