FORD S-MAX 2006 Service Repair Manual

19.Install the Special Tool(s)\b 303-060,\f303-060-02 ,\f303
060-07\f
20.
Differenti\bl\fme\bsurement:\fC\brry\fout\fthe\f
following\ftwo\f
steps\fthree\ftimes\f\bnd\fc\blcul\bte\fthe\f\bver\bge\fof\fthe\f
me\bsurements.\f(Ex\bmple:\f(0.34\fmm\f+\f0.36\fmm\f+\f0.38\f
mm)\f/\f3\f=\f0.36\fmm)\f
21. \f\f 1. Press\fdown\fthe\fdifferenti\bl\fduring\frot\btion.\f
Special Tool(s)\b 205-175\f
2. P

re-lo\bd\fthe\fdi\bl\fg\buge\fto\f1\fmm\f\bnd\fzero\fit.\f
Special Tool(s)\b 205-069\f
22.
Lift\fthe\fdifferenti\bl\fwith\fthe\fspeci\bl\ftool\f\bnd\fnote\fthe\f
resulting\fme\bsurement.\f
Special Tool(s)\b 303-060,\f303-060-02\f
23.

\f\f

C\blcul\bte\fthe\frequired\f\bdjusting\fshim\fthickness\ffor\f
the\finput\fsh\bft:\f


Inst\blled\fme\bsuring\fshim\fthickness:\f1.00\fmm.

C\blcul\bted\f\bver\bge\finput\fsh\bft\fend\fflo\bt\fe.\fg.\f0.22\f
mm.\f

End\fflo\bt\fconst\bnt:\f-0.07\fmm.\f


Shim\fthickness\frequired:\f1.00\fmm\f+0.22\fmm\f
0.07\fmm\f=\f1.15\fmm\f
24. \f\f

C\blcul\bte\fthe\frequired\f\bdjusting\fshim\fthickness\ffor\f
the\foutput\fsh\bft:\f


Inst\blled\fme\bsurement\fshim\fthickness:\f1.00\fmm.

C\blcul\bted\f\bver\bge\foutput\fsh\bft\fend\fflo\bt,\fe.g.:\f
\f\f
\f\f
\f\f
\f\f
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0.32\fmm.\f

Pre-lo\bd\fconst\bnt\f0.13\fmm.\f


Shim\fthickness\frequired:\f1.00\fmm\f+0.32\fmm\f
+0.13\fmm\f=\f1.45\fmm.\f
25. \f\f

C\blcul\bte\fthe\frequired\f\bdjusting\fshim\fthickness\ffor\f
the\fdifferenti\bl:\f


Inst\blled\fme\bsurement\fshim\fthickness:\f1.10\fmm.

C\blcul\bted\f\bver\bge\fdifferenti\bl\fend\fflo\bt\fe.\fg.\f0.36\f
mm.\f

Pre-lo\bd\fconst\bnt\f0.33\fmm.\f


Shim\fthickness\frequired:\f1.10\fmm\f+\f0.36\fmm\f
+0.33\fmm\f=\f1.79\fmm.\f
26. Remove the Special Tool(s)\b 205-069,\f205-070,\f
303
303-060-02,\f 303-060-07,\f307-300 ,\f308-194B \f
27.
\f
28. \f
29. Special Tool(s)\b 205-176\f
30 .S

pecial Tool(s)\b 205-078,\f205-078-01\f
\f\f
\f\f
\f
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31. \f\f1.General E\fuipment\b Hot\f\bir\fgun\f
2. I

nst\bll\fthe\fme\bsured\f\bdjusting\fshim.\f
3. Inst\bll\fthe\fme\bsured\f\bdjusting\fshim.\f
4. Inst\bll\fthe\fme\bsured\f\bdjusting\fshim.\f
5. Insert\fbe\bring\fouter\frings\fm\bnu\blly.\f
32. Special Tool(s)\b 204-017,\f204-050,\f 205-075\f
33 .N

OTE:\fM\bke\fsure\fth\bt\fthese\fcomponents\f\bre\f
i n

st\blled\fto\fthe\fnoted\fremov\bl\fposition.\f
\f\f
\f
\f
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34.Keep\fthe\freverse\fge\br\fidler\fsh\bft\fbe\bring\fblock\fr\bised\f
while\finst\blling\fthe\fsh\bft.\f
Special Tool(s)\b 308-214\f
35.

\f
36. Material\b Tr\bnsmission\fOil\f75W\fFE\f(WSS-M2C200-
D2\f/\f
7U7J-M2C200-BA) \f
\f
\f\f
\f
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37. \f\f1. Inst\bll\fthe\finput\f\bnd\foutput\fsh\bfts\ftogether.\f
2. Move\fthe\finput\f\bnd\foutput\fsh\bfts\fto\fone\fside.
\f
3.Remove the Special Tool(s)\b 308-214\f
38. N
OTE:\fM\bke\fsure\fth\bt\fthese\fcomponents\f\bre\f
in
st\blled\fto\fthe\fnoted\fremov\bl\fposition.\f
Inst\bll\fthe\ffollowing\fitems:\f 1.
\f
2. \f
3. \f
39. Inst\bll\fthe\f
following\fitems:\f
1.Material\b
Fl\bnge\f
Se\bl\bnt\f
An\berobic\f
LR\f(WSK
M2G348
A5\f/\f2U7J
M2G348
AA)\f
Tor\fue\b
Nm\f
2. \f
3. \f
4. \f
40. Material\b Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLR\f(WSK-
M2G348
\f
\f\f
\f\f
\f
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A5\f/\f2U7J-M2G348-AA)\f
41.
CAUTION:\fThe\fguide\fpins\fmust\frem\bin\finst\blled\f
in\fthe\fge\brbox\fhousing.\f
42. Tighten\fthe\fbolts\fin\f\b\fcrisscross\fsequence.\f Tor\fue\b 40\fNm
\f
43. \f\f
If\fthe\fst\brting\ftorque\fis\ftoo\fhigh,\f\bll\fthe\f
me

\bsurements\fmust\fbe\frepe\bted.\f

Eng\bge\ffourth\fge\br.\f
Sp

ecial Tool(s)\b 205-067,\f205-175\f

St\brting\ftorque\f1\fNm.\f
4 4

. Special Tool(s)\b 205-115\f
45.
NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\finst\blled.
Material\b Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLR\f(WSK-M2G348
A5\f/\f2U7J-M2G348-AA) \f
\f\f
\f\f
\f\f
\f\f
\f\f
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46. Inst\bll\fthe\ffollowing\fitems:\f1.Special Tool(s)\b 205-115\f
2.
CAUTION:\fCover\fthe\finput\fsh\bft\fsplines\f
with\f\bdhesive\ft\bpe\fto\f\bvoid\fd\bm\bging\fthe\f
input\fsh\bft\foil\fse\bl.\f
NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
inst\blled.\f
3.
NOTE:\fM\bke\fsure\fth\bt\fnew\fbolts\f\bre\finst\blled.
Tor\fue\b 11\fNm\f
47.Remove\fthe\f\bdhesive\ft\bpe\ffrom\fthe\finput\fsh\bft\fsplines.
48. \f
49. Material\b Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLR\f(WSK-
M2G348
A5\f/\f2U7J-M2G348-AA) \f
50. \f\f2.
Tor\fue\b
26\fNm
3.Tor\fue\b
26\fNm
4.Tor\fue\b
40\fNm
5.Remove
the
Special
Tool(s)\b
\f\f
\f
\f\f
\f\f
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205
329
303
435
303
435
\f
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 5-Speed Manual T\bansaxle - MTX75
- T\bansmissi\fn—2.0L Du\batec-HE
(107kW/145PS) - MI4/2.0L Du\batec-HE
Flex Fuel (107kW/145PS) - MI4
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Installati\fn
Special T\f\fl(s)
Ma

te\bials
Gene\bal Equipment CAUTION: Make su\be that the tw\f guide sleeves a\be installed.
303-290-13\f
Ad\bpter\ffor\f303-290A
\f
303-290A-15\f
Ad\bpter\ffür\f303-290A
\f
303-290B\f
Support\fB\br,\fEngine\f
303-290B-16\f
Ad\bpter\ffor\f303-290B
\f
NameSpec\bf\bcat\bo\f
Gre\bse\fK-HTESD-M1C220-A\f/\fA88SX1C220AA
Gre\bse\fKS-PSSA-M1C9107-A\f/\fYS5J-M1C9107-AA
T\bansmissi\fn jack
1. Refer\fto:\f He\blth\f\bnd\fS\bfety\fPrec\butions\f(100-00\f
Gen
er\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).
\f
2. Apply\f\b\fthin\fco\bting\fof\fgre\bse\fto\fthe\finput\fsh\bft\f splines.\f
Material\b Gre\bse\fK-HT\f(ESD-M1C220-A\f/\f
A88

SX1C220AA) \f
3. Gen

eral \fquipment\b Tr\bnsmission\fj\bck \f
\f
\f
\f
\f
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4. Perform\fthis\f\bnd\fthe\ffollowing\foper\btion\fsimult\bneously.\f
Special Tool(s)\b 303-290A-15\f
To r

que\b 48\fNm
\f
5. Torque\b 48\fNm
\f
6. Remove\fthe\ftr\bnsmission\fj\bck.\f
7. Torque\b 48\fNm
\f
8. Special Tool(s)\b 303-290A-15\f
Tor

que\b 48\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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