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 MANUALSMERCURY2009MILAN PREMIER, 3.0 1, AWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1578 (EXHAUST SYSTEM)REMOVAL AND INSTALLATIONRESONATORINSTALLATION

2009 Mercury Milan Premier, 3.0 1, AWD

Removal And Installation: Resonator: Installation

2009 Mercury Milan Premier, 3.0 1, AWDSECTION Installation

WARNING: This page is about a different car, the 2010 Mercury Mariner and 2010 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

Inspect the resonator flange studs for damage.
- If damaged, replace stud(s), or if stud comes out when removing nut(s), replace the stud(s).
If replacing the resonator flange stud(s), use the C-Frame and Screw Installer/Remover to push the 8-mm stud(s) out of the flange.

Fig 1: Identifying C-Frame And Screw Installer/Remover
Courtesy of FORD MOTOR CO.

NOTE: When positioning the new 8-mm stud in the resonator flange, make sure to line up the new stud seat knurls with witness knurl grooves in the resonator flange.

If replacing the resonator flange stud(s), use a C-clamp and a deep well socket to push the 8-mm stud fully into the flange.
- Make sure the stud is fully and evenly seated into the flange.
  
  Fig 2: Pushing Stud Fully Into Flange
  Courtesy of FORD MOTOR CO.

NOTE: Replace the gasket by hand. Do not rotate the gasket back and forth during installation. Doing so may lessen the gaskets ability to seal and stay correctly positioned during assembly.

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.