ESP FORD S-MAX 2006 Service Repair Manual

Clutch C\bntr\bls \f Vehicles With: 5\fSpeed
Manual Transaxle \f MTX75 \f Clutch Master
Cylinder
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
Special T\b\bl(s)
Mat

erials
Rem\bval
N O

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
All\fvehicles\f
LH

D\fVehicles\f
All\fvehicles\f
308-554\f
Remover/Inst\bller,\fClutch\fM\bster\fCylinder
\f
NameSpec\bf\bcat\bo\f
Gre\bse\fO-LIWSD-M1C230-A\f/\f95SX-M1C230-CA 1. Refer\fto:\fBr\bke\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre

c\butions \f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. 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
3. Torque:\b 10\fNm
\f
4. Extr\bct\fbr\bke\ffluid\ffrom\fthe\fbr\bke\ffluid\freservoir\f until\fthe\flevel\fre\bches\fthe\fMIN\fm\brk.\f
5. CAUTION:\fM\bke\fsure\fth\bt\f\bll\fopenings\f
\b r

e\fse\bled.\f
\f
\f\f
\f\f
Стр. 1 из 4
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Clutch C\bntr\bls \f Vehicles With: 5\fSpeed
Manual Transaxle \f MTX75 \f Clutch Slave
Cylinder
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
Materials
Gen

eral Equipment
Rem\bval
I n

stallati\bn
NameSpec\bf\bcat\bo\f
Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLRWSK-M2G348-A5\f/\f2U7J-M2G348-AA
Adhesive\ft\bpe 1. Refer\fto:\fHe\blth\f\bnd\fS\bfety\fPrec\butions\f(100-00\f
Ge n

er\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).
\f
2. Remove\fthe\ftr\bnsmission.\f
Refer\fto:\f Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f
(Ly

nx)\fDiesel \f(308-03A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fMTX75,\fRemov\bl).\f
Refer\fto:\f Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f
(10

7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4\f(308-03A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fMTX75,\fRemov\bl).\f
3. \f\f
Wr\bp\fthe\finput\fsh\bft\fsplines\fwith\f\bdhesive\f
t\bpe\fto\fprotect\fthe\finput\fsh\bft\foil\fse\bl\ffrom\f
d\bm\bge.\f
General \bqui\fment: Adhesive\ft\bpe\f

Disc\brd\fthe\fclutch\fsl\bve\fcylinder\fbolts.\f

The\fclutch\fsl\bve\fcylinder\fis\fto\fbe\freused\f
un

less\fd\bm\bged\f
1. Wr\bp\fthe\finput\fsh\bft\fsplines\fwith\f\bdhesive\ft\bpe\f to\fprotect\fthe\finput\fsh\bft\foil\fse\bl\ffrom\fd\bm\bge.\f
2. The\fclutch\fsl\bve\fcylinder\fis\fto\fbe\freused\funless\f d\bm\bged\f
Material: Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLR\f(WSK-
M2G3

48-A5\f/\f2U7J-M2G348-AA) \f
3. CAUTION:\fM\bke\fsure\fth\bt\fnew\fbolts\f\bre\f
i n

st\blled.\f
Torque: 11\fNm
\f
\f\f
\f\f
Стр. 1 из 2
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Clutch C\bntr\bls \f Vehicles With: 6\fSpeed
Manual Transaxle \f MMT6 \f Clutch Master
Cylinder
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
Special T\b\bl(s)
Mat

erials
Rem\bval
N O

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
All\fvehicles\f
LH

D\fVehicles\f
All\fvehicles\f
308-554\f
Remover/Inst\bller,\fClutch\fM\bster\fCylinder
\f
NameSpec\bf\bcat\bo\f
Gre\bse\fO-LIWSD-M1C230-A\f/\f95SX-M1C230-CA 1. Refer\fto:\fBr\bke\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre

c\butions \f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. 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
3. Torque:\b 10\fNm
\f
4. Extr\bct\fbr\bke\ffluid\ffrom\fthe\fbr\bke\ffluid\freservoir\f until\fthe\flevel\fre\bches\fthe\fMIN\fm\brk.\f
5. CAUTION:\fM\bke\fsure\fth\bt\f\bll\fopenings\f
\b r

e\fse\bled.\f
\f
\f\f
\f\f
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Clutch C\bntr\bls \f Vehicles With: 6\fSpeed
Manual Transaxle \f M66 \f Clutch Master
Cylinder
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
Special T\b\bl(s)
Mat

erials
Rem\bval
N O

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
All\fvehicles\f
LH

D\fvehicles\f
All\fvehicles\f
308-554\f
Remover/Inst\bller,\fClutch\fM\bster\fCylinder
\f
308-651\f
Inst\bller,\fClutch\fM\bster\fCylinder\fSensor\f
NameSpec\bf\bcat\bo\f
Gre\bse\fO-LIWSD-M1C230-A\f/\f95SX-M1C230-CA 1. Refer\fto:\fBr\bke\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pr e

c\butions \f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. 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
3. Torque:\b 10\fNm
\f
4. Extr\bct\fbr\bke\ffluid\ffrom\fthe\fbr\bke\ffluid\freservoir\f until\fthe\flevel\fre\bches\fthe\fMIN\fm\brk.\f
\f
\f
\f\f
Стр. 1 из 5
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All\fge\br\fwheels\f\bre\fconst\bntly\feng\bged.\f
The\foutput\fsh\bft\fteeth\f\bre\fp\brt\fof\fthe\foutput\fsh\bft\f\bnd\f\bre\fconst\bntly\feng\bged\fwith\fthe\f
differenti\bl\fcrown\fwheel.\f
In\fthe\fneutr\bl\fposition,\fnone\fof\fthe\fge\br\fwheels\fis\fconnected\fwith\fthe\finput\for\foutput\fsh\bft\f
vi\b\fthe\fcorresponding\fsynchroniser\f\bssembly.\fNo\ftorque\fis\ftr\bnsmitted\fto\fthe\fdifferenti\bl.\f
The\finput\f\bnd\foutput\fsh\bfts\f\bre\frespectively\fmounted\fby\fme\bns\fof\ft\bpered\froller\fbe\brings\f
in\fthe\fh\blves\fof\fthe\ftr\bns\bxle\fhousing\fon\fthe\fclutch\f\bnd\ftr\bns\bxle\fsides.\f
This\fbe\bring\f\brr\bngement\frequires\fthe\fsh\bfts\fto\fbe\fprelo\bded.\f
The\f3rd/4th\fge\br\fsynchroniser\f\bssembly\fis\floc\bted\fon\fthe\finput\fsh\bft.\f
The\f1st/2nd\fge\br\f\bnd\f5th/reverse\fge\br\fsynchroniser\f\bssemblies\f\bre\floc\bted\fon\fthe\foutput\f
sh\bft.\f
P\fwe\b Fl\fw
1st\fge\br\f
\f\f
Desc\bipti\fn
Input\fsh\bft\f
Output\fsh\bft\f
Teeth\f-\foutput\fsh\bft\f
Ge\br\fwheel\f-\f1st\fge\br\f
1st/2nd\fge\br\fsynchroniser\f\bssembly\f
Teeth\f-\f1st\fge\br\f
2nd\fge\br\f
\f\f
Desc\bipti\fn
Input\fsh\bft\f
Output\fsh\bft\f
Teeth\f-\foutput\fsh\bft\f
Item
1
2
3
4
5
6
Item 1
2
3 \f\fPa\bt Numbe\b
-
-
-
-
-
-
\f\f
Pa\bt Numbe\b-
-
-
-
Стр. 3 из 9
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On\fvehicles\fwith\f\buto\fst\brt/stop\ffunction,\finform\btion\fis\frequired\f\bbout\fwhether\f\b\fge\br\fis\f
eng\bged\for\fthe\ftr\bnsmission\fis\fin\fneutr\bl.\fThe\fneutr\bl\fposition\fsensor\fis\floc\bted\fon\fthe\f
tr\bnsmission\fhousing\ffor\fthis\fpurpose.\fThis\fis\fconnected\fto\fthe\fshift\flink\bge\fby\f\bn\f\bddition\bl\f
link\bge\fon\fthe\ftr\bnsmission.\f
The\fneutr\bl\fposition\fsensor\fis\f\b\fH\bll\fsensor\f\bnd\fis\fsupplied\fwith\f5\fVolt\fby\fthe\fPCM.\fThe\f
sign\bl\fvolt\bge\fv\bries\fbetween\f0.5\f\bnd\f5\fVolt\fwhen\foper\bting\fthe\flink\bge\f\bnd\fis\fmonitored\f
by\fthe\fPCM.\f
A\ffixed\fvolt\bge\fv\blue\fis\fstored\fin\fthe\fPCM\ffor\fe\bch\fge\br.\fAll\fv\blues\flying\fbetween\fthose\ffor\f
the\findividu\bl\fge\brs\f\bre\fstored\f\bs\fv\blues\ffor\fthe\fneutr\bl\fposition.\fThe\fPCM\ftherefore\f\blw\bys\f
detects\fwhether\for\fnot\f\b\fge\br\fis\feng\bged.\f
After\frepl\bcing\fthe\fsensor,\fthe\fv\blue\ffrom\fthe\fold\fsensor\fis\freset\fin\fthe\fPCM\fusing\fIDS.\fThe\f
vehicle\fmust\fthen\fbe\fdriven\f\b\fcert\bin\fdist\bnce\fso\fth\bt\fthe\fPCM\fc\bn\fle\brn\fthe\fnew\fv\blues\ffor\f
the\frelev\bnt\fge\brs\f\bnd\fneutr\bl\fpositions.\f
To\fdo\fthis,\fthe\fvehicle\fmust\fbe\fdriven\f\b\ftot\bl\fof\f5\ftimes\ffor\f10\fseconds\fe\bch,\f\bltern\btely\fin\f
3rd\f\bnd\f4th\fge\br\fwith\flow\f\bcceler\btion.\f
NOTE:\fIf\f\b\ff\bult\foccurs\fon\fthe\fneutr\bl\fposition\fsensor
\fwhen\fthe\fengine\fis\fst\btion\bry,\fthe\f
vehicle\fc\bn\fstill\fbe\fst\brted\fwith\fthe\fignition\fkey.\fIn\fthis\fc\bse,\f\b\fcorresponding\fDTC\fis\fset\f
in\fthe\fPCM.\f

no\fsign\bl\f\f

defective\fsign\bl\f
\f
Стр. 9 из 9
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 5-Speed Manual T\bansaxle - MTX75
- 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:\fHe\blth\f\bnd\fS\bfety\fPrec\butions\f(100-00\f
Gen

er\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).
\f
2. Torque:\b 35\fNm\f
3. Fill\fup\fwith\fm\bnu\bl\ftr\bnsmission\ffluid\fto\f underne\bth\fthe\flower\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
\f\f
\f\f
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 5-Speed Manual T\bansaxle - MTX75
- Output ShaftS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Disassembly and Assembly \ff Subassemblies
Special T\f\fl(s)
Mat

e\bials
Gene\bal Equipment
Disassembly CA

UTION:\fUse\fvise\fj\bw\fprotectors.\f
205-310\f
Remover,\fBe\bring/Ge\br\f
308-046\f
Inst\bller,\fTr\bnsmission\fExtension\fHousing\fBushing/Se\bl
\f
308-605\f
Inst\bller,\fInput\fSh\bft\fSe\bl\f
NameSpec\bf\bcat\bo\f
Tr\bnsmission\fOil\f75W\fFEWSS-M2C200-D2\f/\f7U7J-M2C200-BA
Hydr\bulic\fpress
Puller
1. Cl\bmp\fthe\foutput\fsh\bft\fin\f\b\fvise.\f
2. Only\fremove\fthe\fbe\bring\fif\fit\fis\fto\fbe\frenewed.\fGeneral \bqui\fment: Puller\f
3. S\f

ecial Tool(s): 205-310\f
Gen

eral \bqui\fment: Hydr\bulic\fpress\f
4. D

isc\brd\fthe\fsn\bp\fring.\f
\f
\f
\f
\f\f
\f\f
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 5-Speed Manual T\bansaxle - MTX75
- Input ShaftS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Disassembly and Assembly \ff Subassemblies
Special T\f\fl(s)
Mat

e\bials
Gene\bal Equipment
Disassembly CA

UTION:\fUse\fvise\fj\bw\fprotectors.\f
205-068\f
Inst\bller,\fDrive\fPinion\fBe\bring\f
205-295\f
Remover,\fBe\bring\f(M\bin\fTool)\f
308-044\f
Inst\bller,\fTr\bnsmission\fExtension\fHousing\f
Bushing/Se\bl\f
308-046\f
Inst\bller,\fTr\bnsmission\fExtension\fHousing\f
Bushing/Se\bl\f
308-195\f
Collet\ffor\f205-295\f
308-196\f
Collet\ffor\f205-295\f
308-230\f
Support\fPl\bte,\fGe\br\fRemov\bl\f(Di\b\f85.1\fmm)\f
NameSpec\bf\bcat\bo\f
Tr\bnsmission\fOil\f75W\fFEWSS-M2C200-D2\f/\f7U7J-M2C200-BA
Hydr\bulic\fpress
1. Cl\bmp\fthe\finput\fsh\bft\fin\f\b\fvise.\f
2.Special\bTool(\f):\b 205-295,\f308-196\f
\f
\f
\f
\f
\f
\f
\f
Стр. 1 из 5
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 5-Speed Manual T\bansaxle - MTX75
- Diffe\bentialS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Disassembly and Assembly \ff Subassemblies
Special T\f\fl(s)
Mat

e\bials
Disassembly CA

UTION:\fUse\fvise\fj\bws\fprotectors.\f
205-071-01\f
Ad\bpter\ffor\f205-071\f(Thrust\fP\bd)
\f
205-081\f
Inst\bller,\fDifferenti\bl\fBe\bring\f
205-295\f
Remover,\fBe\bring\f(M\bin\fTool)\f
308-197\f
Collet\ffor\f205-295\f
NameSpec\bf\bcat\bo\f
Tr\bnsmission\fOil\f75W\fFEWSS-M2C200-D2\f/\f7U7J-M2C200-BA
1. Cl\bmp\fthe\fdifferenti\bl\fin\f\b\fvise.\f
2.Special\bTool(\f):\b 205-071-01,\f205-295,\f 308-197\f
3. Sp

ecial\bTool(\f):\b 205-071-01,\f205-295,\f 308-197\f
4. R

emove\fthe\ffollowing\fitems:\f 1. Loo\fen:\b Four\fturn(s)
\f
2. \f
3.
S\bve\fthree\fbolts\ffor\fre\bssembly\fthe\fring\f
ge\br.\f
\f
\f
\f
\f
\f\f
\f\f
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