Saving a Ford Explorer PTU - can the old thick fluid be removed

The drain/fill seems to be doing some cleaning. Since doing so the first fluid exchange the car has ~400 miles on it. I was able to extract 400ml again and it was nasty already. Grey in color and seemingly thicker than the gear oil I refilled with. I should have taken some pictures but will next time.

My plan is to buy a jug of 75W-140 and keep doing the drain/fill routine until I see improvement in how the removed fluid is looking. I’m also thinking about trying the HP Differential Life Cleaner. I’ll keep the post updated with progress.
 
I would not do solvent. Unless you want to chance the seals. I took apart the PTU in the 2005 Ford Escape I put an engine in. The fluid was nasty, and the bearings/gears were not as good as I would like. I think my PTU had 5 or 6 seals. 😲

But things were good enough to put in new seals all around. I also cleaned the gears etc when apart.

Getting a used PTU is always an option if you if things don't work with the existing one. Dilution is the solution.
 
I had a Ford Taurus X 2008 a while ago that had the same issue. I drilled a 9/16" hole and tapped threads and added a drain. Then I accessed the vent on the top of the PUT and dug out as much goop as I could with long cotton swabs.

Then I ran 24 oz of engine flush for a couple of trips around the block, drained out the concoction and refilled with Schaeffer's 75W-140 that is used in Harley gear cases. Ran great for the 2 years after that until I sold the vehicle.
 
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