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 VARIANT/TRIMSECTION 3 (MANUAL TRANSMISSION)DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESDIFFERENTIALDISASSEMBLY

2009 Mercury Milan Premier, 3.0 1, AWD

Disassembly And Assembly Of Subassemblies: Differential: Disassembly

2009 Mercury Milan Premier, 3.0 1, AWDSECTION Disassembly

WARNING: This page is about a different variant/trim than selected.

Inspect the differential for wear or damage.
- Inspect for damaged or worn gears.
- Inspect for worn or damaged differential bearings.
- Install new components as necessary.
Remove and discard the differential pinion shaft lock pin.

Fig 1: Locating Differential Pinion Shaft Lock Pin

Courtesy of FORD MOTOR CO.

Remove the differential pinion shaft, the differential pinon gears and the thrust washers.
Remove the differential side gears and thrust washers.
- Rotate the differential side gears to remove.

Fig 2: Locating Differential Side Gears

Courtesy of FORD MOTOR CO.

Using the special tools, remove the differential bearing.
- Always install new bearings and cups as a set. Do not install one without the other.

Fig 3: Locating Special Tools (205-D064, 205-DS011, 205-DS023) And Differential Bearing

Courtesy of FORD MOTOR CO.

Remove the speedometer drive gear.

Fig 4: Locating Special Tools (205-D064, 205-DS011, 205-DS023) And Speedometer Drive Gear

Courtesy of FORD MOTOR CO.

Rotate the differential assembly with the speedometer drive gear side facing downward. Remove the other differential bearing.
- Always install new bearings and cups as a set. Do not install one without the other.

Fig 5: Locating Special Tools (205-D064, 205-DS011, 205-DS023) And Differential Bearing

Courtesy 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.