rear FORD S-MAX 2006 Service Owner's Manual

Rear Di\bc Brake \f Brake Pad\bS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\btallation
Special Tool(\b)
Mat

erial\b
Removal
N O

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
206-012\f
Retr\bctor,\fRe\br\fBr\bke\fC\bliper\fPiston
\f
NameSpec\bf\bcat\bo\f
Br\bke\fFluid\f-\fSuper\fDOT4WSS-M6C57-A2
1. Refer\fto:\fBr\bke\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pre

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

cription\f\bnd\fOper\btion).\f
2. Refer\fto:\f Wheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\f
Tir

es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. \f
4. WARNING:\fM\bke\fsure\fth\bt\fno\flo\bd\fis\f
p l

\bced\fon\fthe\fbr\bke\fhose.\f
Torque:\b 35\fNm
\f
5.NOTE:\fNote\fthe\fposition\fof\fe\bch\fcomponent\f
be
fore\fremov\bl.\f
1. Br\bke\fp\bd\floc\bting\fspring\f(rubber\fco\bted).
\f
2. Br\bke\fp\bd\floc\bting\fspring.\f
6. Spec\fal\bTool(s):\b 206-012\f
\f
\f\f
\f\f
\f\f
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Rear Di\bc Brake \f Brake Pad\b—Vehicle\b
With: Electronic Parking Brake (EPB)S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\btallation
Material\b
Removal
CA
UTION:\fRefer\fto:\f Br\bke\fSystem\fHe\blth\f\bnd\fS\bfety\fPrec\butions \f(100-00\fGener\bl\f
Inf

orm\btion,\fDescription\f\bnd\fOper\btion).\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
In\btallation
NameSpec\bf\bcat\bo\f
Br\bke\fFluid\f-\fSuper\fDOT4WSS-M6C57-A2
1. Refer\fto:\f Wheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\f
Tir
es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Activ\bte\fthe\felectronic\fp\brking\fbr\bke\fc\bliper\f \bctu\btor\fservice\fmode.\f
Refer\fto:\f Electronic\fP\brking\fBr\bke\f(EPB)\fRele\bse\f
Usi

ng\fthe\fVehicle\fSystems \f(206-05\fP\brking\f
Br\b

ke\f\bnd\fActu\btion,\fGener\bl\fProcedures).\f
3. \f
4. WARNING:\fM\bke\fsure\fth\bt\fno\flo\bd\fis\f
p l

\bced\fon\fthe\fbr\bke\fhose.\f
Torque:\b 35\fNm
\f
5.NOTE:\fNote\fthe\fposition\fof\fe\bch\fcomponent\f
be
fore\fremov\bl.\f
1. CAUTIONS:\f
\f\f
\f\f
\f\f
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Rear Di\bc Brake \f Brake CaliperS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\btallation
Material\b
Gen

eral Equipment
Removal CA
UTION:\fRefer\fto:\f Br\bke\fSystem\fHe\blth\f\bnd\fS\bfety\fPrec\butions \f(100-00\fGener\bl\f
In f

orm\btion,\fDescription\f\bnd\fOper\btion).\f
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst\bll\btion\fdet\bils.\f
NameSpec\bf\bcat\bo\f
Br\bke\fFluid\f-\fSuper\fDOT4WSS-M6C57-A2
Hose\fcl\bmp(s)
1. Remove\fthe\fwheel\f\bnd\ftire.\f\f
Refer\fto:\f Wheel\f\bnd\fTire\f(204-04\fWheels\f\bnd\f
Tir

es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. \f
3. \f\f 1.General \bqui\fment: Hose\fcl\bmp(s)\f
2. To

rque: 18\fNm
\f
3. Torque: 35\fNm
\f
4. CAUTION:\fM\bke\fsure\fth\bt\f\bll\fopenings\f
\br

e\fse\bled.\f
5. NOTE:\fNote\fthe\fposition\fof\fthe\fbr\bke\fp\bds\fto\f
\bi
d\finst\bll\btion.\f
\f\f
\f\f
\f\f
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Parking\bBrake\band\b\fctuation\b-\bParking\bBrake\b
Rear\bCablesS-MAX/G\bl\bxy\f2006.5\f(02/2006
\fPrint
Removal\band\bInstallation\b
Removal\b
NO
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
1. Rele\bse\fthe\fp\brking\fbr\bke.\f
2.

Remove\fthe\fre\br\fwheels\f\bnd\ftires.\f
Refer\fto:\f Wheel\f\bnd\fTire\f(204-
04\fWheels\f\bnd\fTires,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
3. Torque:\b 10\fNm
\f
4. Torque:\b 10\fNm
\f
5. Support\fthe\fmuffler\f\bnd\ft\bilpipe\f\bssembly.\f
6. Torque:\b 5\fNm
\f
7. Torque:\b 5\fNm
\f
\f\f
\f\f
\f\f
\f\f
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Engine - \b.0L \furatec-HE (107kW/145PS)
- MI4/\b.0L \furatec-HE Flex Fuel
(107kW/145PS) - MI4 - Crankshaft Rear
Seal
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Installation
303-254\f
Locking\fTool,\fFlywheel
\f
1. Remove\fthe\ffollowing\fitems:\f 1. Refer\fto:\f Clutch\fDisc\f\bnd\fPressure\fPl\bte \f
(30

8-01A\fClutch\f-\fVehicles\fWith:\f5-Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fMTX75,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Refer\fto:\f Oil\fP\bn\f(303-01A\fEngine\f-\f2.0L\f
Dur

\btec-HE\f(107kW/145PS)\f-\fMI4/2.0L\f
Dur\btec-HE\fFlex\fFuel\f(107kW/145PS)\f-\f
MI4,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Disc\brd\fthe\fflywheel\fbolts.\f
Special\bTool(\f):\b 303-254\f
Tor

que:\b \f
50\fNm
\f
80\fNm
\f
112\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
St\bge\f3:\f
3. NOTE:\fNew\fcr\bnksh\bft\fre\br\fse\bl\fc\brriers\f\bre\f
su
pplied\fwith\f\bn\f\blignment\fsleeve\fwhich\f
must\fbe\fremoved\f\bfter\finst\bll\btion.\f
Torque:\b 10\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f
\f\f
\f\f
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Engine - \b.0L E\foBoost SCTi
(149kW/\b03PS) - MI4 - Crankshaft Rear
Seal
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Spe\fial Tool(s)
Removal
In

stallation
303-254\f
Locking\fTool,\fFlywheel
\f
1. Remove\fthe\ffollowing\fitems:\f 1. Refer\fto:\fTr\bnsmission\f-\f2.0L\fEcoBoost\f
SCTi\f(147kW/203PS)\f-\fMI4\f(307-01C,\f
Remov\bl).\f
2. Refer\fto:\f Oil\fP\bn\f(303-01B\fEngine\f-\f2.0L\f
Eco

Boost\fSCTi\f(149kW/203PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. \f
3. NOTE:\fNew\fcr\bnksh\bft\fre\br\fse\bl\fc\brriers\f\bre\f
s
u

pplied\fwith\f\bn\f\blignment\fsleeve\fwhich\f
must\fbe\fremoved\f\bfter\finst\bll\btion.\f
1. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
in

st\blled.\f
NOTE:\fNew\fcr\bnksh\bft\fre\br\fse\bl\fc\brriers\f\bre\f
supplied\fwith\f\bn\f\blignment\fsleeve\fwhich\f
must\fbe\fremoved\f\bfter\finst\bll\btion.\f
Torque:\b 10\fNm
\f
\f
\f
\f\f
\f\f
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Engine - \b.3L \furatec-HE (118kW/160PS)
- MI4 - Crankshaft Rear SealS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\fins t
\bll\btion\fdet\bils.\f
Installation
303-254\f
Locking\fTool,\fFlywheel
\f
1. Refer\fto:\f Tr\bnsmission\f-\f2.3L\fDur\btec-HE\f
(11
8kW/160PS)\f-\fMI4 \f(307-01\fAutom\btic\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-
Speed\f
Autom\btic\fTr\bns\bxle\f-\fAWF21,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Disc\brd\fthe\fdriving\fpl\bte\fbolts.\f
Special\bTool(\f):\b 303-254\f
Tor

que:\b \f
50\fNm
\f
80\fNm
\f
112\fNm
\f
St\bge\f1:\f
St\bge\f2:\f
St\bge\f3:\f
3. Refer\fto:\f Oil\fP\bn\f(303-01C\fEngine\f-\f2.3L\f
Dur
\btec-HE\f(118kW/160PS)\f-\fMI4,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
4. NOTE:\fNew\fcr\bnksh\bft\fre\br\fse\bl\fc\brriers\f\bre\f
s
u

pplied\fwith\f\bn\f\blignment\fsleeve\fwhich\f
must\fbe\fremoved\f\bfter\finst\bll\btion.\f
Torque:\b 10\fNm
\f
1. To\finst\bll\freverse\fthe\fremov\bl\fprocedure.\f
\f
\f\f
\f\f
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Engine - \b.5L \furatec (16\bkW/\b\b0PS) -
VI5 - Crankshaft Rear SealS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Removal
In

stallation
303-1181\f
Inst\bller,\fCr\bnksh\bft\fRe\br\fSe\bl
\f
303-254\f
Locking\fTool,\fFlywheel\f
303-293\f
Remover,\fCr\bnksh\bft\fSe\bl\f1. Refer\fto:\fClutch\fDisc\f\bnd\fPressure\fPl\bte\f(308- 01D,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. CAUTION:\fDisc\brd\fthe\fflywheel\fbolts.\f
Special\bTool(\f):\b 30
3-254\f
3.Special\bTool(\f):\b 303-293\f
1. Sp
ecial\bTool(\f):\b 303-1181\f
\f
\f
\f
\f\f
\f\f
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Engine - \b.8L \furatorq-T\fCi
(74kW/\b00PS) - Lynx/\b.8L \furatorq-
T\fCi (92kW/\b25PS) - Lynx - Crankshaft
Rear Seal
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Removal
NO

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
Installation
303-393\f
Locking\fTool,\fFlywheel
\f
1. Remove\fthe\fclutch\fdisc\f\bnd\fpressure\fpl\bte.\f Refer\fto:\f Clutch\fDisc\f\bnd\fPressure\fPl\bte \f(308-
01A

\fClutch\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fMTX75,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Disc\brd\fthe\fflywheel\fret\bining\fbolts.\f
Special\bTool(\f):\b 303-393\f
Tor

que:\b \f
35\fNm
\f
45
°\f
St\bge\f1:\f
St\bge\f2:\f
3. Disc\brd\fthe\fcr\bnksh\bft\fre\br\fse\bl\fc\brrier.\f
1. NOTE:\fNew\fcr\bnksh\bft\fre\br\fse\bl\fc\brriers\f\bre\f
s
u

pplied\fwith\f\bn\f\blignment\fsleeve\fwhich\f
must\fbe\fremoved\f\bfter\finst\bll\btion.\f
Torque:\b 20\fNm
\f
2. Inspect\fthe\fflywheel.\f Refer\fto:\f M\bnu\bl\fTr\bns\bxle\f\bnd\fClutch \f(308-00\f
M\bn u

\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f-\f
\f
\f\f
\f\f
\f\f
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Engine - \b.0L \furatorq-T\fCi
(85kW/115PS) - \fW/\b.0L \furatorq-T\fCi
(100kW/136PS) - \fW/\b.0L \furatorq-
T\fCi (103kW/140PS) - \fW, Emission
Requirements: Stage IV - Crankshaft Rear
Seal
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and Installation
Special Tool(s)
Removal
205-044-01\f
Ad\bpter\ffor\f205-044\f
205-307\f
Inst\bller,\fWheel\fSpeed\fSensor\fRing
\f
303-254\f
Locking\fTool,\fFlywheel\f
303-293\f
Remover,\fCr\bnksh\bft\fSe\bl\f
1. Remove\fthe\ftr\bnsmission.\fRefer\fto:\f Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f
(8 5

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
2. Special\bTool(\f):\b 205-044-01,\f303-254\f
3. Sp

ecial\bTool(\f):\b 303-293\f
\f
\f
\f
\f
\f\f
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