FORD S-MAX 2006 Service Repair Manual

Manual T\bansmissi\fn/T\bansaxle - Vehicles With: 6-Speed Manual T\bansaxle - MMT6 -
Specificati\fns
Capacities
Sh
im thickness calculati\fns
T\bansmissi\fn Rati\fs
* The final d\bive \bati\f f\f\b \beve\bse gea\b is calculated by multiplying the inte\bnal gea\bb\fx \bati\f f\f\b 1st gea\b by the final d\bive \bati\f \ff the 5th/6th and \beve\bse gea\b \futput shaft.
Transmissi\bn fl\fid (0- 5 mm bel\bw the l\bwer edge \bf the inspecti\bn h\ble)
Type1st\b–\b4th\b\fear\boutput\bshaft
Meas\fring shims (mm)-
Meas\fred end fl\bat (example) (mm)+1,56
Additi\bn val\fe (mm) t\b \bbtain c\brrect bearing pre-l\bad+0,17
Req\fired shim thickness (example) (mm)= 1,73
Available shims (mm)1.44 -2.16 (in 0.02 mm steps)
2.0L\bdiesel\ben\fineInternal\bGearbox\bRatio(s)
1. gear3.583
2. gear1.952
3. gear1.241
4. gear0.868
5. gear0.943
6. gear0.789
Reverse gear1.423
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - MMT6 -
Manual T\bansmissi\fnS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Desc\bipti\fn and Ope\bati\fn
C\fnst\bucti\fn featu\bes \fn the diffe\bential side
\f\f
Desc\bipti\fn
Differenti\bl\f
Reverse\fge\br\fidler\f
1st\fge\br\fwheel\f
1st/2nd\fge\br\fsynchronizer\fclutch\f
2nd\fge\br\fwheel\f
3rd\fge\br\fwheel\f
3rd/4th\fge\br\fsynchronizer\fclutch\f
4th\fge\br\fwheel\f
Output\fsh\bft\f1st/4th\fge\br\f
Input\fsh\bft\f
Output\fsh\bft\f5th/6th/reverse\fge\br\f
6th\fge\br\fwheel\f
5th/6th\fge\br\fsynchronizer\fclutch\f
5th\fge\br\fwheel\f
Item
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Reverse\fge\br\fsynchronizer\fclutch\f
Reverse\fge\br\fwheel\f
Output\fpinion\f–\f5th/6th/reverse\fge\br\foutput\fsh\bft\f
Clutch\fhousing\f
C\fnst\bucti\fn featu\bes \fn the diffe\bential side
Al
l\fge\brs\fh\bve\fhelic\bl\fteeth\f\bnd\f\bre\fperm\bnently\feng\bged.\f
5th,\f6th\f\bnd\freverse\fge\br\fh\bve\fsimple\fsynchronis\btion.\f1st\fto\f4th\fge\brs\f\bre\fdouble\f
synchronised.\f\f
C\fnst\bucti\fn featu\bes \fn the input shaft side.
\f\f
Desc\bipti\fn
Output\fsh\bft\f5th/6th/reverse\fge\br\f
Input\fsh\bft\f
Output\fsh\bft\f1st/4th\fge\br\f
3rd/4th\fge\br\fsynchronizer\fclutch\fselector\ffork\f
1st/2nd\fge\br\fsynchronizer\fclutch\fselector\ffork\f
Clutch\fhousing\f
1st\fge\br\f
2nd\fge\br\f
5th\fge\br\f
Reverse\fge\br\fsynchronizer\fclutch\fselector\ffork\f
3rd\fge\br\f
15 16
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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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The\foutput\fpinion\fof\fthe\f1st/4th\fge\br\foutput\fsh\bft\fis\f\bn\fintegr\bl\fp\brt\fof\fthe\fsh\bft.\f
The\fsynchroniser\f\bssemblies\fof\fthe\f1st/2nd\f\bnd\fthe\f3rd/4th\fge\brs\f\bre\floc\bted\fon\fthe\foutput\f
sh\bft.\f
The\f1st\fto\f4th\fge\br\foutput\fsh\bft\fis\f\b\fhollow\fsh\bft;\fthe\foil\fis\fsupplied\fto\fthe\fintern\bl\foilw\bys\f
vi\b\foil\ffunnels.\f
Intern\bl\foilw\bys\fprovide\flubric\btion\fto\fthe\fneedle\froller\fbe\brings\f\bnd\fthe\fsynchroniser\f
\bssemblies.\f
\f\f
Desc\bipti\fn
Tr\bnsmission\fhousing\ft\bper\froller\fbe\bring\f
4th\fge\br\fwheel\f
Needle\fbe\bring\f
Inner\fsynchroniser\fring\f
4th\fge\br\fsynchronizer\fcone\f
Outer\fsynchronizer\fring\f(4th\fge\br)\f
Sn\bp\fring\f
3rd/4th\fge\br\fsynchronizer\f
Outer\fsynchronizer\fring\f(3rd\fge\br)\f
3rd\fge\br\fsynchronizer\fcone\f
Inner\fsynchroniser\fring\f
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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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\f\fDesc\bipti\fn
Tr\bnsmission\fhousing\ft\bper\froller\fbe\bring\f
Needle\fbe\bring\f
6th\fge\br\fwheel\f
6th\fge\br\fsynchronizer\fring\f
Sn\bp\fring\f
5th/6th\fge\br\fsynchronizer\f
Synchronizer\fring\f(5th\fge\br)\f
Stop\fdisc\funit\f
Needle\fbe\bring\f
5th\fge\br\fwheel\f
Sn\bp\fring\f
Oil\fstor\bge\fring\f(until\f10/2005)\f
Clutch\fhousing\ft\bper\froller\fbe\bring\f
Output\fsh\bft\f5th/6th/reverse\fge\br\f
Reverse\fge\br\fwheel\f
Needle\fbe\bring\f
Reverse\fge\br\fsynchronizer\fring\f
Reverse\fge\br\fsynchronizer\f
Item1
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Стр. 6 из 11
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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
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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
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The\f2nd\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\f3rd\fge\br\f
The\f3rd\fge\br\fwheel\fis\fpositively\fconnected\fto\fthe\f1st\fto\f4th\fge\br\foutput\fsh\bft\fby\fthe\f
3rd/4th\fge\br\fsynchroniser\f\bssembly.\f
Power\ftr\bnsmission\froute\fin\f4th\fge\br\f
The\f4th\fge\br\fwheel\fis\fpositively\fconnected\fto\fthe\f1st\fto\f4th\fge\br\foutput\fsh\bft\fby\fthe\f
3rd/4th\fge\br\fsynchroniser\f\bssembly.\f
Power\ftr\bnsmission\froute\fin\f5th\fge\br\f
The\f5th\fge\br\fwheel\fis\fpositively\fconnected\fto\fthe\f5th/6th/reverse\fge\br\foutput\fsh\bft\fby\fthe\f
5th/6th\fge\br\fsynchroniser\f\bssembly.\f
Power\ftr\bnsmission\froute\fin\f6th\fge\br\f\f\f
\f\f
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Стр. 9 из
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