Ford Fusion Sport AWD PTU leaking fluid causing burning smell and performance issues on Ford Fusion

Some Ford Fusion Sport AWD owners report experiencing PTU (Power Transfer Unit) issues, such as leaking fluid that causes a burning smell in the cabin. This odor may result from PTU fluid dripping onto the exhaust system, indicating a potential problem. Additionally, the leaking fluid is often thick, gummy, and black, which can lead to reduced power transfer efficiency and damage to internal components. Owners are advised to promptly inspect the PTU for leaks and make necessary repairs; however, if the burning smell persists, replacing the PTU and vent hose may be required. In situations where adding fluid only offers a temporary fix due to ongoing leaks, a full PTU replacement is often the most effective long-term solution. Some owners have reported needing to replace the PTU at a Ford dealership, sometimes facing backorder issues for the part. Regular inspections of the PTU can help prevent further damage and maintain vehicle performance, making it essential for owners to address these symptoms with a qualified mechanic.