FORD S-MAX 2006 Service Repair Manual

Installati\fn 1. \f\f
1. C

AUTION:\fApply\f\bdhesive\ft\bpe\fto\f
th

e\fsplines\fon\fthe\fsh\bft\fso\fth\bt\fthe\foil\f
se\bl\fdoes\fnot\fbecome\fd\bm\bged.\f\f
2. Special\bTool(\f):\b 3
08-112\f
2. Remove\fthe\f\bdhesive\ft\bpe\ffrom\fthe\finput\fsh\bft\f
splines.\f
3. Refer\fto:\f Clutch\fSl\bve\fCylinder \f(308-02B\fClutch\f
Co n

trols\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fMMT6,\fRemov\bl\f\bnd\fInst\bll\btion).\f
4. Refer\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,\fInst\bll\btion).\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 \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:\fGetriebe\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(118kW/160PS)\f-\fDW,\fAbg\bsnorm:\f
Abg\bsnormstufe\fV\f(308-03C,\fInst\bll\btion).\f
5. Refer\fto:\fKupplungssystem\fentlüften\f-\f
F\bhrzeuge\f
\busgest\bttet\fmit\f6-G\bng\fSch\bltgetriebe\f-\fM66\f
(308-00\fSch\bltgetriebe\fund\fKupplung\f-\f
Allgemeine\fInform\btionen,\fGener\bl\fProcedures).\f
\f
\f
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - MMT6 -
T\bansmissi\fn—1.8L Du\bat\f\bq-TDCi (Lynx)
DieselS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\fval
Special T\f\fl(s)
Ge

ne\bal Equipment
303-290-13\f
Ad\bpter\ffor\f303-290A\f
303-290B\f
Support\fB\br,\fEngine\f
303-290B-15\f
Zus\btzstück\ffür\f303-290B
\f
303-290B-16\f
Ad\bpter\ffor\f303-290B\f
T\bansmissi\fn jack 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. Remove\fthe\ffollowing\fitems:\f 1. Air\fFiltering\f
Refer\fto:\f Air\fCle\bner \f(303-12D\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f1.8L\fDur\btorq-
TDCi\f(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-
TDCi\f(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. B\bttery\f
Refer\fto:\f B\bttery\f(414-01\fB\bttery,\f
Mou

nting\f\bnd\fC\bbles,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. \f
\f
\f
\f
\f
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4. \f
5.CAUTION:\fThe\fge\brshift\fc\bbles\fmust\fnot\f
be

\fkinked\for\ftwisted.\f
6. \f
7. \f
8. Remove\fthe\ffollowing\fitems:\f 1. Subfr\bme\f
Refer\fto:\f Front\fSubfr\bme \f(502-00\fUni-
\f
\f\f
\f\f
\f\f
\f\f
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Body,\fSubfr\bme\f\bnd\fMounting\fSystem,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. Drivesh\bfts\f
Refer\fto:\f Front\fH\blfsh\bft\fLH \f(205-04\fFront\f
Dri

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
Refer\fto:\f Front\fH\blfsh\bft\fRH \f(205-04\fFront\f
Dri

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. c\bt\blytic\fconverter\f
Refer\fto:\f C\bt\blytic\fConverter \f(309-00D\f
Exh

\bust\fSystem\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
9. \f
10. Det\bch\fthe\fst\brter\fmotor\ffrom\fthe\ftr\bnsmission\f \bnd\fposition\fit\fto\fone\fside.\f
11. \f
12. Install t\be Spe\fial Tool(s): 303-290B,\f303-290-
13 ,\f3

03-290B-15 ,\f303-290B-16 \f
13. I

nstall t\be Spe\fial Tool(s): 303-290B-15\f
\f\f
\f\f
\f\f
\f\f
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14.Install t\be Spe\fial Tool(s): 303-290B-15\f
15.
\f
16. \f
17. \f
18. Disc\brd\fthe\fre\br\fengine\fmounting\fbolt.\f
\f\f
\f\f
\f\f
\f\f
\f\f
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19. \f
20.Spe\fial Tool(s): 303-290B,\f303-290-13 ,\f303-
29 0

B-15,\f 303-290B-16 \f
21.

Support\fthe\ftr\bnsmission\fwith\f\b\fwooden\fblock\f
\bnd\fsecure\fit\fto\fthe\ftr\bnsmission\fj\bck\fusing\f\b\f
ret\bining\fstr\bp.\f
General Equipment: Tr\bnsmission\fj\bck\f
22 .

\f
23. Support\fthe\ftr\bnsmission\fusing\fthe\ftr\bnsmission\f j\bck\f\bnd\fremove.\f
General Equipment: Tr\bnsmission\fj\bck\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - MMT6 -
T\bansmissi\fn—2.0L Du\bat\f\bq-TDCi
(85kW/115PS) - DW/2.0L Du\bat\f\bq-TDCi
(100kW/136PS) - DW/2.0L Du\bat\f\bq-TDCi
(103kW/140PS) - DW, 2.0L Du\bat\f\bq-TDCi
(DW) Diesel
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\fval
Special T\f\fl(s)
Ge

ne\bal Equipment
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
T\bansmissi\fn jack 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. \f
3. Remove\fthe\ffollowing\fitems:\f 1. Air\ffilter\f
Refer\fto:\f Air\fCle\bner \f(303-12E\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.0L\fDur\btorq-
TDCi\f(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-
TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-
TDCi\f(103kW/140PS)\f-\fDW/2.0L\fDur\btorq-
\f
\f
\f
\f
\f
\f\f
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TDCi\f(118kW/160PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV/St\bge\fV,\fRemov\bl\f
\bnd\fInst\bll\btion).\f
2. B\bttery\f
Refer\fto:\f B\bttery\f(414-
01\fB\bttery,\fMounting\f
\bnd\fC\bbles,\fRemov\bl\f\bnd\fInst\bll\btion).\f
4. \f
5. \f
6. CAUTION:\fThe\fge\brshift\fc\bbles\fmust\fnot\f
b e

\fkinked\for\ftwisted.\f
7. \f
8. \f\f
Det\bch\fthe\fst\brter\fmotor\ffrom\fthe\f
tr

\bnsmission\f\bnd\fposition\fit\fto\fone\fside.\f
\f
\f\f
\f\f
\f\f
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9. \f
10. Remove\fthe\fsub-fr\bme.\f Refer\fto:\f Front\fSubfr\bme\f-\f2.0L\fDur\btorq-TDCi\f
(1 1

8kW/160PS)\f-\fDW \f(502-00\fUni-Body,\f
Sub

fr\bme\f\bnd\fMounting\fSystem,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
11. \f
12. Remove\fthe\ffollowing\fitems:\f 1. Drivesh\bfts\f
Refer\fto:\f Front\fH\blfsh\bft\fLH \f(205-04\fFront\f
Dr i

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Front\fH\blfsh\bft\fRH \f(205-04\fFront\f
Dri

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. C\bt\blyst\f
Refer\fto:\f C\bt\blytic\fConverter \f(309-00E\f
Exh

\bust\fSystem\f-\f2.0L\fDur\btorq-TDCi\f
(85kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\fEmission\f
Requirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
13.Install
\f\f
\f
\f\f
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t\be
Spe\fial
Tool
(s):
303-
290
B,\f
303-
290
-
03A ,\f
303-
290

-
13 ,\f
303-
290
A-
15 ,\f
303-
29 0

B-
16 \f
14.

\f
15. \f 16.
Spe\fial
Tool
(s):
303-
290
B\f
\f
\f\f
\f\f
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