gem FORD GALAXY 2006 Service Owner's Guide

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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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
I t

em
1
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-
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The\fdifferenti\bl\fh\bs\ft\bper\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
\f\f
Desc\bipti\fn
Tr\bnsmission\fhousing\ft\bper\froller\fbe\bring\f
Differenti\bl\f
Clutch\fhousing\ft\bper\froller\fbe\bring\f
Crown\fwheel\fbolts\f
Crown\fwheel\f
P\fwe\b t\bansmissi\fn in the individual gea\bs
Th
e\ffollowing\fdi\bgr\bms\fshow\f\b\fschem\btic\frepresent\btion\fof\fthe\fpower\fflow.\f
Power\fis\ftr\bnsmitted\fvi\b\fthe\fnon-positive\fge\br\fp\bir\fto\fthe\foutput\fpinion\fof\fthe\foutput\fsh\bft
(s)\f\bnd\fthus\fto\fthe\fdifferenti\bl\fring\fge\br.\f
NOTE:\fThe\fthree\fsh\bfts\f\bre\fshown\f\bw\by\ffrom\ftheir\fre\bl\f
positions\ffor\fcl\brity.\f
Power\ftr\bnsmission\froute\fin\f1st\fge\br\f
The

\f1st\fge\br\fwheel\fis\fpositively\fconnected\fto\fthe\f1st\fto\f4th\fge\br\foutput\fsh\bft\fby\fthe\f
1st/2nd\fge\br\fsynchroniser\f\bssembly.\f
Power\ftr\bnsmission\froute\fin\fsecond\fge\br\f Item
1
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3
4
5
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Pa\bt Numbe\b -
-
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Стр. 8 из 11
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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
Стр. 1 из 2
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Installati\fn 1. \f\f
1. C

AUTION:\fApply\f\bdhesive\ft\bpe\fto\f
th

e\fsplines\fon\fthe\fsh\bft\fso\fth\bt\fthe\foil\f
se\bl\fdoes\fnot\fbecome\fd\bm\bged.\f\f
2. Special\bTool(\f):\b 3
08-112\f
2. Remove\fthe\f\bdhesive\ft\bpe\ffrom\fthe\finput\fsh\bft\f
splines.\f
3. 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
4. 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,\fInst\bll\btion).\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 \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,\fInst\bll\btion).\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,\fInst\bll\btion).\f
5. Refer\fto:\fKupplungssystem\fentlüften\f-\f
F\bhrzeuge\f
\busgest\bttet\fmit\f6-G\bng\fSch\bltgetriebe\f-\fM66\f
(308-00\fSch\bltgetriebe\fund\fKupplung\f-\f
Allgemeine\fInform\btionen,\fGener\bl\fProcedures).\f
\f
\f
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10. Refer\fto:\fKupplungssystem\fentlüften\f(308-00\fSch\bltgetriebe\fund\fKupplung\f-\fAllgemeine\f
Inform\btionen,\fGener\bl\fProcedures).\f
11. Torque\b 48\fNm
\f
12. Remove the Special Tool(s)\b 303-290A-15\f
Tor

que\b 48\fNm
\f
13. Remove the Special Tool(s)\b 303-290A-15\f
To r

que\b 48\fNm
\f
14. Remove the Special Tool(s)\b 303-290B,\f303-290-
13 ,\f3

03-290A-15 ,\f303-290B-16 \f
\f\f
\f\f
\f\f
\f\f
\f\f
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10.Torque\b 80\fNm\f
11. CAUTION:\fM\bke\fsure\fth\bt\f\b\fnew\fbolt\fis\f
i n

st\blled.\f
Torque\b 133\fNm
\f
12. \f\f
2.Torque\b 48\fNm
\f
3. Torque\b 25\fNm
\f
13. Refer\fto:\fKupplungssystem\fentlüften\f(308-00\f Sch\bltgetriebe\fund\fKupplung\f-\fAllgemeine\f
Inform\btionen,\fGener\bl\fProcedures).\f
14. \f\f 1.Torque\b 48\fNm
\f
2. Torque\b 40\fNm
\f
\f\f
\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
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
T\bansmissi\fn D\baining and Filling—2.5L
Du\batec (162kW/220PS) - VI5S-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:\fGesundheits-\fund\fSicherheitsvorkehrungen\f(100-00\fAllgemeine\f
Inform\btionen,\fDescription\f\bnd\fOper\btion).\f
2. \f
3. Torque:\b 35\fNm
\f
4. Fill\fup\fwith\fm\bnu\bl\ftr\bnsmission\ffluid\fto\fbelow\f the\fbottom\fedge\fof\fthe\ffiller\fhole.\f
Mater\fal:\b Tr\bnsmission\fOil\f75W\fFE\f(WSS-
M2 C

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

que:\b 35\fNm
\f
5. \f
\f\f
\f\f
\f
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