tran FORD S-MAX 2006 Service User Guide
[x] Cancel search | Manufacturer: FORD, Model Year: 2006, Model line: S-MAX, Model: FORD S-MAX 2006Pages: 4402, PDF Size: 93.08 MB
Page 942 of 4402

Engine - \b.8L \furatorq-T\fCi (74kW/\b00PS) - Lynx/\b.8L \furatorq-T\fCi
(92kW/\b25PS) - Lynx - Engine—Vehicles With: 6-
Speed Manual Transaxle
(MMT6)
Removal
General Equipment
WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions.
WARNING: Make sure that the fuel pressure has dropped to zero and that the fuel temperature is at ambient temperature.
Cable ties
Vehicle/axle stands
1. Refer \bo: D\fesel Fuel Sys\bem Heal\bh and Safe\by Precau\b\fons
2.
3. Remove \bhe a\fr cleaner. Refer \bo: A\fr Cleaner (303-
12D In\bake A\fr D\fs\br\fbu\b\fon and F\fl\ber\fng
Dura\borq-TDC\f (92kW/125PS) - Lynx, Removal and Ins\balla\b\fon).
4. Remove \bhe ba\b\bery.
Refer \bo: Ba\b\bery (414-
01 Ba\b\bery, Moun\b\fng and Cables, Removal and Ins\balla\b\fon).
5.
6. Dra\fn \bhe cool\fng sys\bem.
Refer \bo:
Cool\fng Sys\bem Dra\fn\fng, F\fll\fng and Bleed\fng
Lynx/1.8L Dura\borq-TDC\f (92kW/125PS) - Lynx, General Procedures).
7.
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Page 981 of 4402

Engine - \b.8L \furatorq-T\fCi (74kW/\b00PS) - Lynx/\b.8L \furatorq-T\fCi
(92kW/\b25PS) - Lynx - Engine—Vehicles With: 5-
Speed Manual Transaxle
(MTX-75)
Installation
General Equipment
WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions.
Cable ties
Vehicle/axle stands
1. Refer \bo: D\fesel Fuel Sys\bem Heal\bh and Safe\by Precau\b\fons
2. Ins\ball \bhe \bransaxle \bo \bhe eng\fne.
3.Torque:\b 48 Nm
4. Torque:\b 48 Nm
5. Torque:\b 48 Nm
6. Torque:\b 48 Nm
7. Torque:\b 48 Nm
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Page 985 of 4402

28.Torque:\b 23 Nm
29. Torque:\b 24 Nm
30.
CAUTION: If \bhe flu\fd \fs sp\flled on \bhe pa\fn\bwork, \bhe affec\bed area mus\b be \fmmed\fa\bely washed down w\f\bh
cold wa\ber.
Bleed \bhe clu\bch sys\bem.
Re
fer \bo: Clu\bch Sys\bem Bleed\fng (308-
00, General Procedures).
31.CAUTION: Gearsh\ff\b cables mus\b no\b be k\fnked or ben\b.
Ins\ball \bhe gearsh\ff\b cables.
32. Adjus\b \bhe gearsh\ff\b cables. Refer \bo: Gearsh\ff\b Cable Adjus\bmen\b -
Veh\fcles W\f\bh: 5
Transm\fss\fon/Transaxle and Clu\bch - General Informa\b\fon, General Procedures).
33.
34.
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Page 988 of 4402

Engine - \b.8L \furatorq-T\fCi (74kW/\b00PS) - Lynx/\b.8L \furatorq-T\fCi
(92kW/\b25PS) - Lynx - Engine—Vehicles With: 6-
Speed Manual Transaxle
(MMT6)
Installation
General Equipment
WARNING: This procedure involves fuel handling. Be prepared for fuel spillage at all times and always observe fuel handling precautions.
Cable ties
Vehicle/axle stands
1. Refer \bo: D\fesel Fuel Sys\bem Heal\bh and Safe\by Precau\b\fons
2. Ins\ball \bhe \bransaxle \bo \bhe eng\fne.
3.Torque:\b 48 Nm
4. Torque:\b 48 Nm
5. Torque:\b 48 Nm
6. Torque:\b 48 Nm
7. Torque:\b 48 Nm
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Page 992 of 4402

28.Torque:\b 23 Nm
29. Torque:\b 24 Nm
30.
31.
CAUTION: If \bhe flu\fd \fs sp\flled on \bhe pa\fn\bwork, \bhe affec\bed area mus\b be \fmmed\fa\bely washed down w\f\bh
cold wa\ber.
Bleed \bhe clu\bch sys\bem.
R e
fer \bo: Clu\bch Sys\bem Bleed\fng (308-
00, General Procedures).
32.CAUTION: Gearsh\ff\b cables mus\b no\b be k\fnked or ben\b.
Ins\ball \bhe gearsh\ff\b cables.
33. Adjus\b \bhe gearsh\ff\b cables. Refer \bo: Gearsh\ff\b Cable Adjus\bmen\b -
Veh\fcles W\f\bh: 6
Transm\fss\fon/Transaxle and Clu\bch - General Informa\b\fon, General Procedures).
34.
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Page 1134 of 4402

NOTE: Cylinder 1 is l\bcated \bn t\fe transaxle side \bf t\fe engine.
T\fe cylinder bl\bck is made fr\bm grey cast ir\bn and is
d\buble-walled. T\fis \felps t\b ac\fieve \fig\f strengt\f. It als\b f\brms a
blanket \bf air t\fat results in c\bnsiderable s\bund insulati\bn.
T\fe serial number \bf t\fe engine and t\fe engine c\bde are l\bcated \bn t\fe intake side \bf t\fe cylinder bl\bck (in line wit\f t\fe
sec\bnd cylinder).
T\fe running surfaces \bf t\fe cylinders are w\brked directly int\b t\fe cylinder bl\bck.
T\fere are tw\b \f\bles \bn t\fe cylinder bl\bck f\br t\fe guide bus\fings f\br securing t\fe cylinder \fead gasket and t\fe cylinder \fead.
Oil Spray Jets
Description
Oil spray n\bzzle retaining b\blt
Oil spray jet (4 \bff)
T\fe efficient c\bmbusti\bn pr\bvided by t\fe direct-
injecti\bn turb\bc\farged diesel engine means t\fat \fig\f temperatures are
transmitted t\b t\fe pist\bns.
T\fere is an \bil spray n\bzzle installed at t\fe l\bwer end \bf eac\f cylinder liner f\br c\b\bling t\fe pist\bns. T\fe \bil spray n\bzzles spray
engine \bil in a targeted manner under t\fe pist\bn cr\bwns.
T\fere are \bil passages integrated in t\fe pist\bn cr\bwns. T\fe sprayed engine \bil enters t\fese \bil passages and t\fus ensures t\fe
necessary pist\bn c\b\bling. Pist\bn c\b\bling is n\bt essential w\fen t\fe engine is c\bld. Lubricati\bn \bf t\fe crank gear and cams\faft
\fas a \fig\fer pri\brity \fere. F\br t\fis reas\bn, t\fe \bil spray n\bzzles \bnly \bpen if an \bil pressure \bf m\bre t\fan 0.5 bar is present at
t\fem.
Cylinder block extension Item
1
2
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Page 1136 of 4402

Description
Flyw\feel side
T\bp t\frust was\fers (2 pieces)
T\bp cranks\faft bearing s\fells (5 pieces)
B\btt\bm cranks\faft bearing s\fells (5 pieces)
Balance s\faft drive gear
L\bwer t\frust was\fers (2 pieces)
T\fe cranks\faft runs \bn fiv
e bearings by means \bf five main bearing caps.
Eac\f main bearing \falf cap is stamped wit\f t\fe c\brresp\bnding cylinder number f\br identificati\bn.
T\fe cranks\faft's radial play is restricted by fo\fr semicirc\flar thr\fst washers t\fat are arranged \bn eit\fer side \bf main
bearing 2.
Lubricati\bn gr\b\bves are f\brmed \bn t\fe t\frust was\fers and must face t\bward t\fe main bearing.
Eac\f main bearing \f\busing and \falf cap c\bntains an upper and l\bwer bearing \falf s\fell manufactured fr\bm aluminum/tin. T\fe
upper \falf s\fells are f\brmed wit\f a drilling and annular gr\b\bve t\b transfer pressurized \bil fr\bm t\fe main bearing, t\fr\bug\f
cranks\faft drillings t\b t\fe c\bnnecting r\bd big-end bearings.
F\br establis\fing t\fe c\brrect cranks\faft main bearing play, t\fe l\bwer main bearing s\fells are available in five different
t\ficknesses.
T\fe balance s\faft drive gear is s\frunk \bnt\b t\fe t\fird cranks\faft web. T\fe \felical drive gear pr\bvides t\fe drive f\br t\fe balance
s\fafts.
Piston and Connecting Rod Assembly Item
A1
2
3
4
5
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Page 1965 of 4402

Transmissi\bn/Transaxl\f C\b\bling -
V\fhicl\fs With: 6-Sp\f\fd Aut\bmatic
Transaxl\f (AWF21) - Sp\fcificati\bns
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Specifica\bions
Autom\btic\fTr\bnsmission\fFluidWSS-M2C924-A
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Page 1966 of 4402

Transmissi\bn/Transaxl\f C\b\bling -
V\fhicl\fs With: 6-Sp\f\fd Aut\bmatic
Transaxl\f (AWF21) - Transmissi\bn
C\b\bling
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
D\fscripti\bn and Op\frati\bn
\f\f
D\fscripti\bn
Tr\bnsmission\ffluid\fcooler\f
Tr\bnsmission\ffluid\fcooler\fsupply\f
Tr\bnsmission\ffluid\fcooler\freturn\f
Quick-rele\bse\fcoupling\f
R\bdi\btor\fsupply\f
R\bdi\btor\freturn\f
The\ftr\bnsmission\ffluid\fcooler\fis\fpositioned\fbehind\fthe\fr\bdi\btor.\f
It
\fis\fconnected\fto\fthe\ftr\bnsmission\fby\fme\bns\fof\ftwo\fhose\flines\fwith\fquick-rele\bse\fcouplings.
\f
It\fis\fconnected\fto\fthe\fr\bdi\btor\fby\fme\bns\fof\ftwo\fhose\flines\fwith\fhose\fcl\bmps.\f
The\fquick-rele\bse\fcouplings\f\bre\fcolour-coded\fto\fprevent\fthem\ffrom\fbeing\fmixed\fup.\fIt\fm
1
2
3
4
5
6
\f
Part Numb\fr -
-
-
-
-
-
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Page 1983 of 4402

Yes CHECK\fthe\fengine\f\bnd\ftr\bnsmission\ffor\fle\bks.INSTALL\f\b\fnew\fclutch\fdisc\f
\bnd\fpressure\fpl\bte.\f
N\f
CHECK\fsystem\foper\btes\fcorrectly\f
PINPOINT TEST B : CLUTCH CHATTER OR SHUDDER
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
B1: TEST CLUTCH CHATTER OR SHUDDER
Ignition\fswitch\fin\fposition\fIII.\f1
St\brt\fthe\fengine,\fdepress\fthe\fclutch\f\bnd\feng\bge\ffirst\fge\br.\f2
Run\fthe\fengine\f\bt\fbetween\f1200\frpm\f\bnd\f1500\frpm.\f3
Rele\bse\fthe\fclutch\fped\bl\fslowly.\f4
Does\fthe\fvehicle\fjerk\fwhen\fit\fst\brts\foff?\f
Yes GO\fto\fB2.\f\f
N\f C
lutch\fOK.\f
B2: TEST ENGINE/TRANSAXLE ISOLATOR, ROLL RESISTOR
Check\fthe\fengine/tr\bns\bxle\fmountings\fisol\btor\f\bnd\froll\fresistor\ffor\f
d\bm\bge\for\floose\fbolts.\f1
Is\fthe\fengine/tr\bns\bxle\fisol\btor\for\froll\frestrictor\floose\for\fd\bm\bged?\f
Yes TIGHTEN\fthe\fbolts\for\fINSTALL\fnew\fbolts\f\bs\fnecess\bry.\fCHECK\fsystem\f
oper\btes\fcorrectly\f
N\f GO\fto\fB3.\f\f
B3: TEST CLUTCH PRESSURE PLATE
Remove\fclutch\fpressure\fpl\bte.\f1
Is\fthe\fclutch\fpressure\fpl\bte\fd\bm\bged?\f
Yes
RENEW\fthe\fclutch\fset.\f
N\f GO\fto\fB4.\f\f
B4: TEST CLUTCH FRICTION DISK
CHECK\fthe\fclutch\fdisc.\f1
Does\fthe\fclutch\fdisc\fshow\fevidence\fof\fd\bm\bge\fdue\fto\ftilting?\f
Yes
RENEW\fthe\fclutch\fset.\f
N\f CHECK\fflywheel.\f
PINPOINT TEST C : CLUTCH DISENGAGES TOO LATE OR NOT AT ALL
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
C1: CHECK FLUID LEVEL
Check\fbr\bke\ffluid\flevel\f1
Is\fthe\fbr\bke\ffluid\flevel\fbetween\fthe\fMAX\f\bnd\fMIN\fm\brks\fon\fthe\fbr\bke\ffluid\f
reservoir?\f
Yes GO\fto\fC2 .\f\f
N\f F
ill\fwith\fbr\bke\ffluid,\fCHECK\fthe\fbr\bke\f\bnd\fclutch\fsystems\ffor\fle\bks.\f
C2: CLUTCH DISENGAGES TOO LATE OR NOT AT ALL
Bleed\fthe\fclutch\fsystem.\f1
Does\fthe\fclutch\fshow\fimproved\fdiseng\bging\fch\br\bcteristics\ffollowing\fbleeding\fof\f
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