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HOMESERVICE MANUALSMERCURY2010MARINER HYBRID, AWDREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 1235 (MANUAL TRANSAXLE)DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIESOUTPUT SHAFTASSEMBLY
2010 Mercury Mariner Hybrid, AWD

Output Shaft: Assembly

2010 Mercury Mariner Hybrid, AWDSECTION Assembly
WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lubricate all output shaft components with the recommended transmission lubricant during reassemble.
    NOTE: Do not reassemble the output shaft dry. Apply lubricant throughout the assembly procedure.
  2. Using the Bearing/Oil Seal Plate, Transaxle Bearing Cup Installer and a suitable press, press on a new bearing.
    Fig 1: Pressing Bearing
    G06275990Courtesy of FORD MOTOR CO.
  3. If installing a new output shaft, using a suitable press, install the new spacer.
  4. Install the friction dampener.
  5. Assemble the synchronizer.
    1. Position the synchronizer hub to the sleeve.
    2. Install the hub inserts.
    3. Install the blocking spring.
    4. Rotate the synchronizer and install the opposite blocking spring.
    Fig 2: Identifying Synchronizer Components
    G06182215Courtesy of FORD MOTOR CO.
  6. Assemble the 1st gear blocking ring set and synchronizer.
  7. Using the Bearing/Oil Seal Plate, Differential Bearing Cup Installer and a suitable press, press on the 1st gear, the synchronizer blocking ring and synchronizer assembly.
    NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts to prevent damage.
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