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HOMESERVICE MANUALSMERCURY2009MILAN PREMIER, 3.0 1, AWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 3 (MANUAL TRANSMISSION)ASSEMBLYTRANSAXLE
2009 Mercury Milan Premier, 3.0 1, AWD

Section 3 (Manual Transmission): Assembly: Transaxle

2009 Mercury Milan Premier, 3.0 1, AWDSECTION Transaxle
WARNING: This page is about a different variant/trim than selected.
Special Tools

Illustration Tool Name Tool Number
GF0003968Courtesy of FORD MOTOR CO.
 Bell Housing Seal Replacer 308-057 (T77J-7025-G)
GF0030029Courtesy of FORD MOTOR CO.
 Differential Bearing Cup Replacer 308-162 (T88C-77000-EH)
GF0030039Courtesy of FORD MOTOR CO.
 Installer, Halfshaft Oil Seal 308-119 (T87C-77000-H)
GF0001210Courtesy of FORD MOTOR CO.
 Front Hub Bearing Cup 204-039 (T77F-1217-B)
GF0001106Courtesy of FORD MOTOR CO.
 Handle 205-153 (T80T-4000-W)
GF0000940Courtesy of FORD MOTOR CO.
 Holding Fixture 307-003 (T57L-500-B)
GF0030063Courtesy of FORD MOTOR CO.
 Rotating Tool 308-165 (T88C-77000-L)
GF0017676Courtesy of FORD MOTOR CO.
 Shim Selection Set 308-161 (T88C-77000-C)
GF0030064Courtesy of FORD MOTOR CO.
 Shim Selection Tool Set 308-164 (T88C-77000-JF)
GF0029965Courtesy of FORD MOTOR CO.
 Torque Adapter 308-160 (T88C-7025-GH)
GF0001072Courtesy of FORD MOTOR CO.
 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-A)
Material

Item Specification
Silicone Gasket and Sealant
TA-30		 WSE-M4G323-A4
Fig 1: Exploded View Of Transaxle Assembly
GF0030065Courtesy of FORD MOTOR CO.
Item Part Number Description
1 4026 Differential
2 - Output shaft assembly
3 7005 Transaxle case
4 - Transaxle case-to-flywheel housing bolt (15 required)
5 - Check ball
6 7L058 5th gear and reverse inhibitor spring
7 - Detent spring bolt
8 7222 Case cover
9 - Case cover bolt (9 required)
10 7N170 Shaft lock nuts
11 7230 Gear shifter fork
12 - Roll pin
13 7107 Synchronizer blocking ring
14 7144 5th speed cluster gear
15 - 5th gear bushing
16 7C072 Transmission shift rod snap ring
17 7241 Shift control shaft (reverse/fifth)
18 7G043 Shift gate
19 7140 Reverse idler gear shaft
20 7141 Reverse idler gear and bushing
21 7G072 Park/neutral position (PNP) switch
22 7005 Flywheel housing
23 - Steel ball
24 - Spring
25 7F116 Shift fork selector lever
26 - Input shaft assembly
27 - Gear shifter fork and main shift control shaft assembly
28 7K316 Fifth speed gear
29 - Reverse idler shaft lock bolt
30 15520 Reversing lamp switch
31 - Washer
32 - Shift rail guide bolt
33 - Synchronizer hub insert (2 required)
34 7107 Synchronizer blocking ring
35 - Synchronizer hub assembly
36 7A443 Shift gate bolt
37 7C355 Shift lever shaft
38 - Magnet
39 - Pin
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.
  1. Using the special tool, install the input shaft seal.
    2. Fig 2: Locating Special Tool (308-057) And Input Shaft Seal
    GF0030066Courtesy of FORD MOTOR CO.
  2. Install the input shaft bearing cup into the flywheel housing.
    3. Fig 3: Locating Input Shaft Bearing Cup Into Clutch Housing
    GF0030057Courtesy of FORD MOTOR CO.
  3. Install the input shaft.
    4. Fig 4: Locating Input Shaft
    GF0030067Courtesy of FORD MOTOR CO.
  4. Install the bearing cup onto the bearing.
    5. Fig 5: Locating Bearing Cup
    GF0030068Courtesy of FORD MOTOR CO.
  5. Install the special tools.
    6. Fig 6: Identifying Special Tools (308-164, 308-161)
    GF0030069Courtesy of FORD MOTOR CO.
  6. Install the transaxle case.
    1. Position the transaxle case to the input shaft and the special tools.
    2. Install the bolts.
      • Tighten to 45 Nm (33 lb-ft).
    7. Fig 7: Identifying Transaxle Case And Bolts
    GF0030070Courtesy of FORD MOTOR CO.
  7. Mount the special tool to the transaxle case.
    8. Fig 8: Mounting Special Tool (100-002) To Transaxle Case
    GF0030071Courtesy of FORD MOTOR CO.
  8. Rotate the input shaft to seat the bearings.
  9. Zero the dial indicator.
    10. Fig 9: Zeroing Dial Indicator
    GF0030072Courtesy of FORD MOTOR CO.
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.