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

Disassembly And Assembly

2009 Mercury Milan Premier, 3.0 1, AWDSECTION Disassembly And Assembly
WARNING: This page is about a different variant/trim than selected.
  1. Place the transaxle clutch housing on a bench.
  2. Remove the 2 vent bolts and the vent.
    3. Fig 1: Locating Vent And Bolts
    GF0030041Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove the differential bearing cup.
    • Inspect the cup for wear or damage. Install a new cup as necessary.
    • Always install new bearings and cups as a set. Do not install one without the other.
    4. Fig 2: Locating Bearings And Cups Set
    GF0030042Courtesy of FORD MOTOR CO.
  4. Remove and discard the differential seal.
  5. Using the special tools, remove the input shaft bearing cup.
    • Inspect the cup for wear or damage. Install a new cup as necessary.
    • Always install new bearings and cups as a set. Do not install one without the other.
    6. Fig 3: Using Special Tools (100-001, 307-163) To Remove Input Shaft Bearing Cup
    GF0030043Courtesy of FORD MOTOR CO.
  6. Using a screwdriver, remove and discard the input shaft oil seal.
    7. Fig 4: Using Screwdriver To Remove Input Shaft Oil Seal
    GF0030044Courtesy of FORD MOTOR CO.
  7. Remove the funnel and the output shaft bearing cup.
    • Inspect the cup for wear or damage. Install a new cup as necessary.
    • Always install new bearings and cups as a set. Do not install one without the other.
    8. Fig 5: Removing Funnel And Output Shaft Bearing Cup
    GF0030045Courtesy of FORD MOTOR CO.
  8. Remove the shift control selector plate bolts and the shift control selector plate.
    9. Fig 6: Locating Shift Control Selector Plate And Bolts
    GF0030046Courtesy of FORD MOTOR CO.
  9. Using a screwdriver, remove and discard the seal cap.
    • An alternate method: make a small hole in the center of the cup and use a slide hammer and screw.
    10. Fig 7: Locating Seal Cap
    GF0030047Courtesy of FORD MOTOR CO.
  10. Align the selector arm with the indentation in the case. Using a punch, remove the selector arm roll pin. Discard the roll pin.
    11. Fig 8: Locating Selector Arm Roll Pin
    GF0030048Courtesy 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.