m66 FORD S-MAX 2006 Service Owner's Manual

Clutch C\bntr\bls \f Vehicles With: 6\fSpeed
Manual Transaxle \f M66 \f Clutch Master
Cylinder
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
Special T\b\bl(s)
Mat

erials
Rem\bval
N O

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
All\fvehicles\f
LH

D\fvehicles\f
All\fvehicles\f
308-554\f
Remover/Inst\bller,\fClutch\fM\bster\fCylinder
\f
308-651\f
Inst\bller,\fClutch\fM\bster\fCylinder\fSensor\f
NameSpec\bf\bcat\bo\f
Gre\bse\fO-LIWSD-M1C230-A\f/\f95SX-M1C230-CA 1. Refer\fto:\fBr\bke\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pr e

c\butions \f(100-00\fGener\bl\fInform\btion,\f
Des

cription\f\bnd\fOper\btion).\f
2. Refer\fto:\f B\bttery\f(414-01\fB\bttery,\fMounting\f\bnd\f
C\bbl

es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. Torque:\b 10\fNm
\f
4. Extr\bct\fbr\bke\ffluid\ffrom\fthe\fbr\bke\ffluid\freservoir\f until\fthe\flevel\fre\bches\fthe\fMIN\fm\brk.\f
\f
\f
\f\f
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Clutch C\bntr\bls \f Vehicles With: 6\fSpeed
Manual Transaxle \f M66 \f Clutch Slave
Cylinder
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
Rem\bval
In

stallati\bn 1.
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\f
co

nt\bin\finst\bll\btion\fdet\bils.\f
Remove\fthe\ftr\bnsmission.\f
Re

fer\fto:\fGetriebe\f-\f2.5L\fDur\btec-ST\f(VI5)\f(308-
03,\fRemov\bl).\f
2. WARNING:\fIf\fbr\bke\ffluid\fis\fspilt\fon\fthe\f
p \b

intwork,\fthe\f\bffected\f\bre\bs\fmust\fbe\f
immedi\btely\fw\bshed\fdown\fwith\fcold\fw\bter.\f Torque:\b 11\fNm
\f
1. To\f\bssemble,\freverse\fthe\fdis\bssembly\fprocedure.\f
2. Inst\bll\fthe\ftr\bnsmission.\f
Refer\fto:\fGetriebe\f-\f2.5L\fDur\btec-ST\f(VI5)\f(308-
03,\fInst\bll\btion).\f
3. Bleed\fthe\fclutch\fsystem.\f
Refer\fto:\fKupplungssystem\fentlüften\f(308-00,\f
Gener\bl\fProcedures).\f
\f\f
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Installati\fn 1. \f\f
1. C

AUTION:\fApply\f\bdhesive\ft\bpe\fto\f
th

e\fsplines\fon\fthe\fsh\bft\fso\fth\bt\fthe\foil\f
se\bl\fdoes\fnot\fbecome\fd\bm\bged.\f\f
2. Special\bTool(\f):\b 3
08-112\f
2. Remove\fthe\f\bdhesive\ft\bpe\ffrom\fthe\finput\fsh\bft\f
splines.\f
3. 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
4. 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,\fInst\bll\btion).\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 \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,\fInst\bll\btion).\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,\fInst\bll\btion).\f
5. Refer\fto:\fKupplungssystem\fentlüften\f-\f
F\bhrzeuge\f
\busgest\bttet\fmit\f6-G\bng\fSch\bltgetriebe\f-\fM66\f
(308-00\fSch\bltgetriebe\fund\fKupplung\f-\f
Allgemeine\fInform\btionen,\fGener\bl\fProcedures).\f
\f
\f
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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
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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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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
T\bansmissi\fn D\baining and Filling—2.5L
Du\batec (162kW/220PS) - VI5S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Gene\bal P\b\fcedu\bes
Mate\bials
NameSpec\bf\bcat\bo\f
Tr\bnsmission\fOil\f75W\fFEWSS-M2C200-D2\f/\f7U7J-M2C200-BA
1. Refer\fto:\fGesundheits-\fund\fSicherheitsvorkehrungen\f(100-00\fAllgemeine\f
Inform\btionen,\fDescription\f\bnd\fOper\btion).\f
2. \f
3. Torque:\b 35\fNm
\f
4. Fill\fup\fwith\fm\bnu\bl\ftr\bnsmission\ffluid\fto\fbelow\f the\fbottom\fedge\fof\fthe\ffiller\fhole.\f
Mater\fal:\b Tr\bnsmission\fOil\f75W\fFE\f(WSS-
M2 C

200-D2\f/\f7U7J-M2C200-BA) \f
Tor

que:\b 35\fNm
\f
5. \f
\f\f
\f\f
\f
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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
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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
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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
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
308-643\f
Inst\bller,\fInput\fSh\bft\fSe\bl\f
1. Refer\fto:\f Tr\bnsmission\f-\f2.5L\fDur\btec\f
(1 6

2kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fM66,\fRemov\bl).\f
Refer\fto:\f Tr\bnsmission\f-\f2.2L\fDur\btorq-TDCi\f
(DW

)\fDiesel\f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fM66,\fRemov\bl).\f
Refer\fto:\f Clutch\fSl\bve\fCylinder \f(308-02C\fClutch\f
Con

trols\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fM66,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. CAUTION:\fT\bke\fextr\b\fc\bre\fnot\fto\f
d \b

m\bge\fthe\fbe\bring.\f
Special\bTool(\f):\b 30
3-336\f
3. \f\f
1. 2.5\fx\f15\fmm\fself-t\bpping\fscrew\f
\f
\f
\f\f
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Installati\fn 1.CAUTION:\fUse\f\bdhesive\ft\bpe\fto\fcover\f
th

e\finput\fsh\bft\fsplines\fto\fprevent\fd\bm\bge\fto\f
the\finput\fsh\bft\fse\bl.\f Special\bTool(\f):\b 30
8-643\f
2. Remove\fthe\f\bdhesive\ft\bpe.\f
3. Refer\fto:\fClutch\fSl\bve\fCylinder \f(308-02C\fClutch\f
Con

trols\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fM66,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\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:\f6-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fM66,\fInst\bll\btion).\f
Refer\fto:\f Tr\bnsmission\f-\f2.2L\fDur\btorq-TDCi\f
(DW

)\fDiesel\f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fM66,\fInst\bll\btion).\f
\f
\f\f
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