FORD S-MAX 2006 Service Repair Manual

The\fge\br\fwheel\fof\fthe\f4th/6th\fge\br\fdrives\fnot\fonly\fthe\fge\br\fwheel\fof\fthe\f4th\fge\br\fbut\f\blso\f
of\fthe\f6th\fge\br.\f
The\f6th\fge\br\fwheel\fis\fpositively\fconnected\fto\fthe\f5th/6th/reverse\fge\br\foutput\fsh\bft\fby\fthe\f
5th/6th\fge\br\fsynchroniser\f\bssembly.\f
Power\ftr\bnsmission\froute\fin\freverse\fge\br\f
The\freverse\fge\br\fidler\fis\fwelded\fto\fthe\f1st\fge\br\fwheel.\fIt\fis\fconst\bntly\feng\bged\fwith\fthe\f
reverse\fge\br\fwheel\f(shown\fsep\br\bted\ffor\fcl\brity).\f
The\freverse\fge\br\fwheel\fis\fpositively\fconnected\fto\fthe\f5th/6th/reverse\fge\br\foutput\fsh\bft\fby\f
the\freverse\fge\br\fsynchroniser\f\bssembly.\f
Inte\bnal shift mechanism \f\f
\f\f
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\f\fDesc\bipti\fn
Counterb\bl\bnce\f
Reverse\fge\br\fswitch\f
Selector\fsh\bft\f
Selector\fg\bte\f
Inte\bnal shift mechanism
Th
e\fintern\bl\fshift\fmech\bnism\fh\bs\fbeen\fnewly\fdeveloped\ffor\fthis\ftr\bnsmission.\f
The\freverse\fge\br\fswitch\fis\floc\bted\fon\fthe\fhousing\fcover\fof\fthe\fintern\bl\fshift\fmech\bnism.\f
The\fcounterb\bl\bnce\fimproves\fthe\fsmoothness\fof\fthe\fge\br\fshifting.\fDue\fto\fits\fm\bss,\fthe\f
synchroniz\btion\fshift\fresist\bnces\fth\bt\fc\bn\fbe\ffelt\fduring\fshifting\f\bre\freduced.\fThe\fge\br\f
shifting\fprocess\fbecomes\fsmoother.\f
The\fintern\bl\fshift\fmech\bnism\fc\bn\fonly\fbe\fch\bnged\f\bs\f\b\fcomplete\funit\fin\fservice.\f Item
1
2
3
4
\f
Pa\bt Numbe\b -
-
-
-
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - MMT6 -
Manual T\bansaxle—Vehicles With: Manual
T\bansaxleS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagn\fsis and Testing
REFER\fto:\f M\b
nu\bl\fTr\bns\bxle\f\bnd\fClutch \f(308-00\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f
-\fG
ener\bl\fInform\btion,\fDi\bgnosis\f\bnd\fTesting).\f
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - MMT6 -
Bea\bing CheckS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Gene\bal P\b\fcedu\bes
1.NOTE:\fEst\bblish\fthe\fc\buse\fof\fthe\fd\bm\bge\f
\bn

d\fresolve\fit.\f
Check\fwhether\fthe\fbe\bring\fc\bge\fis\f
d\bm

\bged\f\bt\fthe\ftop,\fside\for\f\bt\fthe\f
openings\fdue\fto\funprofession\bl\fuse\fof\f\b\f
speci\bl\ftool\for\fuse\fof\fthe\fwrong\ftool.\f

Inst\bll\f\b\fnew\fbe\bring\fif\fnecess\bry.\f
2.

\f\f
Check\fwhether\fthe\fends\fof\fthe\ft\bper\f
ro

llers\f\bre\fdiscolored\f\bs\f\b\fresult\fof\f
in\bdequ\bte\flubric\btion\for\foverhe\bting,\f
possibly\fthrough\fexcessive\fpre-lo\bd.\f

Inst\bll\f\b\fnew\fbe\bring\f\bnd\fnew\fse\bls\fif\f
ne

cess\bry.\f

Check\fthe\fbe\bring\fis\fcorrectly\flubric\bted.\f
3.

\f\f
Check\fwhether\fthe\fends\fof\fthe\ft\bper\f
ro

llers\f\bre\fworn\f\bw\by\fdue\fto\fincorrect\f
inst\bll\btion,\fexcessive\fpre-lo\bd\for\ff\bulty\f
be\bring\fse\bting.\f

Inst\bll\f\b\fnew\fbe\bring\f\bnd\fnew\fse\bls\fif\f
ne

cess\bry.\f

Check\fthe\fbe\bring\fis\fcorrectly\flubric\bted.\f
4 .

\f\f
Check\fwhether\fthe\fbe\bring\fsurf\bces\f\bre\f
gr

\by\for\fgr\by/bl\bck\fwith\fdeposits\fbetween\f
the\frollers.\f

Inst\bll\f\b\fnew\fbe\bring\f\bnd\fnew\fse\bls\fif\f
ne

cess\bry.\f

Check\fthe\fbe\bring\fis\fcorrectly\flubric\bted.\f
5.

\f\f
Check\fwhether\fthe\fbe\bring\fring\fsurf\bces\f
\bre

\fgrooved\fc\bused\fby\fst\btic\fimp\bct.\f

Inst\bll\f\b\fnew\fbe\bring\fif\fits\fsurf\bce\fis\f
ro

ugh,\for\fif\fit\fis\fnoisy.\f
\f\f
\f\f
\f\f
\f\f
\f\f
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6.NOTE:\fOverhe\bting\fc\bn\fc\buse\floss\fof\fsurf\bce\f
h\b
rdness.\f
Check\ffor\f\b\fd\brk\fblue\fcolors\fc\bused\fby\f
ov

erhe\bting\f(yellow\for\fbrown\fis\fnorm\bl)\f
due\fto\fexcessive\fpre-lo\bd\for\fin\bdequ\bte\f
lubric\btion.\f


Inst\bll\f\b\fnew\fbe\bring,\fnew\fse\bls\f\bnd\fcheck\f
other\fcomponents\f\bs\fnecess\bry.\f
7. \f\f
Check\fthe\fsurf\bces\ffor\f\bbr\bsion\fdue\fto\f
me

t\bl\ff\btigue.\f

Inst\bll\f\b\fnew\fbe\bring\f\bnd\fcle\bn\f\bll\fother\f
\bff

ected\fcomponents\f\bs\fnecess\bry.\f
\f\f
\f\f
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - MMT6 -
T\bansmissi\fn D\baining and FillingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Gene\bal P\b\fcedu\bes
Mate\bials
NameSpec\bf\bcat\bo\f
Tr\bnsmission\fOil\f75W\fFEWSS-M2C200-D2\f/\f7U7J-M2C200-BA
1. Refer\fto:\fAllgemeine\fInform\btionen\fzur\fService\fLiter\btur\f(100-00,\fDescription\f\bnd\fOper\btion).\f
2. \f
3. Material\b Tr\bnsmission\fOil\f75W\fFE\f(WSS-
M2 C

200-D2\f/\f7U7J-M2C200-BA) \f
Tor

\fue\b 35\fNm
\f
4. Tor\fue\b 35\fNm
\f
\f
\f
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\f\f
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - MMT6 -
Halfshaft Seal LHS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\fval and Installati\fn
Special T\f\fl(s)
Rem\fval
In

stallati\fn
205-115\f
Inst\bller,\fDrive\fPinion\fSe\bl
\f
308-208\f
Remover,\fH\blfsh\bft\fSe\bl\f 1. Remove\fthe\fleft-h\bnd\ffront\fdrivesh\bft.\fRefer\fto:\f Front\fH\blfsh\bft\fLH \f(205-04\fFront\fDrive\f
H\bl f

sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Special\bTool(\f):\b 308-208\f
1. Sp

ecial\bTool(\f):\b 205-115\f
2. I

nst\bll\fthe\fleft-h\bnd\ffront\fdrivesh\bft.\f
Refer\fto:\f Front\fH\blfsh\bft\fLH \f(205-04\fFront\fDrive\f
H\blf

sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. Check\fthe\flevel\fof\fthe\ftr\bnsmission\ffluid.\f
Refer\fto:\f Tr\bnsmission\fDr\bining\f\bnd\fFilling \f(308-
03A

\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\f
Gener\bl\fProcedures).\f
Refer\fto:\f Tr\bnsmission\fDr\bining\f\bnd\fFilling \f(308-
03 B

\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Gener\bl\fProcedures).\f
\f
\f
\f\f
\f\f
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - MMT6 -
Halfshaft Seal RHS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\fval and Installati\fn
Special T\f\fl(s)
Rem\fval
In

stallati\fn
205-115\f
Inst\bller,\fDrive\fPinion\fSe\bl
\f
308-208\f
Remover,\fH\blfsh\bft\fSe\bl\f 1. Remove\fthe\fright-h\bnd\ffront\fdrivesh\bft.\fRefer\fto:\f Front\fH\blfsh\bft\fRH \f(205-04\fFront\fDrive\f
H\bl f

sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Special\bTool(\f):\b 308-208\f
1. Sp

ecial\bTool(\f):\b 205-115\f
2. I

nst\bll\fthe\fright-h\bnd\ffront\fdrivesh\bft.\f
Refer\fto:\f Front\fH\blfsh\bft\fRH \f(205-04\fFront\fDrive\f
H\blf

sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. Check\fthe\flevel\fof\fthe\ftr\bnsmission\ffluid.\f
Refer\fto:\f Tr\bnsmission\fDr\bining\f\bnd\fFilling \f(308-
03A

\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\f
Gener\bl\fProcedures).\f
Refer\fto:\f Tr\bnsmission\fDr\bining\f\bnd\fFilling \f(308-
03 B

\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Gener\bl\fProcedures).\f
\f
\f
\f\f
\f\f
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - MMT6 -
Input Shaft SealS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\fval and Installati\fn
Special T\f\fl(s)
Rem\fval
303-336\f
Remover,\fCr\bnksh\bft\fRe\br\fSe\bl\f
308-112\f
Inst\bller,\fOutput\fDrive\fFl\bnge\fSe\bl
\f
1. Refer\fto:\f Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f
(Ly
nx)\fDiesel \f(308-03B\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fMMT6,\fRemov\bl).\f
Refer\fto:\f Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f
(85

kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\f2.0L\fDur\btorq-TDCi\f(DW)\f
Diesel\f(308-03B\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f
-\fV

ehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MMT6,\fRemov\bl).\f
Refer\fto:\fGetriebe\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(118kW/160PS)\f-\fDW,\fAbg\bsnorm:\f
Abg\bsnormstufe\fV\f(308-03C,\fRemov\bl).\f
2. Refer\fto:\f Clutch\fSl\bve\fCylinder \f(308-02B\fClutch\f
Co n

trols\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fMMT6,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. CAUTION:\fT\bke\fspeci\bl\fc\bre\fto\f\bvoid\f
d\b

m\bging\fthe\fbe\bring.\f
Special\bTool(\f):\b 30
3-336\f
4. \f\f
1. Self-cutting\fscrew,\f2.5\fx\f15\fmm\f
\f
\f
\f\f
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