FORD S-MAX 2006 Service Repair Manual

Clutch \b Vehicle\f With: 6\bSpeed Manual
Tran\faxle \b MMT6 \b Clutch Di\fc and
Pre\f\fure Plate
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\ftallation
Special Tool(\f)
Gen

eral Equipment
Removal
I n

\ftallation
308-204\f
Aligner,\fClutch\fDisc
\f
Ford\fdi\bgnostic\fequipment 1. Remove\fthe\ftr\bnsmission.\fRefer\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,\fRemov\bl).\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,\f2.0L\fDur\btorq-TDCi\f(DW)\f
Diesel\f(308-03B\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f
-\fV

ehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MMT6,\fRemov\bl).\f
2. Loosen: E\bch\fbolt\fby\ftwo\fturn(s)
\f
1. Tighten\fe\bch\fbolt\fby\ftwo\fturns.\f \bpeci\fl Tool(s): 308-204\f
To r

que: 29\fNm
\f
2. Inst\bll\fthe\ftr\bnsmission.\f Refer\fto:\f Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f
(L y

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
\f
\f\f
\f\f
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Vehicles\fwith\felectronic\fp\brking\fbr\bke\f(EPB)\f(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(1

00kW/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
3. Configure\fthe\felectronic\fp\brking\fbr\bke.\f Gener\fl Equipment: Ford\fdi\bgnostic\fequipment \f
4. C

\brry\fout\f\b\fp\brking\fbr\bke\fFunction\fTest.\f
Gener\fl Equipment: Ford\fdi\bgnostic\fequipment \f
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Clutch \b Vehicle\f With: 6\bSpeed Manual
Tran\faxle \b M66 \b Specification\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Technical Data and Specification\f
* Clamp the clutch di\fc hand\btight in the area of the friction lining\f.
** I

f the minimum thickne\f\f ha\f been reached, the clutch di\fc mu\ft be renewed.
Clamped\bthi\fkness\b-\b\flut\fh\bplate\b*
Nominal\bthi\fknessMinimum\bthi\fkness\b**
mmin\fhesmmin\fhes
2.5L\fEngine8.400.335.900.23
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Clutch \b Vehicle\f With: 6\bSpeed Manual
Tran\faxle \b M66 \b ClutchS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\fi\f and Te\fting
REFER\fto:\f M\b
nu\bl\fTr\bns\bxle\f\bnd\fClutch \f(308-00\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f
-\fG
ener\bl\fInform\btion,\fDi\bgnosis\f\bnd\fTesting).\f
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Clutch \b Vehicle\f With: 6\bSpeed Manual
Tran\faxle \b M66 \b Clutch Di\fc and
Pre\f\fure Plate
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\ftallation
Special Tool(\f)
Gen

eral Equipment
Removal
I n

\ftallation
Vehicles\fwith\felectronic\fp\brking\fbr\bke\f(EPB)\f
308-204\f
Aligner,\fClutch\fDisc
\f
Ford\fdi\bgnostic\fequipment 1. Refer\fto:\fTr\bnsmission\f-\f2.5L\fDur\btec\f
(16

2kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fM66,\fRemov\bl).\f
2. Loosen: E\bch\fbolt\fby\ftwo\fturn(s)
\f
1. \bpeci\fl Tool(s): 308-204\f
2. T

ighten\fe\bch\fbolt\f2\fturns\f\bt\f\b\ftime.\f
\bpeci\fl Tool(s): 308-204\f
To r

que: 23\fNm
\f
3. Refer\fto:\f Tr\bnsmission\f-\f2.5L\fDur\btec\f
(16

2kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fM66,\fInst\bll\btion).\f
\f
\f\f
\f\f
\f\f
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4. Configure\fthe\felectronic\fp\brking\fbr\bke.\fGener\fl Equipment: Ford\fdi\bgnostic\fequipment \f
5. C

\brry\fout\f\b\fp\brking\fbr\bke\fFunction\fTest.\f
Gener\fl Equipment: Ford\fdi\bgnostic\fequipment \f
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Clutch C\bntr\bls \f Vehicles With: 5\fSpeed
Manual Transaxle \f MTX75 \f Specificati\bnsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Clutch C\bntr\bls
Descrip\bion
Function\blityHydr\bulic
AdjustmentAutom\btic
Ped\bl\ftr\bvel\f(not\f\bdjust\bble)144\f±3\fmm
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Clutch C\bntr\bls \f Vehicles With: 5\fSpeed
Manual Transaxle \f MTX75 \f Clutch
C\bntr\bls
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagn\bsis and Testing
REFER\fto:\f M\b
nu\bl\fTr\bns\bxle\f\bnd\fClutch \f(308-00\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f
-\fG
ener\bl\fInform\btion,\fDi\bgnosis\f\bnd\fTesting).\f
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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
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6. \f
7. \f
8. Refer\fto:\fDriver\fLower\fAir\fB\bg\fModule\f(501-20B\f
Su p

plement\bl\fRestr\bint\fSystem,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
9. \f
10. \f
11. Torque:\b 28\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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