FORD S-MAX 2006 Service Repair Manual

housing\f
together.
S\fecial Tool
(s): 308

Pl\bce\fthe\f
be\bring\fouter\f
r\bces\fin\f
position\fon\fthe\f
output\fsh\bft\f
t\bpered\froller\f
be\bring.
7. \f\f

Repe\bt\fthis\f\bnd\fthe\ffollowing\ffour\fsteps\fthree\ftimes\f
\bnd\fdetermine\fthe\f\bver\bge\fv\blues.\f


Pull\fout\fthe\fme\bsuring\frings\fto\f\bpprox.\f10\fmm.

Hold\fthe\fbe\bring\fouter\fr\bces,\fturn\fthe\foutput\fsh\bft\f20\f
times\fwhile\fpressing\fdown\f\bt\fthe\fs\bme\ftime,\fso\fth\bt\f
the\fbe\brings\fsettle.\f
S\fecial Tool(s): 308-603\f
8.
NOTE:\fThe\fmounting\ff\bces\fmust\fbe\fcle\bn\f\bnd\ffree\ffrom\f
foreign\fbodies.\f
Inst\bll\fthe\fspeci\bl\ftools.\f
S \f

ecial Tool(s): 205-070,\f307-430\f
9. \f

\f

M\bke\fcert\bin\fth\bt\fthe\fclutch\fhousing\fdoes\fnot\fbecome\f
skewed.\f


M\bke\fcert\bin\fth\bt\fthe\fspeci\bl\ftools\f\bre\finserted\f
correctly\fin\fthe\fclutch\fhousing\fbe\bring\fouter\fr\bce\f
se\bts.\f

Att\bch\fthe\fclutch\fhousing.\f
S\f

ecial Tool(s): 205-070,\f206-003,\f307-430\f
Tor

que: 32\fNm
\f
10. \f\f

M\bke\fcert\bin\fth\bt\fthe\fclutch\fhousing\fdoes\fnot\fbecome\f
skewed.\f

Det\bch\fthe\fspeci\bl\ftools.\f
S\f

ecial Tool(s): 205-070,\f206-003,\f307-430\f
\f\f
\f\f
\f\f
\f\f
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11. \f\f

While\ft\bking\fthe\fme\bsurements,\fonly\fpress\flightly\fon\f
the\fspeci\bl\ftool,\fto\f\bvoid\fincorrect\fre\bdings.\f

Record\fthe\fme\bsurement\fresults.\f
S\f

ecial Tool(s): 307-300-02,\f307-300-03,\f
308
12. \f\f

Me\bsure\fthe\frequired\fthickness\fof\fthe\f1st\f-
\f4th\fge\br\f
output\fsh\bft\f\bdjustment\fshim:\f


Add\fthe\fme\bsured\fv\blues,\fdivide\fby\fthree\f\bnd\fthen\f
\bdd\fthe\fv\blue\ffor\fthe\fbe\bring\fpre-lo\bd.\f

1st\f-\f4th\fge\br\foutput\fsh\bft\fbe\bring\fpre-
lo\bd:\f0.17\f
mm.\f


Ex\bmple:\f1.56\fmm\f+1.57\fmm\f+1.55\fmm,\fdivided\fby\f
3\f=\f1.56\fmm.\f1.56\fmm\f+0.17\fmm\f=\f1.73\fmm.

Determined\f\bdjusting\fshim\fthickness:\f1.73\fmm.
13. \f\f

Me\bsure\fthe\frequired\fthickness\fof\fthe\f5th/6th\f
ge\br/reverse\fge\br\foutput\fsh\bft\f\bdjustment\fshim:

Add\fthe\fme\bsured\fv\blues,\fdivide\fby\fthree\f\bnd\fthen\f
\bdd\fthe\fv\blue\ffor\fthe\fbe\bring\fpre-lo\bd.\f

Be\bring\fpre-lo\bd\f-\foutput\fsh\bft\f-
\f5th/6th/reverse\f
ge\br:\f0.15\fmm.\f


Ex\bmple:\f1.51\fmm\f+\f1.52\fmm\f+\f1.50\fmm,\fdivided\f
by\f3\f=\f1.51\fmm.\f1.51\fmm\f+\f0.15\fmm\f=\f1.66\fmm.

Determined\f\bdjusting\fshim\fthickness:\f1.66\fmm.
14. Remove\fthe\fspeci\bl\ftools.\f
S\fecial Tool(s): 205-070,\f307-430\f
15.
Remove\fthe\ffollowing\f
items:\f1.
S\fecial Tool
(s): 308
2.Output\fsh\bft\f
be\bring\fouter\f
r\bces\f
3.
Output\fsh\bfts
\f\f
\f\f
\f\f
Стр. 5 из 12
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S\fecial Tool
(s): 308
16. Remove\fthe\ffollowing\fitems:\f
S\fecial Tool(s): 20
6-003\f
17.
CAUTION:\fExtreme\fcle\bnliness\fmust\fbe\fexercised\f
when\fh\bndling\fthese\fcomponents.\f
Tighten\fthe\ftr\bnsmission\fhousing\fbolts,\fworking\fdi\bgon\blly.
Torque: 32\fNm\f
18.Cle\bn\fthe\fend\ff\bce\fof\fthe\fdifferenti\bl\f\bssembly\f\bnd\fm\brk\fit\f
\bt\fone\fpl\bce.\f
S\fecial Tool(s): 205-044-01,\f205-070\f
19.

\f\f

Repe\bt\fthis\f\bnd\fthe\ffollowing\fthree\fsteps\fthree\ftimes\f
\bnd\fdetermine\fthe\f\bver\bge\fv\blues.\f

To\fme\bsure\fthe\fbe\bring\fpre-
lo\bd\fturn\fthe\fdifferenti\bl\f
20\ftimes\fwhile\fpressing\fdown\f\bt\fthe\fs\bme\ftime,\fso\f
th\bt\fthe\fbe\brings\fsettle.\f \f\f
\f\f
\f\f
\f\f
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S\fecial Tool(s): 308-192\f
20.
\f\f

Att\bch\fthe\fdi\bl\fg\buge\fto\fthe\fspeci\bl\ftool\f\bnd\f\blign\fwith\f
the\fm\brk.\f
S\fecial Tool(s): 205-044-01,\f205-070\f

Pre-lo\bd\fthe\fdi\bl\fg\buge\fto\f1\fmm\f\bnd\fzero\fit.\f
2 1

.
Turn\fthe\ftr\bnsmission\fthrough\f180\fdegrees\fwith\fthe\fclutch\f
side\fdownw\brds.\f
22. \f\f 1. To\fme\bsure\fthe\fbe\bring\fpre-
lo\bd\fturn\fthe\fdifferenti\bl\f
20\ftimes\fwhile\fpressing\fdown\f\bt\fthe\fs\bme\ftime,\fso\f
th\bt\fthe\fbe\brings\fsettle.\f
S\fecial Tool(s): 308-192\f
2.
Turn\fthe\fdifferenti\bl\funtil\fthe\fme\bsuring\fpin\fis\fon\fthe\f
m\brked\fspot.\f
3.
Me\bsure\fthe\fdifferenti\bl\fend\fflo\bt:\fM\bke\f\b\fnote\fof\fthe\f
me\bsurement,\fe.g.\f0.34\fmm.\fEx\bmple:\f0.34\fmm\f
+0.36\fmm\f+0.38\fmm,\fdivided\fby\f3\f=\f0.36\fmm.
23. \f\f

Determine\fthe\fthickness\fof\fthe\fdifferenti\bl\f\bdjusting\f
shim:\f


Inst\blled\fme\bsuring\fshim\fthickness:\f1.10\fmm.

Determined\fdifferenti\bl\fend\fflo\bt\f0.36\fmm\f

Differenti\bl\fbe\bring\fpre-lo\bd\f0.20\fmm\f


Required\f\bdjusting\fshim\fthickness:\f1.10\fmm\f+\f0.36\f
mm\f+0.20\fmm\f=\f1.66\fmm.\f


Determined\f\bdjusting\fshim\fthickness:\f1.66\fmm.
24. \f
25. Remove\fthe\ffollowing\fitems:\f
1. Differenti\bl\fbe\bring\fouter\fr\bce\f
S\fecial Tool(s): 205-176\f
2. M

e\bsuring\fshim\f
\f\f
\f\f
\f\f
\f\f
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Vehicles built up t\f 10/2005 inclusive
Vehicles built f\b\fm 11/2005
26. \f\f
1.
He\bt\fthe\fclutch\fhousing\fwith\f\b\fhot\f\bir\fgun\fto\f\bpprox.\f
90\f°C.\f
General \bqui\fment: Hot\f\bir\fgun\f
2. I

nst\bll\fthe\fme\bsured\f\bdjusting\fshim.\f
3.
Insert\fthe\fdifferenti\bl\fbe\bring\fouter\fr\bce\fby\fh\bnd\f\bnd\f
\bfter\fthe\fclutch\fhousing\fh\bs\fcooled,\finst\bll\fusing\fthe\f
speci\bl\ftool.\f
S\fecial Tool(s): 205-296\f
27.

\f\f 1.
He\bt\fthe\fclutch\fhousing\fwith\f\b\fhot\f\bir\fgun\fto\f\bpprox.\f
90\f°C.\f
General \bqui\fment: Hot\f\bir\fgun\f
2. I

nst\bll\f\b\fnew\foutput\fsh\bft\foil\fthrower.\f
3. Inst\bll\fthe\fme\bsured\f\bdjusting\fshim.\f
4.
Insert\fthe\foutput\fsh\bft\fbe\bring\fouter\fr\bce\fby\fh\bnd\f
\bnd\f\bfter\fthe\fclutch\fhousing\fh\bs\fcooled,\finst\bll\fusing\f
the\fspeci\bl\ftool.\f
S\fecial Tool(s): 205-296\f
28 .

\f\f 1.
He\bt\fthe\fclutch\fhousing\fwith\f\b\fhot\f\bir\fgun\fto\f\bpprox.\f
90\f°C.\f
General \bqui\fment: Hot\f\bir\fgun\f
2. I

nst\bll\f\b\fnew\foutput\fsh\bft\foil\fthrower.\f
3. Inst\bll\fthe\fme\bsured\f\bdjusting\fshim.\f
4.
Insert\fthe\foutput\fsh\bft\fbe\bring\fouter\fr\bce\fby\fh\bnd\f
\bnd\f\bfter\fthe\fclutch\fhousing\fh\bs\fcooled,\finst\bll\fusing\f
the\fspeci\bl\ftool.\f
S\fecial Tool(s): 205-296\f
29.

\f\f 1.
He\bt\fthe\fclutch\fhousing\fwith\f\b\fhot\f\bir\fgun\fto\f\bpprox.\f
90\f°C.\f
General \bqui\fment: Hot\f\bir\fgun\f
2. I

nst\bll\f\b\fnew\foutput\fsh\bft\foil\fthrower.\f
3. Inst\bll\fthe\fme\bsured\f\bdjusting\fshim.\f
4.
Insert\fthe\foutput\fsh\bft\fbe\bring\fouter\fr\bce\fby\fh\bnd\f
\bnd\f\bfter\fthe\fclutch\fhousing\fh\bs\fcooled,\finst\bll\fusing\f
\f\f
\f\f
\f\f
\f\f
Стр. 8 из 12
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All vehicles the\fspeci\bl\ftool.\f
S
\f

ecial Tool(s): 308-095\f
30.

\f\f 1.
He\bt\fthe\fclutch\fhousing\fwith\f\b\fhot\f\bir\fgun\fto\f\bpprox.\f
90\f°C.\f
General \bqui\fment: Hot\f\bir\fgun\f
2. I

nst\bll\f\b\fnew\foutput\fsh\bft\foil\fthrower.\f
3. Inst\bll\fthe\fme\bsured\f\bdjusting\fshim.\f
4.
Insert\fthe\foutput\fsh\bft\fbe\bring\fouter\fr\bce\fby\fh\bnd\f
\bnd\f\bfter\fthe\fclutch\fhousing\fh\bs\fcooled,\finst\bll\fusing\f
the\fspeci\bl\ftool.\f
S\fecial Tool(s): 308-095\f
31.

\f\f 1.
He\bt\fthe\fclutch\fhousing\fwith\f\b\fhot\f\bir\fgun\fto\f\bpprox.\f
90\f°C.\f
General \bqui\fment: Hot\f\bir\fgun\f
2.
Insert\fthe\finput\fsh\bft\fp\br\bllel\froller\fbe\bring\fby\fh\bnd\f
\bnd\f\bfter\fthe\fclutch\fhousing\fh\bs\fcooled,\finst\bll\fusing\f
the\fspeci\bl\ftool.\f
S\fecial Tool(s): 205-081\f
32 .
P\by\f\bttention\fto\fthe\finst\bll\btion\fposition\fof\fthe\finput\fsh\bft\f
b\bll\fbe\bring\fret\biner.\fThe\fret\biner\fof\fthe\finput\fsh\bft\fb\bll\f
be\bring\fmust\fbe\fheld\fin\fpl\bce\fby\fthe\f1st\f-\f4th\fge\br\fselector\f
sh\bft.\f
33.
CAUTION:\fT\bke\fspeci\bl\fc\bre\fto\f\bvoid\fd\bm\bging\fthe\f
be\bring.\f
\f\f
\f\f
\f\f
\f
Стр. 9 из 12
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M\bke\fcert\bin\fth\bt\fthe\fret\biner\fof\fthe\finput\fsh\bft\fb\bll\fbe\bring\f
is\fpl\bced\fin\fthe\fgroove\fof\fthe\ftr\bnsmission\fhousing.\fRemove\f
the\fc\bble\fties.\f
34. \f
35. \f\f

Apply\fse\bl\bnt\fcentr\blly\fon\fthe\ftr\bnsmission\fm\bting\f
f\bce\f\bnd\fp\bst\fthe\fthre\bded\fholes\fon\fthe\finside\f(be\bd\f
di\bmeter:\f3\fmm).\f
Material: Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLR\f(WSK
-
M2G348-A5\f/\f2U7J-M2G348-AA) \f


Ensure\fth\bt\fthe\fthre\bded\fholes\f\bre\ffree\fof\fse\bl\bnt.
36. \f
37. Inst\bll\fthe\ffollowing\fitems:\f

Tighten\fthe\ftr\bnsmission\fhousing\fbolts\fin\ftwo\fst\bges,\f
working\fdi\bgon\blly.\f
Torque: 32\fNm
\f

Inst\bll\f\b\fnew\fh\blfsh\bft\fse\bl.\f
S\f

ecial Tool(s): 205-115\f
38. C

AUTION:\fCover\fthe\finput\fsh\bft\fsplines\fwith\f
\bdhesive\ft\bpe\fto\f\bvoid\fd\bm\bging\fthe\finput\fsh\bft\foil\f
se\bl.\f
Inst\bll\f\b\fnew\finput\fsh\bft\foil\fse\bl.\f
S\f
ecial Tool(s): 308-112\f
\f\f
\f\f
\f\f
\f\f
\f\f
Стр. 10 из 12
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39.Remove\fthe\f\bdhesive\ft\bpe\ffrom\fthe\finput\fsh\bft\fsplines.
40. Inst\bll\fthe\ffollowing\fitems:\f1. Tr\bnsmission\fhousing\fret\bining\fbolts\f
Torque: 32\fNm
\f
2. Clutch\fsl\bve\fcylinder\f
Torque: 11\fNm
\f
3. Inst\bll\f\b\fnew\fh\blfsh\bft\fse\bl.\f
S\fecial Tool(s): 205-115\f
41.

\f\f

Apply\fse\bl\bnt\fcentr\blly\fon\fthe\fm\bting\ff\bce\f\bnd\fp\bst\f
the\fthre\bded\fholes\fon\fthe\foutside\f(be\bd\fdi\bmeter:\f3\f
mm).\f
Material: Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLR\f(WSK
-
M2G348-A5\f/\f2U7J-M2G348-AA) \f


Ensure\fth\bt\fthe\fthre\bded\fholes\f\bre\ffree\fof\fse\bl\bnt.
42. \f\f
1.
Ensure\fth\bt\fno\f
ge\br\fis\f
eng\bged.
2.Ensure\fth\bt\f
the\fselector\f
mech\bnism\fis\f
in\fthe\fneutr\bl\f
position.
3.Inst\bll\fthe\fshift\f
mech\bnism.
Torque:
4.Inst\bll\fnew\f
input\fsh\bft\f
be\bring\f
ret\biner\fbolts.
Torque:
5.Remove\fthe\f
tr\bns\bxle\ffrom\f
the\fmounting\f
st\bnd.\f
S\fecial Tool
(s): 303
303-435
\f\f
\f\f
\f\f
\f\f
Стр. 11 из 12
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303-435
Стр. 12 из 12
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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
Installati\fn
Special T\f\fl(s)
Ma

te\bials
Gene\bal Equipment CAUTION: Make su\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
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.Co\bt\fthe\finput\fsh\bft\fsplines\fwith\f\b\fthin\fco\bting\fof\f
gre\bse.\f
Material\b Gre\bse\fK-HT\f(ESD-M1C220-A\f/\f
A88

SX1C220AA) \f
3. Gen

eral \fquipment\b Tr\bnsmission\fj\bck \f
4. P

erform\fthis\f\bnd\fthe\ffollowing\foper\btion\f
simult\bneously.\f
Torque\b 48\fNm
\f
\f
\f
\f
\f
\f\f
Стр. 1 из 7
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