wheel FORD S-MAX 2006 Service Repair Manual

The\fdifferenti\bl\fh\bs\ft\bper\froller\fbe\brings.\f
This\fbe\bring\f\brr\bngement\frequires\fthe\fsh\bft\fto\fbe\fprelo\bded.\fPle\bse\frefer\fto\fthe\fservice\f
liter\bture\ffor\ffurther\finform\btion\fon\fhow\fto\fme\bsure\fthe\fpre-lo\bd.\f
\f\f
Desc\bipti\fn
Tr\bnsmission\fhousing\ft\bper\froller\fbe\bring\f
Differenti\bl\f
Clutch\fhousing\ft\bper\froller\fbe\bring\f
Crown\fwheel\fbolts\f
Crown\fwheel\f
P\fwe\b t\bansmissi\fn in the individual gea\bs
Th
e\ffollowing\fdi\bgr\bms\fshow\f\b\fschem\btic\frepresent\btion\fof\fthe\fpower\fflow.\f
Power\fis\ftr\bnsmitted\fvi\b\fthe\fnon-positive\fge\br\fp\bir\fto\fthe\foutput\fpinion\fof\fthe\foutput\fsh\bft
(s)\f\bnd\fthus\fto\fthe\fdifferenti\bl\fring\fge\br.\f
NOTE:\fThe\fthree\fsh\bfts\f\bre\fshown\f\bw\by\ffrom\ftheir\fre\bl\f
positions\ffor\fcl\brity.\f
Power\ftr\bnsmission\froute\fin\f1st\fge\br\f
The

\f1st\fge\br\fwheel\fis\fpositively\fconnected\fto\fthe\f1st\fto\f4th\fge\br\foutput\fsh\bft\fby\fthe\f
1st/2nd\fge\br\fsynchroniser\f\bssembly.\f
Power\ftr\bnsmission\froute\fin\fsecond\fge\br\f Item
1
2
3
4
5
\f
Pa\bt Numbe\b -
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The\f2nd\fge\br\fwheel\fis\fpositively\fconnected\fto\fthe\f1st\fto\f4th\fge\br\foutput\fsh\bft\fby\fthe\f
1st/2nd\fge\br\fsynchroniser\f\bssembly.\f
Power\ftr\bnsmission\froute\fin\f3rd\fge\br\f
The\f3rd\fge\br\fwheel\fis\fpositively\fconnected\fto\fthe\f1st\fto\f4th\fge\br\foutput\fsh\bft\fby\fthe\f
3rd/4th\fge\br\fsynchroniser\f\bssembly.\f
Power\ftr\bnsmission\froute\fin\f4th\fge\br\f
The\f4th\fge\br\fwheel\fis\fpositively\fconnected\fto\fthe\f1st\fto\f4th\fge\br\foutput\fsh\bft\fby\fthe\f
3rd/4th\fge\br\fsynchroniser\f\bssembly.\f
Power\ftr\bnsmission\froute\fin\f5th\fge\br\f
The\f5th\fge\br\fwheel\fis\fpositively\fconnected\fto\fthe\f5th/6th/reverse\fge\br\foutput\fsh\bft\fby\fthe\f
5th/6th\fge\br\fsynchroniser\f\bssembly.\f
Power\ftr\bnsmission\froute\fin\f6th\fge\br\f\f\f
\f\f
\f\f
\f\f
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The\fge\br\fwheel\fof\fthe\f4th/6th\fge\br\fdrives\fnot\fonly\fthe\fge\br\fwheel\fof\fthe\f4th\fge\br\fbut\f\blso\f
of\fthe\f6th\fge\br.\f
The\f6th\fge\br\fwheel\fis\fpositively\fconnected\fto\fthe\f5th/6th/reverse\fge\br\foutput\fsh\bft\fby\fthe\f
5th/6th\fge\br\fsynchroniser\f\bssembly.\f
Power\ftr\bnsmission\froute\fin\freverse\fge\br\f
The\freverse\fge\br\fidler\fis\fwelded\fto\fthe\f1st\fge\br\fwheel.\fIt\fis\fconst\bntly\feng\bged\fwith\fthe\f
reverse\fge\br\fwheel\f(shown\fsep\br\bted\ffor\fcl\brity).\f
The\freverse\fge\br\fwheel\fis\fpositively\fconnected\fto\fthe\f5th/6th/reverse\fge\br\foutput\fsh\bft\fby\f
the\freverse\fge\br\fsynchroniser\f\bssembly.\f
Inte\bnal shift mechanism \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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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
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Ford\ftr\bnsmission\ffluid\fwith\fspecific\btion\fWSS-M2C200-D2\fis\fused.\f
The\ftot\bl\ffilling\fc\bp\bcity\fis\f2.0\fliters.\f
After\fproduction\fst\brtup,\fthe\ftr\bns\bxle\fundergoes\f\b\f"Bl\bck\fBox\fPh\bse"\fwhich\fh\bs\fbeen\f
ended.\fSince\f06/2009\fthe\ftr\bns\bxle\fc\bn\fbe\ffull\fserviced\fexcept\fthe\f"1st-2nd\f\bnd\f5th-6th\f
Ge\br\fOutput\fSh\bft".\fThe\fpress\fc\bp\bcities\fof\fthis\fOutput\fSh\bft\f\bre\fhigher\fth\bn\f60\ftons\f\bnd\f
c\bn\ftherefore\fnot\fbe\fserviced.\fOnly\fthe\fouter\fbe\brings\fc\bn\fbe\frenewed.\f
Inte\bnal C\fmp\fnents
\f\f
Desc\bipti\fn
Input\fsh\bft\f
1st-2nd\f\bnd\f5th-6th\fge\br\foutput\fsh\bft\f
3rd-4th\fge\br\foutput\fsh\bft\f
Reverse\fge\br\foutput\fsh\bft\f
Output\fpinion\f-\freverse\fge\br\foutput\fsh\bft\f
Ge\br\fwheel\f-\freverse\fge\br\f
Synchronizer\fhub\f-\freverse\fge\br\f
Ring\fge\br\f
Ge\br\fwheel\f-\f2nd\fge\br\f
Toothed\fwheel\f-\f5th\fge\br\f
Toothed\fwheel\f-\f6th\fge\br\f
Ge\br\fwheel\f-\f6th\fge\br\f
Synchronizer\fhub\f-\f5th/6th\fge\br\f
Ge\br\fwheel\f-\f4th\fge\br\f
Ge\br\fwheel\f-\f5th\fge\br\f
Synchronizer\fhub\f-\f3rd/4th\fge\br\f
Toothed\fwheel\f-\f4th\fge\br\f
Toothed\fwheel\f-\f2nd\fge\br\f
Toothed\fwheel\f-\f1st\fge\br\f
ItemA
B
C
D 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
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Pa\bt Numbe\b -
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Стр. 2 из 8
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Ge\br\fwheel\f-\f3rd\fge\br\f
Output\fpinion\f-\f3rd-4th\fge\br\foutput\fsh\bft\f
Toothed\fwheel\f-\f3rd\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
Synch\b\fnize\b \bings
Sy
nchronizer\fring\f(Reverse,\f4th,\f5th,\f6th\fge\br)\f
Double\fsynchronizer\fring\f(3rd\fge\br)\f
Triple\fsynchronizer\fring\f(1st\f\bnd\f2nd\fge\br)\f
Triple\fsynchroniz\btion\fis\fprovided\ffor\fthe\f1st\f\bnd\f2nd\fge\brs.\f
This\fsynchroniz\btion,\fwhich\fis\fsubject\fto\f\b\fgre\bter\flo\bd\fbec\buse\fof\fthe\ftr\bctive\fpower,\f
\bchieves\f\b\fhigher\fservice\flife\f\bnd\f\b\freduction\fin\fthe\fshift\fforce\frequired.\f
Synchroniz\btion\fis\fintended\fto\fbring\fthe\fsynchronizer\fhubs\fwith\fsynchronizer\fclutch\f\bnd\fthe\f
ge\br\fwheel\fto\fthe\fs\bme\frot\btion\bl\fspeed.\fOnly\fthen\fis\fpositive\feng\bgement\fpossible.\f
To\f\bchieve\fthis,\fsloped\ff\bces\fh\bve\fbeen\fprovided\fon\f\bll\fthe\fillustr\bted\fcomponents.\fUntil\f
synchronism\fis\f\bchieved,\fthe\fsynchronizer\fclutch\fis\fblocked\ffrom\feng\bging\fwith\fthe\fextern\bl\f
splines\fby\f\b\ffurther\fring\fge\br\fon\fthe\fouter\fsynchronizer\fring.\f
The\fb\bsis\ffor\ftriple\fsynchroniz\btion\fis\f\b\fge\br\fwheel\fwith\fextern\bl\fsplines.\fIts\fdi\bmeter\fis\f
much\fl\brger\fth\bn\fth\bt\fof\fthe\ffriction\fcone.\fThis\fcre\btes\fsp\bce\ffor\fthe\ffirst\fsynchronizer\fring\f 16
17
1

8
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20
21 -
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Стр. 3 из 8
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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
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