Unt dr FORD GALAXY 2006 Service Repair Manual

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
Assembly
Special T\f\fl(s)
205-044-01\f
Ad\bpter\ffor\f205-044\f
205-070\f
Holding\fFixture,\fDi\bl\fIndic\btor\fG\buge\f
205-081\f
Inst\bller,\fDifferenti\bl\fBe\bring\f
205-115\f
Inst\bller,\fDrive\fPinion\fSe\bl\f
205-176\f
Remover,\fDifferenti\bl\fBe\bring\fCone\f
205-217\f
Inst\bller,\fRe\br\fWheel\fHub\fBe\bring\fCone/Se\bl\f
205-296\f
Inst\bller,\fWheel\fHub\fBe\bring\fCone/Se\bl\f
206-003\f
Holding\fFixture,\fDi\bl\fIndic\btor\fG\buge\f(Disc\fBr\bke)
\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
307-300-02\f
Depth\fG\buge,\fShim\fSelection\f
\f
\f
\f
\f
\f
\f
\f
\f
\f
\f
\f
\f
Стр. 1 из 12
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housing\f
together.
S\fecial Tool
(s): 308

Pl\bce\fthe\f
be\bring\fouter\f
r\bces\fin\f
position\fon\fthe\f
output\fsh\bft\f
t\bpered\froller\f
be\bring.
7. \f\f

Repe\bt\fthis\f\bnd\fthe\ffollowing\ffour\fsteps\fthree\ftimes\f
\bnd\fdetermine\fthe\f\bver\bge\fv\blues.\f


Pull\fout\fthe\fme\bsuring\frings\fto\f\bpprox.\f10\fmm.

Hold\fthe\fbe\bring\fouter\fr\bces,\fturn\fthe\foutput\fsh\bft\f20\f
times\fwhile\fpressing\fdown\f\bt\fthe\fs\bme\ftime,\fso\fth\bt\f
the\fbe\brings\fsettle.\f
S\fecial Tool(s): 308-603\f
8.
NOTE:\fThe\fmounting\ff\bces\fmust\fbe\fcle\bn\f\bnd\ffree\ffrom\f
foreign\fbodies.\f
Inst\bll\fthe\fspeci\bl\ftools.\f
S \f

ecial Tool(s): 205-070,\f307-430\f
9. \f

\f

M\bke\fcert\bin\fth\bt\fthe\fclutch\fhousing\fdoes\fnot\fbecome\f
skewed.\f


M\bke\fcert\bin\fth\bt\fthe\fspeci\bl\ftools\f\bre\finserted\f
correctly\fin\fthe\fclutch\fhousing\fbe\bring\fouter\fr\bce\f
se\bts.\f

Att\bch\fthe\fclutch\fhousing.\f
S\f

ecial Tool(s): 205-070,\f206-003,\f307-430\f
Tor

que: 32\fNm
\f
10. \f\f

M\bke\fcert\bin\fth\bt\fthe\fclutch\fhousing\fdoes\fnot\fbecome\f
skewed.\f

Det\bch\fthe\fspeci\bl\ftools.\f
S\f

ecial Tool(s): 205-070,\f206-003,\f307-430\f
\f\f
\f\f
\f\f
\f\f
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S\fecial Tool(s): 308-192\f
20.
\f\f

Att\bch\fthe\fdi\bl\fg\buge\fto\fthe\fspeci\bl\ftool\f\bnd\f\blign\fwith\f
the\fm\brk.\f
S\fecial Tool(s): 205-044-01,\f205-070\f

Pre-lo\bd\fthe\fdi\bl\fg\buge\fto\f1\fmm\f\bnd\fzero\fit.\f
2 1

.
Turn\fthe\ftr\bnsmission\fthrough\f180\fdegrees\fwith\fthe\fclutch\f
side\fdownw\brds.\f
22. \f\f 1. To\fme\bsure\fthe\fbe\bring\fpre-
lo\bd\fturn\fthe\fdifferenti\bl\f
20\ftimes\fwhile\fpressing\fdown\f\bt\fthe\fs\bme\ftime,\fso\f
th\bt\fthe\fbe\brings\fsettle.\f
S\fecial Tool(s): 308-192\f
2.
Turn\fthe\fdifferenti\bl\funtil\fthe\fme\bsuring\fpin\fis\fon\fthe\f
m\brked\fspot.\f
3.
Me\bsure\fthe\fdifferenti\bl\fend\fflo\bt:\fM\bke\f\b\fnote\fof\fthe\f
me\bsurement,\fe.g.\f0.34\fmm.\fEx\bmple:\f0.34\fmm\f
+0.36\fmm\f+0.38\fmm,\fdivided\fby\f3\f=\f0.36\fmm.
23. \f\f

Determine\fthe\fthickness\fof\fthe\fdifferenti\bl\f\bdjusting\f
shim:\f


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

Determined\fdifferenti\bl\fend\fflo\bt\f0.36\fmm\f

Differenti\bl\fbe\bring\fpre-lo\bd\f0.20\fmm\f


Required\f\bdjusting\fshim\fthickness:\f1.10\fmm\f+\f0.36\f
mm\f+0.20\fmm\f=\f1.66\fmm.\f


Determined\f\bdjusting\fshim\fthickness:\f1.66\fmm.
24. \f
25. Remove\fthe\ffollowing\fitems:\f
1. Differenti\bl\fbe\bring\fouter\fr\bce\f
S\fecial Tool(s): 205-176\f
2. M

e\bsuring\fshim\f
\f\f
\f\f
\f\f
\f\f
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39.Remove\fthe\f\bdhesive\ft\bpe\ffrom\fthe\finput\fsh\bft\fsplines.
40. Inst\bll\fthe\ffollowing\fitems:\f1. Tr\bnsmission\fhousing\fret\bining\fbolts\f
Torque: 32\fNm
\f
2. Clutch\fsl\bve\fcylinder\f
Torque: 11\fNm
\f
3. Inst\bll\f\b\fnew\fh\blfsh\bft\fse\bl.\f
S\fecial Tool(s): 205-115\f
41.

\f\f

Apply\fse\bl\bnt\fcentr\blly\fon\fthe\fm\bting\ff\bce\f\bnd\fp\bst\f
the\fthre\bded\fholes\fon\fthe\foutside\f(be\bd\fdi\bmeter:\f3\f
mm).\f
Material: Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLR\f(WSK
-
M2G348-A5\f/\f2U7J-M2G348-AA) \f


Ensure\fth\bt\fthe\fthre\bded\fholes\f\bre\ffree\fof\fse\bl\bnt.
42. \f\f
1.
Ensure\fth\bt\fno\f
ge\br\fis\f
eng\bged.
2.Ensure\fth\bt\f
the\fselector\f
mech\bnism\fis\f
in\fthe\fneutr\bl\f
position.
3.Inst\bll\fthe\fshift\f
mech\bnism.
Torque:
4.Inst\bll\fnew\f
input\fsh\bft\f
be\bring\f
ret\biner\fbolts.
Torque:
5.Remove\fthe\f
tr\bns\bxle\ffrom\f
the\fmounting\f
st\bnd.\f
S\fecial Tool
(s): 303
303-435
\f\f
\f\f
\f\f
\f\f
Стр. 11 из 12
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15. Inst\bll\fthe\ffollowing\fitems:\f1. c\bt\blytic\fconverter\f
Refer\fto:\f C\bt\blytic\fConverter \f(309-00D\f
Ex h

\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
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. Subfr\bme\f
Refer\fto:\f Front\fSubfr\bme \f(502-00\fUni-
Bod

y,\fSubfr\bme\f\bnd\fMounting\fSystem,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
16. Torque\b 40\fNm
\f
17. \f\f 1.Torque\b 25\fNm
\f
2. Torque\b 10\fNm
\f
18. Torque\b 25\fNm
\f
\f\f
\f\f
\f\f
Стр. 4 из
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15.Remove the Special Tool(s)\b 303-290B,\f303-290-
13 ,\f3
03-290A-15 ,\f303-290B-16 \f
16.

Inst\bll\fthe\fc\bt\blytic\fconverter.\f
Refer\fto:\f C\bt\blytic\fConverter \f(309-00E\fExh\bust\f
Sy s

tem\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
17. \f\f 1.Torque\b 10\fNm
\f
2. Torque\b 10\fNm
\f
18. Inst\bll\fthe\ffollowing\fitems:\f 1. 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
Dr i

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Subfr\bme\f
Refer\fto:\f Front\fSubfr\bme \f(502-00\fUni-
Bod

y,\fSubfr\bme\f\bnd\fMounting\fSystem,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
19. \f\f 1.Torque\b 25\fNm
\f
2. Torque\b 80\fNm
\f
20. \f
\f\f
\f\f
\f\f
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Ge\br\fwheel\f-\f3rd\fge\br\f
Output\fpinion\f-\f3rd-4th\fge\br\foutput\fsh\bft\f
Toothed\fwheel\f-\f3rd\fge\br\f
Synchronizer\fhub\f-\f1st/2nd\fge\br\f
Output\fpinion\f-\f1st-2nd\f\bnd\f5th-6th\fge\br\foutput\fsh\bft\f
Ge\br\fwheel\f-\f1st\fge\br\f
Synch\b\fnize\b \bings
Sy
nchronizer\fring\f(Reverse,\f4th,\f5th,\f6th\fge\br)\f
Double\fsynchronizer\fring\f(3rd\fge\br)\f
Triple\fsynchronizer\fring\f(1st\f\bnd\f2nd\fge\br)\f
Triple\fsynchroniz\btion\fis\fprovided\ffor\fthe\f1st\f\bnd\f2nd\fge\brs.\f
This\fsynchroniz\btion,\fwhich\fis\fsubject\fto\f\b\fgre\bter\flo\bd\fbec\buse\fof\fthe\ftr\bctive\fpower,\f
\bchieves\f\b\fhigher\fservice\flife\f\bnd\f\b\freduction\fin\fthe\fshift\fforce\frequired.\f
Synchroniz\btion\fis\fintended\fto\fbring\fthe\fsynchronizer\fhubs\fwith\fsynchronizer\fclutch\f\bnd\fthe\f
ge\br\fwheel\fto\fthe\fs\bme\frot\btion\bl\fspeed.\fOnly\fthen\fis\fpositive\feng\bgement\fpossible.\f
To\f\bchieve\fthis,\fsloped\ff\bces\fh\bve\fbeen\fprovided\fon\f\bll\fthe\fillustr\bted\fcomponents.\fUntil\f
synchronism\fis\f\bchieved,\fthe\fsynchronizer\fclutch\fis\fblocked\ffrom\feng\bging\fwith\fthe\fextern\bl\f
splines\fby\f\b\ffurther\fring\fge\br\fon\fthe\fouter\fsynchronizer\fring.\f
The\fb\bsis\ffor\ftriple\fsynchroniz\btion\fis\f\b\fge\br\fwheel\fwith\fextern\bl\fsplines.\fIts\fdi\bmeter\fis\f
much\fl\brger\fth\bn\fth\bt\fof\fthe\ffriction\fcone.\fThis\fcre\btes\fsp\bce\ffor\fthe\ffirst\fsynchronizer\fring\f 16
17
1

8
19
20
21 -
-
-
-
-
\f\f
\f\f
\f\f
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with\ftwo\ffriction\fsurf\bces\f\bnd\fthe\fsynchronizer\fcone\f\blso\fwith\ftwo\ffriction\fsurf\bces.\fThe\f
outer\fsynchronizer\fcone\fis\fvirtu\blly\funch\bnged.\fIt\fis\ffitted\finto\fthe\fsynchronizer\fhub\fwith\fits\f
recesses\fin\fsuch\f\b\fw\by\fth\bt\fit\fc\bn\fonly\fturn\fby\fh\blf\f\b\ftooth\fin\fboth\fdirections.\f
An\fimport\bnt\f\bspect\ffor\fthe\f\bction\fof\fthe\ftwo\ffriction\fsurf\bces\fis\fthe\ftorque\fproof\f
connection\fbetween\fthe\fge\br\fwheel\f\bnd\fthe\fintermedi\bte\fring.\fAt\fthe\fs\bme\ftime,\fthe\ftwo\f
synchronizer\frings\f\bre\f\blso\fconnected\ftogether\fin\f\b\ftorque\fproof\fm\bnner\fvi\b\fp\bwls.\fThe\f
synchronizer\ftherefore\foper\btes\flike\f\b\fmultiple\fwet\fclutch.\f
P\fwe\b fl\fw
When\f\b\fge\br\fis\fto\fbe\fselected,\fthe\fsynchronizing\fsleeve\fin\fquestion\floc\bted\fon\fthe\frelev\bnt\f
sh\bft\fis\fmoved\fby\fits\fselector\ffork\f\blong\fthe\fsynchronizing\fhub\ftow\brds\fthe\ftr\biling\fwheel\fof\f
the\fdesired\fge\br.\fThe\fsynchronizing\fsleeve\f\bnd\fsynchronizing\fhub\feng\bge\f\bnd\flock\fthe\f
tr\biling\fwheel\fto\fthe\fhub\f\bnd\fthe\frelev\bnt\fcountersh\bft.\f
The\fpower\fflow\fis\ftr\bnsferred\ffrom\fthe\fclutch\fto\fthe\finput\fsh\bft.\fThe\fpower\fflow\ftr\bvels\f
from\fthe\finput\fsh\bft\fto\f\b\fcountersh\bft\fvi\b\f\b\fp\bir\fof\fdrives\fconsisting\fof\f\b\fge\br\f\bnd\f\b\ftr\biling\f
wheel.\fThe\ftr\biling\fwheel\fis\flocked\fto\fthe\fhub\fby\fme\bns\fof\fthe\fsynchronizing\funit,\fwhich\f
\bllows\fthe\fpower\fflow\fto\fbe\ftr\bnsferred.\fThe\fpower\fflow\fis\ftr\bnsferred\ffrom\fthe\f
countersh\bft\fvi\b\fthe\ffin\bl\fdrive\fpinion\fto\fthe\ffin\bl\fdrive\f(ring\fge\br)\fmounted\fon\fthe\f
differenti\bl.\f
1st\fge\br\f
\f\f
Desc\bipti\fn
Input\fsh\bft\f
1st-2nd\f\bnd\f5th-6th\fge\br\foutput\fsh\bft\f
Ring\fge\br\f
Toothed\fwheel\f-\f1st\fge\br\f
Synchronizer\fhub\f-\f1st/2nd\fge\br\f
Output\fpinion\f-\f1st-2nd\f\bnd\f5th-6th\fge\br\foutput\fsh\bft\f
Ge\br\fwheel\f-\f1st\fge\br\f
2nd\fge\br\f
\f\f
Desc\bipti\fn
Input\fsh\bft\f
Item
A
B4
15
19
20
21
Item A \f\fPa\bt Numbe\b
-
-
-
-
-
-
-
\f\f
Pa\bt Numbe\b-
-
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
T\bansmissi\fn—2.5L Du\batec
(162kW/220PS) - VI5S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\fval
Special T\f\fl(s)
Ge

ne\bal Equipment
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
T\bansmissi\fn jack 1. Refer\fto:\fHe\blth\f\bnd\fS\bfety\fPrec\butions\f(100-00\f
Gen

er\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).
\f
2. Remove\fthe\f\bir\fcle\bner.\f
Refer\fto:\f Air\fCle\bner \f(303-12C\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
3. Remove\fthe\fb\bttery\fc\brrier.\f
Refer\fto:\f B\bttery\f(414-01\fB\bttery,\fMounting\f\bnd\f
C\bbl

es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
4. CAUTION:\fThe\fge\brshift\fc\bbles\fmust\fnot\f
be

\fkinked\for\ftwisted.\f\f
5. \f
\f
\f
\f
\f
\f\f
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11. \f
12. Remove\fsubfr\bme\ffrom\fvehicle.\fRefer\fto:\f Front\fSubfr\bme \f(502-00\fUni-Body,\f
Su b

fr\bme\f\bnd\fMounting\fSystem,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
13. Remove\fthe\f\bxle\fsh\bfts.\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
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
14. \f
15. \f
16. Special\bTool(\f):\b 303-290B,\f303-290-13 ,\f303-
29 0

A-15 ,\f303-290B-16 \f
\f\f
\f\f
\f\f
\f\f
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