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

Transaxle Case: 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. 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 cover and the 2 vent cover bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 1: Locating Vent Cover Bolts
    G06276039Courtesy of FORD MOTOR CO.
  3. Using the Clutch Housing Oil Seal Installer, install a new input shaft seal.
    Fig 2: Installing Input Shaft Seal
    G06276040Courtesy of FORD MOTOR CO.
  4. Install the input shaft bearing cup into the clutch housing.
    Fig 3: Locating Input Shaft Bearing Cup
    G06276041Courtesy of FORD MOTOR CO.
  5. Align and install the funnel and the output shaft bearing cup into the clutch housing.
    Fig 4: Locating Funnel & Output Shaft Bearing Cup
    G06276042Courtesy of FORD MOTOR CO.
  6. Using the Differential Bearing Cup Installer and Handle, install the differential bearing cup into the clutch housing.
    Fig 5: Installing Differential Bearing Cup Into Clutch Housing
    G06276043Courtesy of FORD MOTOR CO.
  7. Using the Halfshaft Oil Seal Installer, install new halfshaft seals.
    Fig 6: Installing Halfshaft Seals
    G06276044Courtesy of FORD MOTOR CO.
  8. Install the shift control selector 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).
    Fig 7: Locating Shift Control Selector Plate With Bolts
    G06276029Courtesy of FORD MOTOR CO.
  9. Install the shift lever boot.
    Fig 8: Locating Shift Lever Boot
    G06276035Courtesy of FORD MOTOR CO.
  10. Install shift lever seal into the case.
    Fig 9: Locating Shift Lever Seal
    G06276036Courtesy of FORD MOTOR CO.
  11. Install the shift lever rod into the case. Install the control arm key.
    Fig 10: Locating Control Arm Key
    G06276033Courtesy of FORD MOTOR CO.
  12. Install the control arm, 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.
    NOTE: Use care not to let the washer fall off the rod.
    • Tighten to 12 Nm (106 lb-in).
    Fig 11: Locating Washer, Spring & Control Arm
    G06276032Courtesy of FORD MOTOR CO.
  13. Install the shift lever assembly.
    1. Install the 2 shift lever assembly bolts and attach the boot and bushing to the case.
      • Tighten to 22 Nm (16 lb-ft).
    2. Attach the shift arm, boot and bushing to the shift assembly.
    Fig 12: Identifying Shift Lever Assembly Bolts
    G06276030Courtesy of FORD MOTOR CO.
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