drive FORD S-MAX 2006 Service Repair Manual

Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - MMT6 -
Halfshaft Seal RHS-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\fright-h\bnd\ffront\fdrivesh\bft.\fRefer\fto:\f Front\fH\blfsh\bft\fRH \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\fright-h\bnd\ffront\fdrivesh\bft.\f
Refer\fto:\f Front\fH\blfsh\bft\fRH \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
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - MMT6 -
Input Shaft SealS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\fval and Installati\fn
Special T\f\fl(s)
Rem\fval
303-336\f
Remover,\fCr\bnksh\bft\fRe\br\fSe\bl\f
308-112\f
Inst\bller,\fOutput\fDrive\fFl\bnge\fSe\bl
\f
1. 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,\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
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,\fRemov\bl).\f
2. 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
3. CAUTION:\fT\bke\fspeci\bl\fc\bre\fto\f\bvoid\f
d\b

m\bging\fthe\fbe\bring.\f
Special\bTool(\f):\b 30
3-336\f
4. \f\f
1. Self-cutting\fscrew,\f2.5\fx\f15\fmm\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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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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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - MMT6 -
T\bansmissi\fn
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Disassembly
Special T\f\fl(s) All vehicles
205-078\f
Remover,\fDrive\fPinion\fSe\bl\f
205-078-01\f
Ad\bpter\ffor\f205-078\f(Thrust\fP\bd)\f
205-080\f
Inst\bller,\fDifferenti\bl\fBe\bring\f
205-176\f
Remover,\fDifferenti\bl\fBe\bring\fCone
\f
303-435\f
Mounting\fSt\bnd\f
303-435-04\f
Mounting\fBr\bcket\ffor\f303-435\f
303-435-12A\f
Mounting\fPl\bte\ffor\f303-435-04\f
308-208\f
Remover,\fH\blfsh\bft\fSe\bl\f 1. \f\f1.
Mount\fthe\f
tr\bns\bxle\f
on\fthe\f
mounting\f
st\bnd.\f
Special\b
Tool(\f):\b
303-435
303-435
04,\f303
435-12A
2.NOTE:\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 -
1st-4th Gea\b Output ShaftS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Disassembly and Assembly \ff Subassemblies
Special T\f\fl(s)
Mat

e\bials
Gene\bal Equipment
Disassembly CA

UTION:\fM\bke\fsure\fvice\fj\bw\fprotectors\f\bre\fused.\f All\fvehicles\f
204-050\f
Inst\bller,\fFront\fWheel\fHub\fBe\bring\fCup/Se\bl\f
205-071-01\f
Ad\bpter\ffor\f205-071\f(Thrust\fP\bd)\f
205-295\f
Remover,\fBe\bring\f(M\bin\fTool)\f
308-046\f
Inst\bller,\fTr\bnsmission\fExtension\fHousing\fBushing/Se\bl
\f
308-196\f
Collet\ffor\f205-295\f
308-197\f
Collet\ffor\f205-295\f
308-604\f
Inst\bller,\fOutput\fDrive\fFl\bnge\fSe\bl\f
NameSpec\bf\bcat\bo\f
Tr\bnsmission\fOil\f75W\fFEWSS-M2C200-D2\f/\f7U7J-M2C200-BA
Hot\f\bir\fgun
1. Cl\bmp\fthe\foutput\fsh\bft\fin\fthe\fvice.\f
2.Special\bTool(\f):\b 205-071-01,\f205-295,\f 308-197\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 -
5th-6th and Reve\bse Gea\b Output ShaftS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Disassembly and Assembly \ff Subassemblies
Special T\f\fl(s)
Mat

e\bials
Gene\bal Equipment
Disassembly CA

UTION:\fUse\fprotective\fcovers.\f All\fvehicles\f
204-050\f
Inst\bller,\fFront\fWheel\fHub\fBe\bring\fCup/Se\bl\f
205-071-01\f
Ad\bpter\ffor\f205-071\f(Thrust\fP\bd)\f
205-295\f
Remover,\fBe\bring\f(M\bin\fTool)\f
308-046\f
Inst\bller,\fTr\bnsmission\fExtension\fHousing\fBushing/Se\bl
\f
308-196\f
Collet\ffor\f205-295\f
308-197\f
Collet\ffor\f205-295\f
308-604\f
Inst\bller,\fOutput\fDrive\fFl\bnge\fSe\bl\f
NameSpec\bf\bcat\bo\f
Tr\bnsmission\fOil\f75W\fFEWSS-M2C200-D2\f/\f7U7J-M2C200-BA
Hot\f\bir\fgun
1. Cl\bmp\fthe\foutput\fsh\bft\fin\f\b\fvise.\f
2.Special\bTool(\f):\b 205-071-01,\f205-295,\f 308-197\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
S-MAX/G\bl\bxy\f2006.5\f(02/2006
Assembly
Special T\f\fl(s)
205-044-01\f
Ad\bpter\ffor\f205-044\f
205-070\f
Holding\fFixture,\fDi\bl\fIndic\btor\fG\buge\f
205-081\f
Inst\bller,\fDifferenti\bl\fBe\bring\f
205-115\f
Inst\bller,\fDrive\fPinion\fSe\bl\f
205-176\f
Remover,\fDifferenti\bl\fBe\bring\fCone\f
205-217\f
Inst\bller,\fRe\br\fWheel\fHub\fBe\bring\fCone/Se\bl\f
205-296\f
Inst\bller,\fWheel\fHub\fBe\bring\fCone/Se\bl\f
206-003\f
Holding\fFixture,\fDi\bl\fIndic\btor\fG\buge\f(Disc\fBr\bke)
\f
303-435\f
Mounting\fSt\bnd\f
303-435-04\f
Mounting\fBr\bcket\ffor\f303-435\f
303-435-12A\f
Mounting\fPl\bte\ffor\f303-435-04\f
307-300-02\f
Depth\fG\buge,\fShim\fSelection\f
\f
\f
\f
\f
\f
\f
\f
\f
\f
\f
\f
\f
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Mate\bials
Gene\bal Equipment
NOTE: The t\bansmissi\fn must c\f\fl t\f \b\f\fm tempe\batu\be bef\f\be pe\bf\f\bming measu\bements.
All vehicles
307-300-03\f
Ad\bpter\ffor\f307-300-02\f
307-430\f
G\buge,\fTr\bnsmission\fEnd\fPl\by\f
308-095\f
Inst\bller,\fInput\fSh\bft\fBe\bring\f
308-112\f
Inst\bller,\fOutput\fDrive\fFl\bnge\fSe\bl\f
308-192\f
Remover,\fH\blfsh\bft\f
308-603\f
G\buge,\fDifferenti\bl/Tr\bnsfer\fGe\br\fBe\bring\fShim\f
NameSpec\bf\bcat\bo\f
Fl\bnge\fSe\bl\bnt\f-\fAn\berobic\fLRWSK-M2G348-A5\f/\f2U7J-M2G348-AA
H\ft ai\b gun1. \f\f1. H
e\bt\fthe\ftr\bnsmission\fhousing\fto\f\bpprox.\f90\f
°
\b\fhot\f\bir\fgun.\f
General \bqui\fment: Hot\f\bir\fgun\f
2.
Insert\fthe\foutput\fsh\bft\fbe\bring\fouter\fr\bce\fby\fh\bnd\f
\bnd\f\bfter\fthe\ftr\bnsmission\fhousing\fh\bs\fcooled,\finst\bll\f
using\fthe\fspeci\bl\ftool.\f
S\fecial Tool(s): 205-217\f
2. \f

\f 1. He\bt\fthe\ftr\bnsmission\fhousing\fto\f\bpprox.\f90\f
°
\b\fhot\f\bir\fgun.\f
General \bqui\fment: Hot\f\bir\fgun\f
2.
Insert\fthe\foutput\fsh\bft\fbe\bring\fouter\fr\bce\fby\fh\bnd\f
\f
\f
\f
\f
\f
\f
\f\f
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15. Inst\bll\fthe\ffollowing\fitems:\f1. c\bt\blytic\fconverter\f
Refer\fto:\f C\bt\blytic\fConverter \f(309-00D\f
Ex h

\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
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. Subfr\bme\f
Refer\fto:\f Front\fSubfr\bme \f(502-00\fUni-
Bod

y,\fSubfr\bme\f\bnd\fMounting\fSystem,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
16. Torque\b 40\fNm
\f
17. \f\f 1.Torque\b 25\fNm
\f
2. Torque\b 10\fNm
\f
18. Torque\b 25\fNm
\f
\f\f
\f\f
\f\f
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