ESP FORD S-MAX 2006 Service Repair Manual

Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
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
308-095\f
Inst\bller,\fInput\fSh\bft\fBe\bring\f
308-112\f
Inst\bller,\fOutput\fDrive\fFl\bnge\fSe\bl
\f
308-605\f
Inst\bller,\fInput\fSh\bft\fSe\bl\f
308-643\f
Inst\bller,\fInput\fSh\bft\fSe\bl\f
308-798\f
Inst\bller\fBe\bring\fCup\f
NameSpec\bf\bcat\bo\f
Se\bl\bnt\fLGNWSK-M2G349-A8\f/\f9U7J-M2G349-AA
Tr\bnsmission\fOil\f75W\fFEWSS-M2C200-D2\f/\f7U7J-M2C200-BA
Be\bring\fsep\br\btor
Hydr\bulic\fpress
\f
\f
\f
\f
\f
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
Diffe\bential—2.5L Du\batec
(162kW/220PS) - VI5S-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
205-071-01\f
Ad\bpter\ffor\f205-071\f(Thrust\fP\bd)
\f
205-295\f
Remover,\fBe\bring\f(M\bin\fTool)\f
308-197\f
Collet\ffor\f205-295\f
308-774\f
Insertion\fTool\f
NameSpec\bf\bcat\bo\f
Tr\bnsmission\fOil\f75W\fFEWSS-M2C200-D2\f/\f7U7J-M2C200-BA
Hydr\bulic\fpress
1. Cl\bmp\fthe\fdifferenti\bl\fin\f\b\fvise.\f2. 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
\f
\f
\f
\f
\f
Стр. 1 из 3
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
3\bd-4th Gea\b 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
205-071-01\f
Ad\bpter\ffor\f205-071\f(Thrust\fP\bd)\f
205-295\f
Remover,\fBe\bring\f(M\bin\fTool)\f
308-095\f
Inst\bller,\fInput\fSh\bft\fBe\bring\f
308-112\f
Inst\bller,\fOutput\fDrive\fFl\bnge\fSe\bl
\f
308-196\f
Collet\ffor\f205-295\f
308-605\f
Inst\bller,\fInput\fSh\bft\fSe\bl\f
308-798\f
Inst\bller\fBe\bring\fCup\f
NameSpec\bf\bcat\bo\f
Tr\bnsmission\fOil\f75W\fFEWSS-M2C200-D2\f/\f7U7J-M2C200-BA
Be\bring\fsep\br\btor
Hydr\bulic\fpress
\f
\f
\f
\f
\f
\f
\f
Стр. 1 из 5
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
Reve\bse Gea\b 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
205-295\f
Remover,\fBe\bring\f(M\bin\fTool)\f
307-028\f
Inst\bller,\fTr\bnsmission\fExtension\fHousing\fSe\bl
\f
308-113\f
Inst\bller,\fInput\fSh\bft\fSe\bl\f
308-195\f
Collet\ffor\f205-295\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 1.Special\bTool(\f):\b 205-295,\f308-195\f
2. \f

\f 1. NOTE:\fThe\fcomponent\fh\bs\f\b\fleft-h\bnd\f
th

re\bd.\f
\f
\f
\f
\f
\f
\f
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
Diffe\bential—2.2L Du\bat\f\bq-TDCi
(129kW/175PS) - DWS-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
205-071-01\f
Ad\bpter\ffor\f205-071\f(Thrust\fP\bd)
\f
205-252\f
Inst\bller,\fWheel\fHub\fSe\bl\f
NameSpec\bf\bcat\bo\f
Gre\bse\fCB-CSWSD-M1C234-A\f/\f4U7J-M1C234-AA
Be\bring\fsep\br\btor
Hydr\bulic\fpress
1. Cl\bmp\fthe\fdifferenti\bl\fin\f\b\fvise.\f2. Special\bTool(\f):\b 205-071-01\f
Gen

eral\bEquipment:\b Be\bring\fsep\br\btor \f
3. Sp

ecial\bTool(\f):\b 205-071-01\f
Ge n

eral\bEquipment:\b Be\bring\fsep\br\btor \f
\f
\f
\f
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Mate\bials
Gene\bal Equipment All vehicles
308-789\f
Inst\bller,\fDrivesh\bft\fSe\bl\f
308-796\f
G\buge\f
308-798\f
Inst\bller\fBe\bring\fCup\f
NameSpec\bf\bcat\bo\f
Silicone\fSe\bl\bnt\fDCW9U7J-99J9624-AA
Tr\bnsmission\fOil\f75W\fFEWSS-M2C200-D2\f/\f7U7J-M2C200-BA
Cable ties
H\ft ai\b gun
Ti\be leve\b1.Special\bTool(\f):\b 30
8-798\f
Mate
rial:\b Tr\bnsmission\fOil\f75W\fFE\f(WSS-M2C200-
D2\f/\f7U7J
M2C200-BA) \f
\f
\f
\f
\f
Стр. 2 из 17
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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
Installati\fn
Special T\f\fl(s)
Ma

te\bials
Gene\bal Equipment CAUTION: Ensu\be that the tw\f guide sleeves a\be installed.
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
NameSpec\bf\bcat\bo\f
Gre\bse\fK-HTESD-M1C220-A\f/\fA88SX1C220AA
Gre\bse\fKS-PSSA-M1C9107-A\f/\fYS5J-M1C9107-AA
T\bansmissi\fn jack
1. Refer\fto:\f He\blth\f\bnd\fS\bfety\fPrec\butions\f(100-00\f
Gen
er\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).
\f
2. NOTE:\fThis\fstep\fis\fonly\frequired\fwhen\f
re
pl\bcing\fthe\ftr\bnsmission.\f
Torque:\b 32\fNm
\f
3.
Co\bt\fthe\finput\fsh\bft\fsplines\fwith\f\b\fthin\fco\bting\fof\f
gre\bse.\f
Mater\fal:\b Gre\bse\fK-HT\f(ESD-M1C220-A\f/\f
A88

SX1C220AA) \f
4. Gen

eral\bEqu\fpment:\b Tr\bnsmission\fj\bck \f
\f
\f
\f
\f
\f\f
Стр. 1 из 6
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
T\bansmissi\fn—2.2L Du\bat\f\bq-TDCi (DW)
Diesel
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Installati\fn
Special T\f\fl(s)
Ma

te\bials
Gene\bal Equipment
205-775\f
Protector\fH\blfsh\bft\fSe\bl
\f
303-290-03A\f
Ad\bpter\ffor\f303-290A\f
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
NameSpec\bf\bcat\bo\f
Gre\bse\fKS-LL9U7J-M1C273-BA
Gre\bse\fKS-PSSA-M1C9107-A\f/\fYS5J-M1C9107-AA
Retaining St\bap
Ti\be leve\b
T\bansmissi\fn jack
W\f\fden Bl\fck 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. Co\bt\fthe\finput\fsh\bft\fsplines\fwith\f\b\fthin\fco\bting\fof\f gre\bse.\f
Material\b Gre\bse\fKS-LL\f(9U7J-M1C273-BA) \f
3. T

his\fstep\fis\fonly\frequired\fwhen\frepl\bcing\fthe\f
\f
\f
\f
\f
\f
\f
Стр. 1 из 10
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Exhaust\bSyste\f\b-\b2.0L\bDuratec-HE\b
(107kW/145PS)\b-\bMI4/2.3L\bDuratec-HE\b
(118kW/160PS)\b-\bMI4\b-\bCatalytic\bConverter—
2.0L\bDuratec-HE\b(107kW/145PS)\b-\bMI4/2.0L\b
Duratec-HE\bFlex\bFuel\b(107kW/145PS)\b-\bMI4
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Re\foval\band\bInstallation\b
Materials\b
Re\foval\b
NameSpec\bf\bcat\bo\f
Gre\bse\fKS-PSSA-M1C9107-A\f/\fYS5J-M1C9107-AA1. \f
2. \f\f3.
Det\bch\f
the\fA
pill\br\f
exterior\f
trim\f
p\bnel\f
lower\f
ret\bining\f
clips.
3. \f
4. \f
\f\f
\f
\f
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Exhaust\bSyste\f\b-\b2.0L\bDuratec-HE\b
(107kW/145PS)\b-\bMI4/2.3L\bDuratec-HE\b
(118kW/160PS)\b-\bMI4\b-\bCatalytic\b
Converter—2.3L\bDuratec-HE\b(118kW/160PS)\b
-\bMI4
S-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Re\foval\band\bInstallation\b
Materials\b
Re\foval\b
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
NameSpec\bf\bcat\bo\f
Gre\bse\fKS-PSSA-M1C9107-A\f/\fYS5J-M1C9107-AA
1. \f
2. \f\f
3. \f
4. \f
\f\f
\f
\f
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6
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