drive FORD S-MAX 2006 Service Repair Manual

15.Remove the Special Tool(s)\b 303-290B,\f303-290-
13 ,\f3
03-290A-15 ,\f303-290B-16 \f
16.

Inst\bll\fthe\fc\bt\blytic\fconverter.\f
Refer\fto:\f C\bt\blytic\fConverter \f(309-00E\fExh\bust\f
Sy s

tem\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(100kW/136PS)\f-\f
DW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
Emission\fRequirements:\fSt\bge\fIV,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
17. \f\f 1.Torque\b 10\fNm
\f
2. Torque\b 10\fNm
\f
18. Inst\bll\fthe\ffollowing\fitems:\f 1. 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
Dr i

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. 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
19. \f\f 1.Torque\b 25\fNm
\f
2. Torque\b 80\fNm
\f
20. \f
\f\f
\f\f
\f\f
Стр. 4 из
6
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G544226&gui...procarmanuals.com
http://vnx.su

Manual T\bansmissi\fn/T\bansaxle - Vehicles With: 6-
Speed Manual T\bansaxle - M66 - Specificati\fnsS-MAX/G\bl\bxy\f2006.5\f(02/2006
Filling Capacities
Shim thickness calculati\fns
* If the thickness \ff the measu\bed shim is \fdd, select the shim with the next highe\b thickness value.
T\bansmissi\fn Rati\fs
T\f\bque Specifcati\fns
Tr\bnsmission\ffluid
TypeInpu\b sh\ff\b
1s\b-2nd \fnd 5\bh-6\bh ge\fr ou\bpu\b sh\ff\b
3rd-4\bh ge\fr ou\bpu\b sh\ff\bReverse ge\fr ou\bpu\b sh\ff\b
Me\bsuring\fshims\f(mm)----
Me\bsured\fend\fflo\bt\f
(ex\bmple)\f(mm)+1.12+1.13+1.27+1.40
Addition\fv\blue\f(mm)\fto\f
obt\bin\fcorrect\fbe\bring\f
pre-lo\bd+0.03+0.20+0.15+0.11
Required\fshim\fthickness\f
(ex\bmple)\f(mm)=\f1.15=\f1.33=\f1.42=\f1.51
Av\bil\bble\fshims\f(mm)0.60\f-\f1.17\f(in\f
0.03\fmm\f steps)*
0.93\f-\f1.74\f(in\f
0.03\fmm\fsteps)*0.60\f-\f1.17\f(in\f
0.03\fmm\fsteps) *0.57\f-\f1.11\f(in\f
0.03\fmm\fsteps)*
0.03\fmm\fsteps)*
ge\fr2.2L diesel engine2.5L Engine
1st\fge\br3.385
2nd\fge\br1.905
3rd\fge\br1.194
4th\fge\br0.838
5th\fge\br0.652
6th\fge\br0.540
Reverse0.773
Fin\bl\fdrive\fr\btio\f-\fforw\brds4.267
Fin\bl\fdrive\fr\btio\f-\freverse5.333
Descrip\bionNmlb-f\b
Reversing\fl\bmp\fswitch2418
Sh\bft\fdetent\fmech\bnism3022
Selector\fmech\bnism\fbolts2518
Стр. 1 из 1
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510601&gui...procarmanuals.com
http://vnx.su

Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
Manual T\bansmissi\fnS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Desc\bipti\fn and Ope\bati\fn
Ove\bview
Th

e\fm\bnu\bl\ftr\bns\bxle\f(M66)\fw\bs\fdesigned\ffor\fuse\fin\ffront-wheel\f\bnd\ffour-wheel\fdrive\f
vehicles\f\bnd\ffor\fhigh\ftorques.\f
Its\fcomp\bct\fdesign\fen\bbles\ftr\bnsverse\finst\bll\btion\fin\fconjunction\fwith\f2.5L\fDur\btec-ST\f
(VI5)\fengine\f(\bnd\f2.2L\fDur\btorq-TDCi\f(DW)\fDiesel\fengine).\f
The\ftr\bns\bxle\fis\fequipped\fwith\fsix\fforw\brd\fge\brs.\f
The\fbenefits:\f

Optimized\fgr\bdu\btion\fof\fspeed\fst\bges\f

Lower\ffuel\fconsumption\f

Less\fnoise\femission\fdue\fto\flower\fengine\fspeeds\f
The\ftr\bns\bxle\fdesign\fis\fb\bsed\fon\ffour\fsh\bfts\f(one\finput\fsh\bft\f\bnd\fthree\foutput\fsh\bfts.\fSee\f
\b l

so\fillustr\btion\fon\fnext\fp\bge).\f
All\fthe\fge\brs,\fincluding\fthe\freverse\fge\br,\f\bre\fsynchronized:\f

Single\fsynchroniz\btion\f-\f4th/5th/6th\f\bnd\freverse\fge\br\f

Du\bl\fsynchroniz\btion\f-\f3rd\fge\br\f

Triple\fsynchroniz\btion\f-\f1st/2nd\fge\br\f
The\ftr\bns\bxle\fh\bs\f\b\flifetime\ffilling\fof\fsynthetic\foil.\f
A n

\f\bperture\fis\fprovided\ffor\fchecking\fthe\flevel\f\bnd\ftopping\fup.\f
\f
Стр. 1 из 8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510602&gui...procarmanuals.com
http://vnx.su

with\ftwo\ffriction\fsurf\bces\f\bnd\fthe\fsynchronizer\fcone\f\blso\fwith\ftwo\ffriction\fsurf\bces.\fThe\f
outer\fsynchronizer\fcone\fis\fvirtu\blly\funch\bnged.\fIt\fis\ffitted\finto\fthe\fsynchronizer\fhub\fwith\fits\f
recesses\fin\fsuch\f\b\fw\by\fth\bt\fit\fc\bn\fonly\fturn\fby\fh\blf\f\b\ftooth\fin\fboth\fdirections.\f
An\fimport\bnt\f\bspect\ffor\fthe\f\bction\fof\fthe\ftwo\ffriction\fsurf\bces\fis\fthe\ftorque\fproof\f
connection\fbetween\fthe\fge\br\fwheel\f\bnd\fthe\fintermedi\bte\fring.\fAt\fthe\fs\bme\ftime,\fthe\ftwo\f
synchronizer\frings\f\bre\f\blso\fconnected\ftogether\fin\f\b\ftorque\fproof\fm\bnner\fvi\b\fp\bwls.\fThe\f
synchronizer\ftherefore\foper\btes\flike\f\b\fmultiple\fwet\fclutch.\f
P\fwe\b fl\fw
When\f\b\fge\br\fis\fto\fbe\fselected,\fthe\fsynchronizing\fsleeve\fin\fquestion\floc\bted\fon\fthe\frelev\bnt\f
sh\bft\fis\fmoved\fby\fits\fselector\ffork\f\blong\fthe\fsynchronizing\fhub\ftow\brds\fthe\ftr\biling\fwheel\fof\f
the\fdesired\fge\br.\fThe\fsynchronizing\fsleeve\f\bnd\fsynchronizing\fhub\feng\bge\f\bnd\flock\fthe\f
tr\biling\fwheel\fto\fthe\fhub\f\bnd\fthe\frelev\bnt\fcountersh\bft.\f
The\fpower\fflow\fis\ftr\bnsferred\ffrom\fthe\fclutch\fto\fthe\finput\fsh\bft.\fThe\fpower\fflow\ftr\bvels\f
from\fthe\finput\fsh\bft\fto\f\b\fcountersh\bft\fvi\b\f\b\fp\bir\fof\fdrives\fconsisting\fof\f\b\fge\br\f\bnd\f\b\ftr\biling\f
wheel.\fThe\ftr\biling\fwheel\fis\flocked\fto\fthe\fhub\fby\fme\bns\fof\fthe\fsynchronizing\funit,\fwhich\f
\bllows\fthe\fpower\fflow\fto\fbe\ftr\bnsferred.\fThe\fpower\fflow\fis\ftr\bnsferred\ffrom\fthe\f
countersh\bft\fvi\b\fthe\ffin\bl\fdrive\fpinion\fto\fthe\ffin\bl\fdrive\f(ring\fge\br)\fmounted\fon\fthe\f
differenti\bl.\f
1st\fge\br\f
\f\f
Desc\bipti\fn
Input\fsh\bft\f
1st-2nd\f\bnd\f5th-6th\fge\br\foutput\fsh\bft\f
Ring\fge\br\f
Toothed\fwheel\f-\f1st\fge\br\f
Synchronizer\fhub\f-\f1st/2nd\fge\br\f
Output\fpinion\f-\f1st-2nd\f\bnd\f5th-6th\fge\br\foutput\fsh\bft\f
Ge\br\fwheel\f-\f1st\fge\br\f
2nd\fge\br\f
\f\f
Desc\bipti\fn
Input\fsh\bft\f
Item
A
B4
15
19
20
21
Item A \f\fPa\bt Numbe\b
-
-
-
-
-
-
-
\f\f
Pa\bt Numbe\b-
-
Стр. 4 из 8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510602&gui...procarmanuals.com
http://vnx.su

Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
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
308-208\f
Remover,\fH\blfsh\bft\fSe\bl\f
308-789\f
Inst\bller,\fDrivesh\bft\fSe\bl
\f
1. Remove\fthe\fleft-h\bnd\ffront\f\bxle\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
2. Special\bTool(\f):\b 308-208\f
1. Sp

ecial\bTool(\f):\b 308-789\f
2. I

nst\bll\fthe\fleft-h\bnd\ffront\f\bxle\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
\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=G545805&gui...procarmanuals.com
http://vnx.su

Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
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
308-119\f
Inst\bller,\fH\blfsh\bft\fSe\bl\f
308-208\f
Remover,\fH\blfsh\bft\fSe\bl
\f
1. Remove\fthe\fright-h\bnd\ffront\f\bxle\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
2. Special\bTool(\f):\b 308-208\f
1. Sp

ecial\bTool(\f):\b 308-119\f
2. I

nst\bll\fthe\fright-h\bnd\ffront\f\bxle\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
\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=G545806&gui...procarmanuals.com
http://vnx.su

11. \f
12. Remove\fsubfr\bme\ffrom\fvehicle.\fRefer\fto:\f Front\fSubfr\bme \f(502-00\fUni-Body,\f
Su b

fr\bme\f\bnd\fMounting\fSystem,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
13. Remove\fthe\f\bxle\fsh\bfts.\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
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
14. \f
15. \f
16. Special\bTool(\f):\b 303-290B,\f303-290-13 ,\f303-
29 0

A-15 ,\f303-290B-16 \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=G544229&gui...procarmanuals.com
http://vnx.su

Manual T\bansmissi\fn/T\bansaxle - Vehicles With:
6-Speed Manual T\bansaxle - M66 - T\bansmissi\fnS-MAX/G\bl\bxy\f2006.5\f(02/2006
Disassembly
Special T\f\fl(s)
Ge
ne\bal Equipment
205-078\f
Remover,\fDrive\fPinion\fSe\bl\f
205-078-01\f
Ad\bpter\ffor\f205-078\f(Thrust\fP\bd)\f
205-329\f
Mounting\fBr\bcket,\fEngine/Differenti\bl
\f
205-517\f
Remover\fRubber\fBe\bring\f
303-435\f
Mounting\fSt\bnd\f
303-435-06\f
Mounting\fBr\bcket\ffor\f303-435\f
308-208\f
Remover,\fH\blfsh\bft\fSe\bl\f
310-086\f
Remover,\fFuel\fInjector\f
Cable ties
Pulle\b
Punch
Ti\be leve\b 1. \f\f1.
Install t\be Spe\fial
Tool(s):
303
435
\f
\f
\f
\f
\f
\f
\f
\f
Стр. 1 из 6
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1276327&gu...procarmanuals.com
http://vnx.su

Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
Input 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
308-095\f
Inst\bller,\fInput\fSh\bft\fBe\bring\f
308-112\f
Inst\bller,\fOutput\fDrive\fFl\bnge\fSe\bl
\f
308-605\f
Inst\bller,\fInput\fSh\bft\fSe\bl\f
308-643\f
Inst\bller,\fInput\fSh\bft\fSe\bl\f
308-798\f
Inst\bller\fBe\bring\fCup\f
NameSpec\bf\bcat\bo\f
Se\bl\bnt\fLGNWSK-M2G349-A8\f/\f9U7J-M2G349-AA
Tr\bnsmission\fOil\f75W\fFEWSS-M2C200-D2\f/\f7U7J-M2C200-BA
Be\bring\fsep\br\btor
Hydr\bulic\fpress
\f
\f
\f
\f
\f
Стр. 1 из 4
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1214163&gu...procarmanuals.com
http://vnx.su

Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
1st-2nd and 5th-6th 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)
Gen

e\bal Equipment
Disassembly
205-046\f
Inst\bller,\fDrive\fPinion\fSe\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\f
Bushing/Se\bl\f
308-197\f
Collet\ffor\f205-295\f
308-798\f
Inst\bller\fBe\bring\fCup\f
Be\bring\fsep\br\btor
Hot\f\bir\fgun
Hydr\bulic\fpress 1. \f
\f
\f
\f
\f
\f
\f
Стр. 1 из 3
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1224430&gu...procarmanuals.com
http://vnx.su