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HOMESERVICE MANUALSFORD2009FUSION SEL, 3.0 1, FWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 625 (MANUAL TRANSAXLE/TRANSMISSION)DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESTRANSAXLE CASEASSEMBLY
2009 Ford Fusion SEL, 3.0 1, FWD

Transaxle Case: Assembly

2009 Ford Fusion SEL, 3.0 1, FWDSECTION Assembly
WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. Do not install the following components into the transaxle case at this time. These components will be installed during final assembly.
    • Input shaft bearing cup and shim
    • Output shaft bearing cup and shim
    • Differential bearing cup and shim
    • Funnel
  2. Working on the transaxle clutch housing side, install the vent and the 2 vent bolts.
  3. Using the special tool, install a new input shaft seal.
    Fig 1: Locating Special Tool, And Input Shaft Seal
    G04682250Courtesy of FORD MOTOR CO.
  4. Install the input shaft bearing cup into the clutch housing.
    Fig 2: Locating Input Shaft Bearing Cup Into Clutch Housing
    G04682251Courtesy of FORD MOTOR CO.
  5. Install the funnel into the clutch housing.
    Fig 3: Locating Funnel Into Clutch Housing
    G04682252Courtesy of FORD MOTOR CO.
  6. Using the special tool, install the output shaft bearing cup into the clutch housing.
    Fig 4: Locating Special Tool, Output Shaft Bearing Cup Into Clutch Housing
    G04682253Courtesy of FORD MOTOR CO.
  7. Using the special tool, install the differential bearing cup into the clutch housing.
    Fig 5: Locating Special Tool And Differential Bearing Cup Into Clutch Housing
    G04682254Courtesy of FORD MOTOR CO.
  8. Using the special tool, install new halfshaft seals.
    Fig 6: Identifying Special Tool
    G04682255Courtesy of FORD MOTOR CO.
  9. Install the control rod into the case, through the selector rod and into the change arm. Align the selector arm with the hole in the control rod and install a new roll pin. Align the change arm with the hole in the control rod and install a new roll pin.
  10. Install a new seal cap.
    Fig 7: Locating Seal Cap
    G04682256Courtesy of FORD MOTOR CO.
  11. Install the shift control selector plate, aligning the selector arm with the plate.
    • Tighten the bolt on the left to 10 Nm (89 lb-in).
    • Tighten the bolt on the right to 28 Nm (21 lb-ft).
      Fig 8: Locating Shift Control Selector Plate And Bolts
      G04682257Courtesy of FORD MOTOR CO.
  12. Install the shift lever boot.
    Fig 9: Locating Shift Lever Boot
    G04682258Courtesy of FORD MOTOR CO.
  13. Install the shift lever into the case. Install the control arm and key, the spring and the washer. Push the assembly inward. Align the control arm bolt with the notch on the shift lever rod. Install the bolt.
    Fig 10: Locating Control, Key, Spring And Washer
    G04682259Courtesy of FORD MOTOR CO.
    14. NOTE: Position the shift lever boot into the case.
RENDER: 1.0x

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  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.