Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSFORD2009FUSION SEL, 3.0 1, FWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1514 (MANUAL TRANSAXLE)ASSEMBLYTRANSAXLEMATERIAL
2009 Ford Fusion SEL, 3.0 1, FWD
Section 1514 (Manual Transaxle): Assembly: Transaxle: Material
2009 Ford Fusion SEL, 3.0 1, FWDSECTION Material
WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
MATERIAL SPECIFICATION TABLE
| Item | Specification |
|---|---|
| Silicone Gasket and Sealant TA-30 | WSE-M4G323-A4 |
PART NUMBER REFERENCE TABLE
| Item | Part Number | Description |
|---|---|---|
| 1 | 7505 | Clutch housing |
| 2 | - | Control rod |
| 3 | - | Control end |
| 4 | - | 1st/2nd shift fork |
| 5 | - | Control lever |
| 6 | - | Interlock lever |
| 7 | - | 3rd/4th shift fork |
| 8 | - | inner shift lever |
| 9 | - | Spring pin |
| 10 | - | Push pin component and spring |
| 11 | 4026 | Differential |
| 12 | - | Secondary shaft gear assembly |
| 13 | - | Primary shaft gear assembly |
| 14 | - | Shift fork and shift rod assembly |
| 15 | - | Reverse idler gear |
| 16 | - | Reverse shift fork |
| 17 | - | 5th/reverse shift rod end |
| 18 | - | 5th/reverse shift rod |
| 19 | 7L027 | Magnet |
| 20 | 7F116 | Crank lever component |
| 21 | - | O-ring |
| 22 | 7C355 | Crank lever shaft |
| 23 | - | Pin |
| 24 | 7005 | Transaxle case component |
| 25 | 7G072 | Neutral switch |
| 26 | - | Push pin component |
| 27 | - | Detent spring |
| 28 | - | Detent spring bolt and washer |
| 29 | 15520 | Reversing lamp switch |
| 30 | - | Lock bolt |
| 31 | - | Shift rail guide bolt |
| 32 | - | Reverse idler shaft lock bolt |
| 33 | - | Clutch hub |
| 34 | - | Clutch hub sleeve |
| 35 | - | Secondary 5th gear |
| 36 | - | Spacer |
| 37 | - | Gear sleeve |
| 38 | - | 5th gear |
| 39 | - | 5th gear synchronizer |
| 40 | - | Synchronizer key spring |
| 41 | - | 5th/6th clutch hub |
| 42 | - | 5th/6th shift fork |
| 43 | - | Secondary 6th gear |
| 44 | - | Synchronizer key spring |
| 45 | - | 6th gear synchronizer |
| 46 | - | 6th gear |
| 47 | - | Gear sleeve |
| 48 | - | Bearing (secondary shaft) |
| 49 | - | Bearing (primary shaft) |
| 50 | 7N170 | Locknut (secondary shaft) |
| 51 | 7N170 | Locknut (primary shaft) |
| 52 | 7222 | Rear cover |
NOTE:
Whenever the transaxle has been disassembled, the bearing preload must be adjusted. The input shaft, output shaft and differential bearing preload can be adjusted by selecting shims to insert between the bearing races and the case.
- Install the input shaft.
- Install the bearing cup onto the bearing.
- Install the Shim Selection Set.
- Install the transaxle case.
- Position the transaxle case in place.
- Install the Shim Selection Set bolts.
- Tighten to 45 Nm (33 lb-ft).
- Mount the Dial Indicator Gauge with Holding Fixture to the transaxle case.
- Rotate the input shaft to seat the bearings.
- Zero the Dial Indicator Gauge with Holding Fixture.
- Rotate the input shaft until the Dial Indicator Gauge returns to zero, then raise the input shaft and read the end play.
- Take and record 3 readings within 0.10 mm (0.003 in) of each other. Use the formula below to select the correct shim size.
SHIM SIZE SPECIFICATION TABLEAverage the 3 readings Example Reading A 0.019 Reading B 0.014 Reading C +0.021
0.054 ÷ 3 = 0.018Final Shim Size 0.018 NOTE: The shaft must be lifted equally on both sides or it may bind on one side, resulting in an incorrect reading.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.