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.

SYS.OK|MANUAL.DB● LIVE

HOMESERVICE MANUALSMERCURY2009MILAN PREMIER, 3.0 1, AWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1514 (MANUAL TRANSAXLE)DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESOUTPUT SHAFTDISASSEMBLY

2009 Mercury Milan Premier, 3.0 1, AWD

Output Shaft: Disassembly

2009 Mercury Milan Premier, 3.0 1, AWDSECTION Disassembly

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.

NOTE: When pressing off components, hold the shaft so it does not fall.

Measure the output shaft clearances.
1. Measure the clearance between 1st gear and the differential drive gear. First gear endplay is 0.05-0.33 mm (0.001-0.012 in).
2. Measure the clearance between 2nd gear and secondary 3rd gear. Second gear endplay is 0.18-0.51 mm (0.007-0.02 in).
Fig 1: Measuring Clearance Between 2nd Gear & Secondary 3rd Gear
Courtesy of FORD MOTOR CO.
Using the Bearing Puller and a suitable press, press off the bearing and 4th gear.
- Discard the bearing.
- Always install new bearings and cups as a set.
Fig 2: Pressing Bearing & 4th Gear
Courtesy of FORD MOTOR CO.
Remove and discard the snap ring.

Fig 3: Locating Discard Snap Ring
Courtesy of FORD MOTOR CO.
Using the Bearing Puller and a suitable press, press off the 3rd gear and 2nd gear.

Fig 4: Pressing 3rd Gear & 2nd Gear
Courtesy of FORD MOTOR CO.
Remove the synchronizer blocking ring, the synchronizer inner cone and the synchronizer outer cone.
NOTE: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.

RENDER: 1.0x

NO RELATED

Recommended Tools & Savings

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Affiliate disclosure: We may earn a commission at no extra cost to you.

Shop Manual-Ready Tools Free Quote Check Quote Shield Pro

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.