drive FORD S-MAX 2006 Service Repair Manual

Inst\bll\btion),\f
Front\fH\blfsh\bft\fRH\f(Remov\bl\f\bnd\f
Ins

t\bll\btion).\f
Steering\f\bngle-
dependent\f
tr\bnsmission\fnoise
\f
*CHECK\fdifferenti\bl\fsplines\ffor\fd\bm\bge.\fTurn\f
the\fdifferenti\bl\fbevel\fge\brs\f\bg\binst\fone\f
\bnother.\fFor\fthis\fpurpose,\fREMOVE\fthe\f
differenti\bl.\f\f
REFER\fto:\f Front\fH\blfsh\bft\fLH \f(205-04\fFront\f
Dri

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f
\f
Front\fH\blfsh\bft\fRH \f(205-04\fFront\fDrive\f
H\blf
sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
The\fengine\f\bnd\f
tr\bns\bxle\f
\bssembly\fis\fin\f
cont\bct\fwith\fthe\f
body.\f
*Look\ffor\fpoints\fof\fcont\bct\f\bnd\fREPAIR\f\bs\f
necess\bry.\f
*
Coll\br\fscrews\f–\f
engine/ge\brbox\f
*TIGHTEN\fthe\ftr\bnsmission\fbolts.REFER\fto:\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-
TDCi\f(Lynx)\f
Diesel \f(308-03A\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\f
Inst\bll\btion),\f
Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4 \f(308-
03A\f
M\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fInst\bll\btion),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-
TDCi\f(Lynx)\f
Diesel\f(308-03B\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Inst\bll\btion),\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:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Inst\bll\btion),\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:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fM66,\f
Inst\bll\btion).\f
*
Tr\bns\bxle\ffluid\f
level\flow.\f
*Check\fthe\ftr\bnsmission\ffluid\flevel.\f
*
Tr\bns\bxle\f
be\brings\f\bnd\fge\br\f
wheels\f(usu\blly\fon\f
high-mile\bge\f
vehicles).\f
*
REMOVE\fthe\ftr\bns\bxle.\fCHECK\fthe\fbe\brings\f
\bnd\fge\br\fwheels\f\bnd\fINSTALL\fnew\f
components\f\bs\fnecess\bry.REFER\fto:\f Tr\bnsmission\f-\f1.8L\fDur\btorq-
TDCi\f(Lynx)\f
Diesel \f(308-03A\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\f
Remov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f
(1 0

7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4 \f(308-
03A\f
M\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
*
Стр. 5 из
20
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510462&gui...procarmanuals.com
http://vnx.su

Pinp\fint test
Drivesh\bft\fguide\fbe\bring\f
Excessive\fcr\bnksh\bft\fend\fpl\by.\f
*
*Pinpoint\fTest\f
E.\f
\f
Fluid\fLe\bk\bgeClutch\fm\bster\fcylinder\f
Clutch\fsl\bve\fcylinder\f
Hydr\bulic\flines\fin\f\bre\b\fof\fengine\f\bnd\f
tr\bnsmission\f
*
*
*GO\fto\f
Pinpoint\fTest\f
F.\f \f
*
PINPOINT TEST A : CLUTCH SLIPPING
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
A1: TEST CLUTCH SLIPPAGE
Lock\fthe\fwheels\f\bnd\f\bpply\fthe\fp\brking\fbr\bke.\f1
Ignition\fswitch\fin\fposition\fIII.\f2
St\brt\fthe\fengine,\fdepress\fthe\fclutch\fped\bl\f\bnd\feng\bge\ffourth\fge\br.\f3
Run\fthe\fengine\f\bt\f\bpprox.\f2000\frpm.\f4
Rele\bse\fthe\fclutch\fped\bl\fslowly.\f5
Does\fthe\fengine\fst\bll\fwhen\fthe\fclutch\fped\bl\fis\ffully\frele\bsed?\f
Yes Clutch\fOK.\f
N\f GO\fto\fA2.\f\f
A2: CHECK CLUTCH PEDAL FREE PLAY
Me\bsure\fthe\fclutch\fped\bl\ffree\fpl\by.\f1
Depress\fthe\fclutch\fped\bl\fby\fh\bnd\funtil\f\bn\fincre\bse\fin\fresist\bnce\fis\fcle\brly\f
felt,\fthen\frele\bse\fthe\fclutch\fped\bl\f\bg\bin.\f2
Is\fthe\fclutch\fped\bl\ffree\fpl\by\f\bpprox.\f10\fmm?\f
Yes Clutch\fped\bl\ffree\fpl\by\fOK.\f
N\f GO\fto\fA3.\f\f
A3: CHECK THE CLUTCH DIAPHRAGM SPRING
Remove\fthe\ftr\bnsmission.\fCHECK\fthe\fclutch\fdi\bphr\bgm\fspring.\fREFER\fto:\f
Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0
L\fDur\btec-
HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4 \f(308-03A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel \f(308-03A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.
0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\f2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f(308-03B\f
M\bnu

\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fMMT6,\fRemov\bl),\f Tr\bnsmission\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
M66,\fRemov\bl).\f
1
Is\fthe\fclutch\fdi\bphr\bgm\fspring\fbroken?\f
Yes
Renew\fthe\fclutch\fset.\f
N\f GO\fto\fA4.\f\f
A4: TEST CLUTCH FRICTION DISK
Remove\fthe\fclutch\fdisc\f\bnd\fclutch\fpressure\fpl\bte.\f\f1
Is\fthe\fclutch\fdisc\fcont\bmin\bted\fwith\foil\for\fthe\fclutch\fpressure\fpl\bte\fbroken?\f
Стр. 7 из 20
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510462&gui...procarmanuals.com
http://vnx.su

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
Стр. 2 из
4
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G544130&gui...procarmanuals.com
http://vnx.su

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
Стр. 2 из
4
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G544130&gui...procarmanuals.com
http://vnx.su

10. Refer\fto:\fDriver\fLower\fAir\fB\bg\fModule\f(501-20B\f
Sup
plement\bl\fRestr\bint\fSystem,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
11. \f
12. \f
13. Torque:\b 28\fNm
\f
14. Torque:\b 28\fNm
\f
\f\f
\f\f
\f\f
\f\f
Стр. 3 из
5
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G544132&gui...procarmanuals.com
http://vnx.su

Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 5-Speed Manual T\bansaxle - MTX75
- Specificati\fnsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Capacities
T\bansmissi\fn \bati\fs
Shim thickness \bequi\bed
Liters
M\bnu\bl\ftr\bnsmission\ffluid\f(0-5\fmm\fbelow\fthe\flower\fedge\fof\fthe\ffiller\fhole)1.9
1\b8L diese\f engine2\b0L engine
1st\fge\br3.8003.800
2nd\fge\br2.0482.136
3rd\fge\br1.2581.483
4th\fge\br0.8651.114
5th\fge\br0.6740.902
Reverse\fge\br3.7273.727
Fin\bl\fdrive3.5634.067
DescriptionInput shaftOutput shaftDifferentia\f assemb\fy
Me\bsuring\fshims\f(mm)1.001.001.10
Me\bsured\fend\fflo\bt\f
(ex\bmple)\f(mm)+\f0.22+\f0.32+\f0.36
Prelo\bd\ffigure\f(mm)–+\f0.13+\f0.33
End\fflo\bt\f(mm)–\f0.07––
Required\fshim\fthickness\f
(ex\bmple)\f(mm)=\f1.15=\f1.45=\f1.79
Shims\f\bv\bil\bble\f(mm)1.15\f–\f1.71\f(in\fsteps\f
of\f0.01\fmm)
1.31\f–\f1.91\f(in\fsteps\f
of\f0,02\fmm)
1.40\f–\f2.20\f(in\fsteps\fof\f
0.05\fmm)
Стр. 1 из 1
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510570&gui...procarmanuals.com
http://vnx.su

Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 5-Speed Manual T\bansaxle - MTX75
- Manual T\bansaxleS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Desc\bipti\fn and Ope\bati\fn
Manual T\bansmissi\fn
MT

X-75\fme\bns:\f

M:\fM\bnu\bl\f\f

T:\fTr\bnsmission\f\f

X:\fTr\bns\bxle\f(front\fwheel\fdrive)\f\f

75:\fDist\bnce\fbetween\finput\f\bnd\foutput\fsh\bft\fin\fmm.\f\f

Tr\bnsmission\fwith\fdifferent\f\bxes\f(input\f\bnd\foutput\fsh\bfts)\f\f

The\ffin\bl\fdrive\fis\fintegr\bted\finto\fthe\ftr\bnsmission\fhousing.\f

5-speed\fm\bnu\bl\ftr\bnsmission\ffor\fFWD\f\f

1st/2nd\fge\br\fdouble\fsynchroniser\f\f

3rd/4th\fge\br\f\bnd\f5th/reverse\fge\br\fsingle\fsynchroniser\f
Overview\f
\f\f
Desc\bipti\fn
Tr\bns\bxle\fhousing\f-\fclutch\fside\f
Item 1
\f
Pa\bt Numbe\b -
-
Стр. 1 из 9
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G428671&gui...procarmanuals.com
http://vnx.su

Ge\br\fwheel\f-\f4th\fge\br\f
Sn\bp\fring\f
Needle\froller\fbe\bring\f-\f5th\fge\br\f
Ge\br\fwheel\f-\f5th\fge\br\f
Synchroniser\fring\f-\f5th\fge\br\f
5th/reverse\fge\br\fsynchronizer\f\bssembly\f
Sn\bp\fring\f
Reverse\fge\br\fsynchroniser\fring\f
Reverse\fge\br\fneedle\froller\fbe\bring\f
Ge\br\fwheel\f-\freverse\fge\br\f
T\bpered\froller\fbe\bring\f(tr\bns\bxle\fside)\f
The\freverse\fge\br\fidler\fruns\fon\f\b\fneedle\froller\fbe\bring\fon\fthe\freverse\fge\br\fidler\fspindle.\f
Th

e\freverse\fge\br\fidler\fis\fdriven\fby\fthe\finput\fsh\bft.\fIts\ffunction\fis\fto\freverse\fthe\fdirection\fof\f
rot\btion\fof\fthe\foutput\fsh\bft\fin\freverse\fge\br.\f
Reverse\fge\br\fidler\f
\f\f
Desc\bipti\fn
Mounting\f
Thrust\fw\bsher\f
Reverse\fge\br\fidler\f
Needle\froller\fbe\bring\f
Thrust\fw\bsher\f
Neut\bal p\fsiti\fn sens\f\b
V e

hicles\fwith\f\buto\fst\brt/stop\ffunction\f
17
18
1

9
20
21
22
23
24
25
26
27
Item 1
2
3
4
5 -
-
-
-
-
-
-
-
-
-
\f
Pa\bt Numbe\b
-
-
-
-
-
Стр. 8 из 9
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G428671&gui...procarmanuals.com
http://vnx.su

On\fvehicles\fwith\f\buto\fst\brt/stop\ffunction,\finform\btion\fis\frequired\f\bbout\fwhether\f\b\fge\br\fis\f
eng\bged\for\fthe\ftr\bnsmission\fis\fin\fneutr\bl.\fThe\fneutr\bl\fposition\fsensor\fis\floc\bted\fon\fthe\f
tr\bnsmission\fhousing\ffor\fthis\fpurpose.\fThis\fis\fconnected\fto\fthe\fshift\flink\bge\fby\f\bn\f\bddition\bl\f
link\bge\fon\fthe\ftr\bnsmission.\f
The\fneutr\bl\fposition\fsensor\fis\f\b\fH\bll\fsensor\f\bnd\fis\fsupplied\fwith\f5\fVolt\fby\fthe\fPCM.\fThe\f
sign\bl\fvolt\bge\fv\bries\fbetween\f0.5\f\bnd\f5\fVolt\fwhen\foper\bting\fthe\flink\bge\f\bnd\fis\fmonitored\f
by\fthe\fPCM.\f
A\ffixed\fvolt\bge\fv\blue\fis\fstored\fin\fthe\fPCM\ffor\fe\bch\fge\br.\fAll\fv\blues\flying\fbetween\fthose\ffor\f
the\findividu\bl\fge\brs\f\bre\fstored\f\bs\fv\blues\ffor\fthe\fneutr\bl\fposition.\fThe\fPCM\ftherefore\f\blw\bys\f
detects\fwhether\for\fnot\f\b\fge\br\fis\feng\bged.\f
After\frepl\bcing\fthe\fsensor,\fthe\fv\blue\ffrom\fthe\fold\fsensor\fis\freset\fin\fthe\fPCM\fusing\fIDS.\fThe\f
vehicle\fmust\fthen\fbe\fdriven\f\b\fcert\bin\fdist\bnce\fso\fth\bt\fthe\fPCM\fc\bn\fle\brn\fthe\fnew\fv\blues\ffor\f
the\frelev\bnt\fge\brs\f\bnd\fneutr\bl\fpositions.\f
To\fdo\fthis,\fthe\fvehicle\fmust\fbe\fdriven\f\b\ftot\bl\fof\f5\ftimes\ffor\f10\fseconds\fe\bch,\f\bltern\btely\fin\f
3rd\f\bnd\f4th\fge\br\fwith\flow\f\bcceler\btion.\f
NOTE:\fIf\f\b\ff\bult\foccurs\fon\fthe\fneutr\bl\fposition\fsensor
\fwhen\fthe\fengine\fis\fst\btion\bry,\fthe\f
vehicle\fc\bn\fstill\fbe\fst\brted\fwith\fthe\fignition\fkey.\fIn\fthis\fc\bse,\f\b\fcorresponding\fDTC\fis\fset\f
in\fthe\fPCM.\f

no\fsign\bl\f\f

defective\fsign\bl\f
\f
Стр. 9 из 9
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G428671&gui...procarmanuals.com
http://vnx.su

Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 5-Speed Manual T\bansaxle - MTX75
- Halfshaft Seal LHS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\fval and Installati\fn
Special T\f\fl(s)
Rem\fval
In

stallati\fn
205-115\f
Inst\bller,\fDrive\fPinion\fSe\bl
\f
308-208\f
Remover,\fH\blfsh\bft\fSe\bl\f 1. Remove\fthe\fleft-h\bnd\ffront\fdrivesh\bft.\fRefer\fto:\f Front\fH\blfsh\bft\fLH \f(205-04\fFront\fDrive\f
H\bl f

sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Special\bTool(\f):\b 308-208\f
1. Sp

ecial\bTool(\f):\b 205-115\f
2. I

nst\bll\fthe\fleft-h\bnd\ffront\fdrivesh\bft.\f
Refer\fto:\f Front\fH\blfsh\bft\fLH \f(205-04\fFront\fDrive\f
H\blf

sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. Check\fthe\flevel\fof\fthe\ftr\bnsmission\ffluid.\f
Refer\fto:\f Tr\bnsmission\fDr\bining\f\bnd\fFilling \f(308-
03A

\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\f
Gener\bl\fProcedures).\f
Refer\fto:\f Tr\bnsmission\fDr\bining\f\bnd\fFilling \f(308-
03 B

\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Gener\bl\fProcedures).\f
\f
\f
\f\f
\f\f
Стр. 1 из 1
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G544153&gui...procarmanuals.com
http://vnx.su