tran FORD S-MAX 2006 Service Owner's Manual
[x] Cancel search | Manufacturer: FORD, Model Year: 2006, Model line: S-MAX, Model: FORD S-MAX 2006Pages: 4402, PDF Size: 93.08 MB
Page 1986 of 4402
TEST CONDITIONSDETAILS/RESULTS/ACTIONS
E1: CHECK THE TRANSMISSION AT IDLING A)
Ignition\fswitch\fin\fposition\fIII.\f1
St\brt\fthe\fengine.\f2
Depress\fthe\fclutch\fped\bl\ffully.\f3
Is\fthe\fnoise\f\bpp\brent\fwhen\fthe\fclutch\fis\foper\bted?\f
Yes GO\fto\fE3 .\f\f
N\f T
here\fis\f\b\fproblem\fwith\fthe\ftr\bns\bxle.\fREFER\fto\f
Symptom\fCh\brt(s).\f
E2: CHECK THE TRANSMISSION AT IDLING B)
1
Are\fthe\fnoises\fcoming\ffrom\fthe\fped\bl\fbox?\f
Yes Go\fto\f"Service\f–\fClutch\fPed\bl".\f
N\f
GO\fto\fE3 .\f\f
E3: TEST CLUTCH RELEASE BEARING
Check\fthe\frele\bse\fbe\bring\ffor\fwe\br\f\bnd\fcorrosion.\f1
Are\fthere\fsigns\fof\fwe\br\for\frust?\f
Yes
INSTALL\f\b\fnew\fclutch\frele\bse\fbe\bring.\f
N\f
CHECK\fthe\fcr\bnksh\bft\ffor\fexcessive\fend\fflo\bt.Are\f
there\fstill\fnoises? GO\fto\fE5.\f\f
E4: ENGINE SELECTION – DIESEL ENGINES
1
Does\fthe\fengine\fh\bve\f\b\f1.8L\fdiesel\fengine\for\f\b\f2.0L\f
diesel\fengine?\f
Yes
Vehicles\fwith\f\b\f1.8L\fdiesel\fengine GO\fto\fE5
.\fVehicles\f
with\f\b\f2.0L\fdiesel\fengineGO\fto\fE13.\f\f
N\f GO
\fto\fE22 .\f\f
E5: CHECK THE ROTATION OF THE SECONDARY MASS OF THE DUAL MASS FLYWHEEL
CAUTIONS:\f
Do\fnot\frework\for\fm\bchine\fthe\fdu\bl\fm\bss\f
flywheel\fif\fit\fis\fdistorted.\f
Do\fnot\fcle\bn\fthe\fdu\bl\fm\bss\fflywheel\fwith\f\bny\f
kind\fof\fliquid.\fUse\fonly\f\b\fdry\fcloth\fto\fcle\bn\fthe\f
flywheel.\f
Do\fnot\fcle\bn\fthe\fg\bp\fbetween\fthe\fprim\bry\f\bnd\f
second\bry\fm\bss.\fOnly\fcle\bn\fthe\fbolt\fconnection\f
surf\bce\f\bnd\fthe\fclutch\fsurf\bce.\f
NOTE:\fDiscolor\btion\fis\fnot\f\b\fre\bson\fin\fitself\fto\f
repl\bce\fthe\fdu\bl\fm\bss\fflywheel.\f Remove\fthe\fclutch\fdisc\f\bnd\fclutch\fpressure\fpl\bte.\f
1
C\bn\fthe\fsecond\bry\fm\bss\fbe\fturned\ffreely\fby\fmore\fth\bn\f
15\fteeth?\f
Yes INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
N\f GO\fto\fE8 .\f\f
\f\f
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Page 2005 of 4402
Clutch \b Vehicle\f With: 5\bSpeed Manual
Tran\faxle \b MTX75 \b Specification\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Technical Data and Specification\f
* Clamp the clutch di\fc hand\btight in the area of the friction lining\f.
** I
f the minimum thickne\f\f ha\f been reached, the clutch di\fc mu\ft be renewed.
Clamped\bthi\fkness\b-\b\flut\fh\bplate\b*
Nominal\bthi\fknessMinimum\bthi\fkness\b**
mmin\fhmmin\fh
1.8L\fdiesel\fengine7.300.295.000.20
2.0L\fengine8.200.325.700.22
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Page 2006 of 4402
Clutch \b Vehicle\f With: 5\bSpeed Manual
Tran\faxle \b MTX75 \b ClutchS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\fi\f and Te\fting
REFER\fto:\f M\b
nu\bl\fTr\bns\bxle\f\bnd\fClutch \f(308-00\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f
-\fG
ener\bl\fInform\btion,\fDi\bgnosis\f\bnd\fTesting).\f
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Page 2007 of 4402
Clutch \b Vehicle\f With: 5\bSpeed Manual
Tran\faxle \b MTX75 \b Clutch Di\fc and
Pre\f\fure Plate
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\ftallation
Special Tool(\f)
Gen
eral Equipment
Removal
I n
\ftallation
308-204\f
Aligner,\fClutch\fDisc
\f
Ford\fdi\bgnostic\fequipment 1. Remove\fthe\ftr\bnsmission.\fRefer\fto:\f Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f
(Ly
nx)\fDiesel \f(308-03A\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fMTX75,\fRemov\bl).\f
Refer\fto:\f Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4\f(308-03A\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fMTX75,\fRemov\bl).\f
2. Loosen: E\bch\fbolt\fby\ftwo\fturn(s)
\f
1. Tighten\fe\bch\fbolt\fby\ftwo\fturns.\f \bpeci\fl Tool(s): 308-204\f
To r
que: 29\fNm
\f
2. Inst\bll\fthe\ftr\bnsmission.\f Refer\fto:\f Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f
(Ly
nx)\fDiesel \f(308-03A\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fMTX75,\fInst\bll\btion).\f
Refer\fto:\f Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f
(1 0
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4\f(308-03A\fM\bnu\bl\f
\f
\f\f
\f\f
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Page 2009 of 4402
Clutch \b Vehicle\f With: 6\bSpeed Manual
Tran\faxle \b MMT6 \b Specification\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Technical Data and Specification\f
* Clamp the clutch di\fc hand\btight in the area of the friction lining\f.
** I
f the minimum thickne\f\f ha\f been reached, the clutch di\fc mu\ft be renewed.
Clamped\bthi\fkness\b-\b\flut\fh\bplate\b*
Nominal\bthi\fknessMinimum\bthi\fkness\b**
mmin\fhmmin\fh
1.8L\fdiesel\fengine7.300.295.000.20
2.0L\fdiesel\fengine8.200.325.700.22
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Page 2010 of 4402
Clutch \b Vehicle\f With: 6\bSpeed Manual
Tran\faxle \b MMT6 \b ClutchS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\fi\f and Te\fting
REFER\fto:\f M\b
nu\bl\fTr\bns\bxle\f\bnd\fClutch \f(308-00\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f
-\fG
ener\bl\fInform\btion,\fDi\bgnosis\f\bnd\fTesting).\f
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Page 2011 of 4402
Clutch \b Vehicle\f With: 6\bSpeed Manual
Tran\faxle \b MMT6 \b Clutch Di\fc and
Pre\f\fure Plate
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\ftallation
Special Tool(\f)
Gen
eral Equipment
Removal
I n
\ftallation
308-204\f
Aligner,\fClutch\fDisc
\f
Ford\fdi\bgnostic\fequipment 1. Remove\fthe\ftr\bnsmission.\fRefer\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
2. Loosen: E\bch\fbolt\fby\ftwo\fturn(s)
\f
1. Tighten\fe\bch\fbolt\fby\ftwo\fturns.\f \bpeci\fl Tool(s): 308-204\f
To r
que: 29\fNm
\f
2. Inst\bll\fthe\ftr\bnsmission.\f Refer\fto:\f Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f
(L y
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
\f
\f\f
\f\f
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Page 2013 of 4402
Clutch \b Vehicle\f With: 6\bSpeed Manual
Tran\faxle \b M66 \b Specification\fS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Technical Data and Specification\f
* Clamp the clutch di\fc hand\btight in the area of the friction lining\f.
** I
f the minimum thickne\f\f ha\f been reached, the clutch di\fc mu\ft be renewed.
Clamped\bthi\fkness\b-\b\flut\fh\bplate\b*
Nominal\bthi\fknessMinimum\bthi\fkness\b**
mmin\fhesmmin\fhes
2.5L\fEngine8.400.335.900.23
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Page 2014 of 4402
Clutch \b Vehicle\f With: 6\bSpeed Manual
Tran\faxle \b M66 \b ClutchS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagno\fi\f and Te\fting
REFER\fto:\f M\b
nu\bl\fTr\bns\bxle\f\bnd\fClutch \f(308-00\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f
-\fG
ener\bl\fInform\btion,\fDi\bgnosis\f\bnd\fTesting).\f
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Page 2015 of 4402
Clutch \b Vehicle\f With: 6\bSpeed Manual
Tran\faxle \b M66 \b Clutch Di\fc and
Pre\f\fure Plate
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal and In\ftallation
Special Tool(\f)
Gen
eral Equipment
Removal
I n
\ftallation
Vehicles\fwith\felectronic\fp\brking\fbr\bke\f(EPB)\f
308-204\f
Aligner,\fClutch\fDisc
\f
Ford\fdi\bgnostic\fequipment 1. Refer\fto:\fTr\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,\fRemov\bl).\f
2. Loosen: E\bch\fbolt\fby\ftwo\fturn(s)
\f
1. \bpeci\fl Tool(s): 308-204\f
2. T
ighten\fe\bch\fbolt\f2\fturns\f\bt\f\b\ftime.\f
\bpeci\fl Tool(s): 308-204\f
To r
que: 23\fNm
\f
3. 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
\f
\f\f
\f\f
\f\f
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