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General Ford Flex Discussions • Re: Preparing for the next major maintenance - 120k?

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I had mentioned these items in another thread, but I recently installed the Powerstop Z37 Top Cop front and rear brake pads, R1 Concepts black cross drilled and slotted front and rear rotors, and Powerstop red powder coated front and rear brake calipers and brackets. Already had the Goodridge stainless lines as well. This setup was installed to replace an aging Powerstop Z36 setup. I've been finding that I get around 60k or so out of a a set of brakes regardless of it being stock or aftermarket, so it was about time. Unfortunately the Z37 pads do not come as a kit and need to be ordered individually. I decided this time around to go with the black zinc coated R1 Concepts rotors instead of the Powerstop rotors to see if they hold up better as far as corrosion.

I also had installed the PPE catless downpipes after finding a tuner that would code out the rear o2 sensors. I wasn't having any issues with the stock downpipes yet, but I'm glad that I installed these when I had set aside time to do so. There was much torch work involved in getting the old downpipes off, and the flex sections on the old pipes were definitely tired. The PPE downpipes are very nice and fit very well, but there was one small area I had to heat and hammer in a bit on the rear downpipe to give it a little more clearance around the subframe, otherwise they cleared the stock bellyshield and everywhere else just fine.

While I had the downpipes off I figured it a good time to try and tackle the issue with the PTU vent puking crap out of it. There is an updated PTU vent from Ford, but knowing that the stock vent was simply a jiggle cap setup similar to what "old" truck diffs used I assumed that I could just make my own. I had pulled the jiggle cap/fitting setup out of the PTU, cut the cap off it, and found that the fitting was almost completely plugged up with gunk and barely allowing air through it. I pulled the drain and fill plugs out of the PTU and ran a bunch of brake cleaner through the vent hole as well as a bunch of compressed air to get all the gunk cleaned out of the PTU. I then cleaned the fitting out and attached a length of hose with a new diff vent breather to the end of it, installed the fitting into the PTU, and mounted the other end to the thermostat housing. So far no issues with the puking. My thoughts on it are that as the fluid gets crappy int the PTU it plugs up the vent area, starts building pressure inside the PTU, and then pukes out the vent through the small area that it can. With extending the vent section it allows the PTU to breathe better without plugging the small fitting and jiggle cap that sits right at the top of the PTU.

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