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HOMESERVICE MANUALSMERCURY2009MILAN PREMIER, 3.0 1, AWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT VARIANT/TRIMSECTION 3 (MANUAL TRANSMISSION)DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESTRANSAXLE CASEASSEMBLY
2009 Mercury Milan Premier, 3.0 1, AWD

Transaxle Case: Assembly

2009 Mercury Milan Premier, 3.0 1, AWDSECTION Assembly
WARNING: This page is about a different variant/trim than selected.
  1. Do not install the following components into the transaxle case at this time. These components will be installed during final assembly.
    • Input shaft bearing cup and shim
    • Output shaft bearing cup and shim
    • Differential bearing cup and shim
    • Funnel
  2. Working on the transaxle clutch housing side, install the vent and the 2 vent bolts.
  3. Using the special tool, install a new input shaft seal.
    4. Fig 1: Locating Special Tool (308-057), And Input Shaft Seal
    GF0030056Courtesy of FORD MOTOR CO.
  4. Install the input shaft bearing cup into the clutch housing.
    5. Fig 2: Locating Input Shaft Bearing Cup Into Clutch Housing
    GF0030057Courtesy of FORD MOTOR CO.
  5. Install the funnel into the clutch housing.
    6. Fig 3: Locating Funnel Into Clutch Housing
    GF0030058Courtesy of FORD MOTOR CO.
  6. Using the special tool, install the output shaft bearing cup into the clutch housing.
    7. Fig 4: Locating Special Tools (204-039, 205-153), Output Shaft Bearing Cup Into Clutch Housing
    GF0030059Courtesy of FORD MOTOR CO.
  7. Using the special tool, install the differential bearing cup into the clutch housing.
    8. Fig 5: Locating Special Tool (205-153, 308-162) And Differential Bearing Cup Into Clutch Housing
    GF0030060Courtesy of FORD MOTOR CO.
  8. Using the special tool, install new halfshaft seals.
    9. Fig 6: Identifying Special Tool (308-119)
    GF0030061Courtesy of FORD MOTOR CO.
  9. Install the control rod into the case, through the selector rod and into the change arm. Align the selector arm with the hole in the control rod and install a new roll pin. Align the change arm with the hole in the control rod and install a new roll pin.
  10. Install a new seal cap.
    11. Fig 7: Locating Seal Cap
    GF0030047Courtesy of FORD MOTOR CO.
  11. Install the shift control selector plate, aligning the selector arm with the plate.
    • Tighten the bolt on the left to 10 Nm (89 lb-in).
    • Tighten the bolt on the right to 28 Nm (21 lb-ft).
    12. Fig 8: Locating Shift Control Selector Plate And Bolts
    GF0030046Courtesy of FORD MOTOR CO.
  12. Install the shift lever boot.
    13. Fig 9: Locating Shift Lever Boot
    GF0030053Courtesy of FORD MOTOR CO.
  13. Install the shift lever into the case. Install the control arm and key, the spring and the washer. Push the assembly inward. Align the control arm bolt with the notch on the shift lever rod. Install the bolt.
    14. Fig 10: Locating Washer, Spring, Control Arm And Key
    GF0030052Courtesy of FORD MOTOR CO.
RENDER: 1.0x

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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

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  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.