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

Disassembly and Assembly

2009 Ford Fusion SEL, 3.0 1, FWDSECTION Disassembly and 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. Place the transaxle clutch housing on a bench.
  2. Remove the 2 vent bolts and the vent.
    Fig 1: Locating Vent And Bolts
    G04682235Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove the differential bearing cup.
    • Inspect the cup for wear or damage. Install a new cup as necessary.
    • Always install new bearings and cups as a set. Do not install one without the other.
      Fig 2: Locating Bearings And Cups Set
      G04682236Courtesy of FORD MOTOR CO.
  4. Remove and discard the differential seal.
  5. Using the special tools, remove the input shaft bearing cup.
    • Inspect the cup for wear or damage. Install a new cup as necessary.
    • Always install new bearings and cups as a set. Do not install one without the other.
      Fig 3: Using Special Tools To Remove Input Shaft Bearing Cup
      G04682237Courtesy of FORD MOTOR CO.
  6. Using a screwdriver, remove and discard the input shaft oil seal.
    Fig 4: Using Screwdriver To Remove Input Shaft Oil Seal
    G04682238Courtesy of FORD MOTOR CO.
  7. Remove the funnel and the output shaft bearing cup.
    • Inspect the cup for wear or damage. Install a new cup as necessary.
    • Always install new bearings and cups as a set. Do not install one without the other.
      Fig 5: Removing Funnel And Output Shaft Bearing Cup
      G04682239Courtesy of FORD MOTOR CO.
  8. Remove the shift control selector plate bolts and the shift control selector plate.
    Fig 6: Locating Shift Control Selector Plate And Bolts
    G04682240Courtesy of FORD MOTOR CO.
  9. Using a screwdriver, remove and discard the seal cap.
    • An alternate method: make a small hole in the center of the cup and use a slide hammer and screw.
      Fig 7: Locating Hole
      G04682241Courtesy of FORD MOTOR CO.
  10. Align the selector arm with the indentation in the case. Using a punch, remove the selector arm roll pin. Discard the roll pin.
    Fig 8: Locating Selector Arm Roll Pin
    G04682242Courtesy of FORD MOTOR CO.
    11. NOTE: Slide the control arm rearward.
RENDER: 1.0x

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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.