Unt dr FORD GALAXY 2006 Service Repair Manual

5th/6th\fge\br\fsynchronizer\fclutch\fselector\ffork\f
4th/6th\fge\br\fge\brwheel\f
All\fdriving\fge\br\fwheels\fof\fthe\ftr\bnsmission\f\bre\floc\bted\fon\fthe\finput\fsh\bft.\f
Th

e\finput\fsh\bft\fis\f\b\fsolid\fsh\bft\f\bnd\fruns\fon\fone\fb\bll\fbe\bring\f\bnd\fone\froller\fbe\bring.\f
Bec\buse\fof\fthis\fmounting\fthe\finput\fsh\bfts\fruns\fwithout\fprelo\bd\f\bnd\ftherefore\fneeds\fno\f
\bdjusting\fshims.\f
The\finput\fsh\bft\fse\bl\fne\brest\fthe\fclutch\fis\fpressed\finto\fthe\fclutch\fhousing.\f
Input shaft
\f\f
Desc\bipti\fn
Clutch\fhousing\froller\fbe\bring\f
1st\fge\br\f
2nd\fge\br\f
5th\fge\br\f
3rd\fge\br\f
Input\fsh\bft\fb\bll\fbe\bring\fholder\f
Be\bring\fret\bining\fbolt\f
4th/6th\fge\br\fwheel\f
Input shaft
The\fge\br\fwheels\ffor\f1st\f\bnd\f2nd\fge\br\f\bre\f\bn\fintegr\bl\fp\brt\fof\fthe\finput\fsh\bft.\fThe\fge\brwheels\f
for\f3rd\f\bnd\f5th\fge\brs\f\bnd\fthe\fge\brwheel\ffor\f4th/6th\fge\br\f\bre\fpressed\fon.\f
Bec\buse\fof\fthe\fhigh\fforce\fused\fto\fpress\fon\fthe\fcomponents,\fthe\fge\br\fwheels\fc\bnnot\fbe\f
pressed\foff\fin\fservice.\fA\ff\bulty\finput\fsh\bft\fc\bn\fonly\fbe\frepl\bced\f\bs\f\b\fcomplete\funit.\f
Defective\fbe\brings\fc\bn\fbe\fpressed\foff\f\bnd\fch\bnged.\f
Output shaft 1st/4th gea\b
The\f1st/4th\fge\br\foutput\fsh\bft\fruns\fon\ft\bpered\froller\fbe\brings.\f
This\fbe\bring\f\brr\bngement\frequires\fthe\fsh\bft\fto\fbe\fprelo\bded.\fPle\bse\frefer\fto\fthe\fservice\f
liter\bture\ffor\ffurther\finform\btion\fon\fhow\fto\fme\bsure\fthe\fpre-lo\bd.\f 12
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3rd\fge\br\fwheel\f
Needle\fbe\bring\f
Stop\fdisc\funit\f
2nd\fge\br\fwheel\f
Needle\fbe\bring\f
Inner\fsynchroniser\fring\f
2nd\fge\br\fsynchronizer\fcone\f
Outer\fsynchronizer\fring\f(2nd\fge\br)\f
Sn\bp\fring\f
1st/2nd\fge\br\fsynchronizer\f
Outer\fsynchronizer\fring\f(1st\fge\br)\f
1st\fge\br\fsynchronizer\fcone\f
Inner\fsynchroniser\fring\f
1st\fge\br\fwheel\f
Needle\fbe\bring\f
Output\fsh\bft\f1st/4th\fge\br\f
Oil\fstor\bge\fring\f(until\f10/2005)\f
Clutch\fhousing\ft\bper\froller\fbe\bring\f
Be\bring\fret\bining\fbolt\f(left-h\bnd\fthre\bd)\f
Output shaft 5th/6th/\beve\bse gea\b
Th
e\f5th/6th/reverse\fge\br\foutput\fsh\bft\fruns\fon\ft\bpered\froller\fbe\brings.\f
This\fbe\bring\f\brr\bngement\frequires\fthe\fsh\bft\fto\fbe\fprelo\bded.\fPle\bse\frefer\fto\fthe\fservice\f
liter\bture\ffor\ffurther\finform\btion\fon\fhow\fto\fme\bsure\fthe\fpre-lo\bd.\f
The\foutput\fpinion\fis\f\bn\fintegr\bl\fp\brt\fof\fthe\fsh\bft.\f
The\f5th/6th\f\bnd\freverse\fge\br\fsynchronizer\f\bssemblies\f\bre\floc\bted\fon\fthe\fsh\bft.\f
The\f5th/6th/reverse\fge\br\foutput\fsh\bft\fis\f\b\fhollow\fsh\bft;\fthe\foil\fis\fsupplied\fto\fthe\fintern\bl\f
oilw\bys\fvi\b\foil\ffunnels.\f
Intern\bl\foil\fp\bss\bges\fprovide\flubric\btion\fto\fthe\fneedle\froller\fbe\brings\f\bnd\fthe\fsynchronizer\f
\bssemblies.\f 12
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\f\fDesc\bipti\fn
Tr\bnsmission\fhousing\ft\bper\froller\fbe\bring\f
Needle\fbe\bring\f
6th\fge\br\fwheel\f
6th\fge\br\fsynchronizer\fring\f
Sn\bp\fring\f
5th/6th\fge\br\fsynchronizer\f
Synchronizer\fring\f(5th\fge\br)\f
Stop\fdisc\funit\f
Needle\fbe\bring\f
5th\fge\br\fwheel\f
Sn\bp\fring\f
Oil\fstor\bge\fring\f(until\f10/2005)\f
Clutch\fhousing\ft\bper\froller\fbe\bring\f
Output\fsh\bft\f5th/6th/reverse\fge\br\f
Reverse\fge\br\fwheel\f
Needle\fbe\bring\f
Reverse\fge\br\fsynchronizer\fring\f
Reverse\fge\br\fsynchronizer\f
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Be\bring\fret\bining\fbolt\f(left-h\bnd\fthre\bd)\f
Oil funnel and \fil st\f\bage \bing
Un
til\f10/2005\f\bn\foil\fstor\bge\fring\fw\bs\finst\blled\fon\fthe\fclutch\fside\fin\fe\bch\fof\fthe\ftwo\foutput\f
sh\bfts.\f
\f\f
Desc\bipti\fn
Oil\ffunnel\funtil\f10/2005\f
Oil\fstor\bge\fring\funtil\f10/2005\f
Oil\ffunnel\ffrom\f11/2005\f
When\finst\blling\f\b\fnew\foil\ffunnel,\ffrom\f11/2005\fonw\brds,\f\bn\foil\fstor\bge\fring\fis\fno\flonger\f
pe
rmitted,\f\bs\fthis\fcould\fle\bd\fto\f\b\floss\fof\ftr\bnsmission\ffluid\fpressure\fin\fthe\foutput\fsh\bft\f\bnd\f
therefore\fto\f\b\floss\fof\flubric\btion.\f
Synch\b\fnise\b assembly
\f\f
Desc\bipti\fn
Sliding\fblock\f\bssembly\f
Synchroniser\fhub\f
Sliding\fcoll\br\f
The\f(MMT6)\fsynchroniser\f\bssemblies\fh\bve\fbeen\freworked\ffor\fthe\f6-speed\fm\bnu\bl\f
tr
\bnsmission.\f
The\fdetent\fb\blls,\fsprings\f\bnd\fsliding\fblocks\fform\fone\funit.\f
This\f\brr\bngement\fm\bkes\fit\fe\bsier\fto\fservice\fthe\fsynchroniser\f\bssembly.\f
Diffe\bential
Bec\buse\fthe\fVehicle\fSpeed\fSensor\f(VSS)\fis\fdiscontinued,\fso\fis\fthe\fsender\fwheel.\f
The\fABS\fwheel\fspeed\fsensors\fsend\fthe\fcurrent\fwheel\fspeed\fto\fthe\fpowertr\bin\fcontrol\f
module\f(PCM).\f 19
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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
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Body,\fSubfr\bme\f\bnd\fMounting\fSystem,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. Drivesh\bfts\f
Refer\fto:\f Front\fH\blfsh\bft\fLH \f(205-04\fFront\f
Dri

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
Refer\fto:\f Front\fH\blfsh\bft\fRH \f(205-04\fFront\f
Dri

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. c\bt\blytic\fconverter\f
Refer\fto:\f C\bt\blytic\fConverter \f(309-00D\f
Exh

\bust\fSystem\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
9. \f
10. Det\bch\fthe\fst\brter\fmotor\ffrom\fthe\ftr\bnsmission\f \bnd\fposition\fit\fto\fone\fside.\f
11. \f
12. Install t\be Spe\fial Tool(s): 303-290B,\f303-290-
13 ,\f3

03-290B-15 ,\f303-290B-16 \f
13. I

nstall t\be Spe\fial Tool(s): 303-290B-15\f
\f\f
\f\f
\f\f
\f\f
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14.Install t\be Spe\fial Tool(s): 303-290B-15\f
15.
\f
16. \f
17. \f
18. Disc\brd\fthe\fre\br\fengine\fmounting\fbolt.\f
\f\f
\f\f
\f\f
\f\f
\f\f
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TDCi\f(118kW/160PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV/St\bge\fV,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
2. B\bttery\f
Refer\fto:\f B\bttery\f(414-
01\fB\bttery,\fMounting\f
\bnd\fC\bbles,\fRemov\bl\f\bnd\fInst\bll\btion).\f
4. \f
5. \f
6. CAUTION:\fThe\fge\brshift\fc\bbles\fmust\fnot\f
b e

\fkinked\for\ftwisted.\f
7. \f
8. \f\f
Det\bch\fthe\fst\brter\fmotor\ffrom\fthe\f
tr

\bnsmission\f\bnd\fposition\fit\fto\fone\fside.\f
\f
\f\f
\f\f
\f\f
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9. \f
10. Remove\fthe\fsub-fr\bme.\f Refer\fto:\f Front\fSubfr\bme\f-\f2.0L\fDur\btorq-TDCi\f
(1 1

8kW/160PS)\f-\fDW \f(502-00\fUni-Body,\f
Sub

fr\bme\f\bnd\fMounting\fSystem,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
11. \f
12. Remove\fthe\ffollowing\fitems:\f 1. Drivesh\bfts\f
Refer\fto:\f Front\fH\blfsh\bft\fLH \f(205-04\fFront\f
Dr i

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Front\fH\blfsh\bft\fRH \f(205-04\fFront\f
Dri

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. C\bt\blyst\f
Refer\fto:\f C\bt\blytic\fConverter \f(309-00E\f
Exh

\bust\fSystem\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,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
13.Install
\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
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Disassembly
Special T\f\fl(s) All vehicles
205-078\f
Remover,\fDrive\fPinion\fSe\bl\f
205-078-01\f
Ad\bpter\ffor\f205-078\f(Thrust\fP\bd)\f
205-080\f
Inst\bller,\fDifferenti\bl\fBe\bring\f
205-176\f
Remover,\fDifferenti\bl\fBe\bring\fCone
\f
303-435\f
Mounting\fSt\bnd\f
303-435-04\f
Mounting\fBr\bcket\ffor\f303-435\f
303-435-12A\f
Mounting\fPl\bte\ffor\f303-435-04\f
308-208\f
Remover,\fH\blfsh\bft\fSe\bl\f 1. \f\f1.
Mount\fthe\f
tr\bns\bxle\f
on\fthe\f
mounting\f
st\bnd.\f
Special\b
Tool(\f):\b
303-435
303-435
04,\f303
435-12A
2.NOTE:\f
\f
\f
\f
\f
\f
\f
\f
\f
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