torque FORD S-MAX 2006 Service Repair Manual

Electro\bic E\bgi\be \fo\btrols - 2.0L Duratorq-
TD\fi (85kW/115PS) - DW/2.0L Duratorq-
TD\fi (100kW/136PS) - DW/2.0L
Duratorq-TD\fi (103kW/140PS) - DW -
Powertrai\b \fo\btrol Module (P\fM)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal a\bd I\bstallatio\b
Ge\beral Equipme\bt
Removal
Vehicles\fwith\fPCM\fsecurity\fshield\f
3.5\fmm\fdrill\fbit
Center\fpunch
Ford\fdi\bgnostic\fequipment1.NOTE:\fThis\fstep\fis\fonly\fnecess\bry\fwhen\f
i
n

st\blling\f\b\fnew\fcomponent.\f
Downlo\bd\fthe\fPCM\f\bnd\fthrottle\fbody\fconfigur\btion\f
in
form\btion\finto\fthe\fdi\bgnostic\ftool,\fusing\fthe\f
Progr\bmm\bble\fModules\fInst\bll\btion\froutine.\f\f
General \bqui\fment: Ford\fdi\bgnostic\fequipment \f
2. R

efer\fto:\f B\bttery\fDisconnect\f\bnd\fConnect\f(414-01\f
B\btt

ery,\fMounting\f\bnd\fC\bbles,\fGener\bl\f
Procedures).\f
3. Left-h\bnd\fside\fwheel\f\bnd\ftire.\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
4. \f
5. \f
6. Torque: 3\fNm
\f
\f\f
\f\f
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Vehicles\fwithout\fPCM\fsecurity\fshield\f
I\bstallatio\b Vehicles\fwith\fPCM\fsecurity\fshield\f7.
General
\bqui\fment:
Center\f
punch
\f
Ge n

eral
\bqui\fment:
3.5\fmm\f
drill\fbit \f
8. \f
9

. Torque: 3\fNm
\f
1. To\finst\bll,\freverse\fthe\fremov\bl\fprocedure.\f
\f\f
\f
\f\f
\f\f
Стр. 2 из
3
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Automati\b Tra\fsmissio\f/Tra\fsaxle -
Vehi\bles With: 6-Speed Automati\b
Tra\fsaxle - AWF21 - Automati\b
Tra\fsmissio\f
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Des\briptio\f a\fd Operatio\f
Tr\bnsmission\fDescription\f
Th

e\fAWF21\fis\f\bn\felectronic\blly\fcontrolled\f6-speed\f\butom\btic\ftr\bnsmission\fwhich\fw\bs\f
developed\ftogether\fwith\fAisin\fW\brner.\f
It\fh\bs\fthe\ffollowing\ffe\btures:\f

Two\fpl\bnet\bry\fge\brsets,\fone\fof\fwhich\fis\fdesigned\f\bs\f\b\fR\bvigne\bux\fge\brset\f\f

Shift\fSelect\f\bs\fst\bnd\brd\f\f

Ge\br\fposition\fsensor\fintegr\bted\fin\fthe\fTCM\f(tr\bnsmission\fcontrol\fmodule)\f\f

Drivers\fc\bn\fchoose\fbetween\fnorm\bl\f\bnd\fsport\fmode\fge\brshift\fprogr\bms.\f\f

A\ftot\bl\fof\f8\fsolenoid\fv\blves\fto\fcontrol\fthe\fhydr\bulic\fcircuit.\f
6\f

solenoid\fv\blves\fto\fcontrol\fthe\fge\brshift\fprogress.\f
1\fsolenoid\fv\blve\fto\fcontrol\fthe\flockup\ffunction\fof\fthe\ftorque\fconverter.\f
1\fsolenoid\fv\blve\fto\fcontrol\fthe\fsystem\fpressure.\f

In\f1st,\f2nd\f\bnd\freverse\fge\br\fthe\fengine\ftorque\fis\flimited\fto\f400\fNm.\f\f

The\fm\bximum\fpermitted\ftorque\f\bt\fthe\finput\fsh\bft\fof\fthe\ftr\bnsmission\fbehind\fthe\f
co

nverter\fis\f700\fNm\fwhen\f\b\fforw\brd\fge\br\fis\feng\bged\f(D\for\fShift\fSelect)\f\bnd\f600\fNm\f
when\freverse\fis\feng\bged.\f\f

Oil\fc\bp\bcity\fof\f7\flitres.\fThe\foil\flevel\fon\fthe\f2.0L\fDur\btorq\f(DW)\fdiesel\f\bpplic\btion\fis\f
ch

ecked\fthrough\f\bn\foverflow\fpipe,\f\bnd\fon\fthe\f2.3L\fDur\btec-HE\f(MI4)\f\bpplic\btion,\fit\fis\f
checked\fusing\f\b\fconvention\bl\fengine\foil\fdipstick.\f\f

Weight:\f94\fkg.\f
Tr\bnsmission\fr\btios\fin\fthe\findividu\bl\fge\brs:\f -
-
-
Ge\brTr\bnsmission\fR\btio
Without\fend\fst\bgeIncl.\fend\fst\bge\ffor\f(DW)\fdieselIncl.\fend\fst\bge\ffor\f2.3L\fMI4
First4,14813,8115,56
Second2,3707,898,89
Third1,5565,185,4
Fourth1,1553,854,33
\f
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Tr\bnsmission\fcomponents\f
R\bvigne\bux\fpl\bnet\bry\fge\brset\f
One\fof\fthe\fspeci\bl\ffe\btures\fof\fthe\fAWF21\ftr\bnsmission\fis\fits\fR\bvigne\bux\fpl\bnet\bry\fge\brset.\fThe\fR\bvigne\bux\fpl\bnet\bry\fge\brset\fh\bs\fthe\ffollowing\ffe\btures:\f

It\foffers\fthe\fpossibility\fof\fmore\fge\brs\fth\bn\f\b\fconvention\bl\fpl\bnet\bry\fge\brset.\f\f

Comp\bct\fdesign\f(sp\bce-s\bving)\fin\frel\btion\fto\fthe\f\bv\bil\bble\ftr\bnsmission\fr\btios.\f\f

Two\fsun\fge\brs\fwith\fdifferent\fdi\bmeters\f\f

Two\fsets\fof\fpl\bnet\bry\fge\brs\f-\finner\f\bnd\fouter.\fThe\finner\fpl\bnet\bry\fge\brs\f\bre\fin\fconst\bnt\f
me

sh\fwith\fthe\fsm\bller,\fre\br\fsun\fge\br\f\bnd\fwith\fthe\fouter\fpl\bnet\bry\fge\brs.\fThe\fouter\f
pl\bnet\bry\fge\brs\f\bre\fin\fconst\bnt\fmesh\fwith\fthe\fring\fge\br\f\bnd\fthe\fl\brger,\ffront\fsun\fge\br.\f\f

The\fpl\bnet\bry\fge\brs\f\bre\f\bll\ffitted\fon\f\b\fjoint\fpl\bnet\bry\fge\br\fholder.\f
Oper\btion\f
T h

e\ftr\bnsmission\fr\btios\f\bre\f\bchieved\fvi\b\fthe\ffollowing\fcombin\btions\fof\flocked\f\bnd/or\f
coupled\fcomponents.\fThe\ft\bble\fshows\fthe\fprinciple\fof\fobt\bining\f\b\fhigh\fr\btio\f(1),\f\b\flow\fr\btio\f
5th0,8592,863,22
6th0,6862,282,57
Reverse3,39411,3012,73
ItemCompo\be\bt
1C2\fclutch
2B2\fbr\bke
3F1\ffreewheel
4Front\fpl\bnet\bry\fge\brset
5C1\fclutch
6B1\fbr\bke
7C3\fclutch
8TORQUE\fCONVERTER
9Differenti\bl\funit
10Driven\fge\br\fwheel\fof\fthe\fintermedi\bte\fst\bge
11Driving\fge\br\fwheel\fof\fthe\fintermedi\bte\fst\bge
12R\bvigne\bux\fpl\bnet\bry\fge\br\fset
13Turbine\fsh\bft
\f
Стр. 2 из 4
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(6)\f\bnd\f\b\freverse\frot\btion\f(i.e.\freverse\fge\br\fwith\f\b\fhigh\fr\btio).\f
\f\f
Des\briptio\f
Ring\fge\br\f
Long\fpl\bnet\fge\br\f
Sm\bll\fpl\bnet\fge\br\f
Short\fpl\bnet\fge\br\f
Tr\bnsmission\finput\fsh\bft\f
L\brge\fsun\fge\br\f
On\fthe\fAWF21\ftr\bnsmission\fthe\fR\bvigne\bux\fpl\bnet\bry\fge\brset\fis\fconnected\fin\fseries\fwith\f\b\f
c o

nvention\bl\fpl\bnet\bry\fge\brset.\fThe\fconvention\bl\fpl\bnet\bry\fge\brset\fc\bn\fgener\bte\f\b\fspeed\f
reduction\fon\fthe\ftwo\fsun\fge\brs\fof\fthe\fR\bvigne\bux\fpl\bnet\bry\fge\brset\ffor\fge\brs\f1\fto\f5\f\bnd\ffor\f
reverse\fge\br.\f
Electric\bl\fcontrol\f
The\ffollowing\fcomponents\f\bre\fp\brt\fof\fthe\fcontrol\fsystem\ffor\fthe\f\butom\btic\f
tr\bnsmission:\f

TCM.\fControls\f\bctiv\btion\f\bnd\fde\bctiv\btion\fof\fthe\fsolenoid\fv\blves\fby\fprocessing\fthe\finput\f
si

gn\bls\ffrom,\f\bmong\fothers\fthe\fspeed\fsensor\f\bnd\frot\btion\bl\fspeed\fsensor\fof\fthe\f
tr\bnsmission,\f\bs\fwell\f\bs\fthe\ftemper\bture\fsensor.\fIt\f\blso\fs\bves\f\bd\bptive\fd\bt\b,\fDTCs\f\bnd\f
frozen\fv\blues\ffor\fdi\bgnosis.\f\f

Ge\brshift\fposition\fsensor,\fintegr\bted\fin\fthe\fTCM.\f\f

Solenoid\fv\blves\fS1\f\bnd\fS2.\fPrim\brily\fcontrol\fengine\fbr\bking\fin\f1st\fge\br.\f\f

Solenoid\fv\blve\fSLU.\fControls\fthe\flockup\ffunction,\f\bnd\fis\f\blso\fused\fduring\fcert\bin\f
ge

\brshift\fprocesses.\f\f
Item
1
2
3
4
5
6
Gear\f/\fratioI\bput\ftorqueLockedOutput\ftorque
1Sm\bll\fsun\fge\brPl\bnet\bry\fge\br\fholderRIng\fge\br
2Sm\bll\fsun\fge\brL\brge\fsun\fge\brRIng\fge\br
3Sm\bll\fsun\fge\br\f\bnd\fl\brge\fsun\fge\brNo\fcomponentRing\fge\br
4Sm\bll\fsun\fge\br\f\bnd\fpl\bnet\bry\fge\br\fholderNo\fcomponentRing\fge\br
5L\brge\fsun\fge\br\f\bnd\fpl\bnet\bry\fge\br\fholderNo\fcomponentRIng\fge\br
6Pl\bnet\bry\fge\br\fholderL\brge\fsun\fge\brRIng\fge\br
Reverse.L\brge\fsun\fge\brPl\bnet\bry\fge\br\fholderRIng\fge\br
\f
Part Number -
-
-
-
-
-
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Solenoid\fv\blve\fSLT.\fControls\fthe\ftr\bnsmission\fsystem\fpressure.\f\f

The\fsolenoid\fv\blves\fSLC1,\fSLC2\f\bnd\fSLC3\fcontrol\fwhich\fclutches\f\bre\fused.\f\f

Solenoid\fv\blve\fSLB1.\fControls\fthe\fuse\fof\fbr\bke\fB1.\f\f

Rot\btion\bl\fspeed\fsensor,\finput\fsh\bft\f\f

Output\fsh\bft\frot\btion\bl\fspeed\fsensor\f\f

Oil\ftemper\bture\fsensor\f\f

GSM\f(Ge\br\fSelector\fModule),\fin\fthe\fge\br\fselector\fhousing.\fProvides\finform\btion\fto\fthe\f
TC

M\f\bbout\fthe\fdesired\fdriving\fmode,\fetc.\fShift\fselect\fmode\f\bnd\fsport\fmode\fW.\f\f

Hydr\bulic\fsystem\fwith\foil\fpump,\ftorque\fconverter,\fhydr\bulic\fcontrol\fhousing\f\bnd\foil\f
co

oler.\f\f

A\ffront\fpl\bnet\bry\fge\brset\f\bnd\f\b\fre\br\fpl\bnet\bry\fge\brset,\fthe\ftr\bnsmission\fr\btios\fof\fwhich\f
\bre

\fcontrolled\fby\fclutches\f\bnd\fbr\bkes.\f
Solenoid\fv\blves\f
ItemCompo\be\bt
1Oil\ftemper\bture\fsensor
2Solenoid\fv\blve\fSLU
3Solenoid\fv\blve\fSLC3
4Solenoid\fv\blve\fSLB1
5Input\fsh\bft\frot\btion\bl\fspeed\fsensor
6Output\fsh\bft\frot\btion\bl\fspeed\fsensor
7Solenoid\fv\blve\fS1
8Solenoid\fv\blve\fS2
9Solenoid\fv\blve\fSLT
10Solenoid\fv\blve\fSLC2
11Solenoid\fv\blve\fSLC1
12tr\bnsmission\fcontrol\fmodule
\f
Стр. 4 из 4
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P\brking\fthe\fvehicle,\f\f

performing\ftests\for\fm\bking\f\bdjustments,\f\f

le\bving\fthe\fvehicle\fst\bnding\fwith\fthe\fengine\frunning.\f
K\fow a\fd u\fdersta\fd \bustomer \bo\f\ber\f
The\fproblem\fmust\fbe\ffully\funderstood\fbefore\ff\bult\fdi\bgnosis\fis\fst\brted,\fin\forder\fto\fcle\brly\f
es
t\bblish\fthe\fc\buse\fof\f\b\fconcern.\fDet\biled\finform\btion\ffrom\fthe\fcustomer\fm\by\fbe\fneeded\f
for\fthis.\f
Ask\fthe\fcustomer\funder\fwhich\fconditions\fthe\fconcern\f\bppe\brs.\fFor\fex\bmple:\f

Cold\for\fw\brm\fengine?\f\f

At\fwh\bt\fengine\fspeed,\fvehicle\fspeed,\flo\bd?\f\f

In\fwhich\fge\br\for\fr\bnge?\f\f

At\fhigh\for\flow\foutdoor\ftemper\bture?\f\f

With\fthe\fvehicle\flo\bded\for\fempty?\f\f

On\fwh\bt\fro\bd\fsurf\bce?\f\f

In\fwh\bt\fdriving\fsitu\btion:\f
wh

ile\f\bcceler\bting?\f
on\foverrun?\f
when\fshifting\fup\for\fdown?\f

Do\fnoises\foccur?\f\f

Wh\bt\fis\fthe\fqu\blity\fof\fthe\fshift?\f\f

Does\fthe\fge\br\feng\bged\fcorrespond\fto\fthe\fdispl\by?\f\f

When\fthe\fincorrect\foper\btion\foccurred,\fdid\f\b\fw\brning\f\bppe\br\fin\fthe\fIC?\f
Verifi\batio\f of Co\fditio\f
NOTE:\fIf\fnoise\for\fvibr\btion\fis\f\b\fconcern,\fcheck\ffor\fdependency\fon:\frpm,\fvehicle\fspeed,\f
ge
\br\fr\bnge\for\ftemper\bture.\f
NOTE:\fIn\fsome\fc\bses,\ff\bults\fin\fthe\f\butom\btic\ftr\bnsmission\fm\by\fc\buse\fconcerns\fover\fthe\f
w\by\fthe\fengine\fruns.\fFor\fex\bmple,\fit\fc\bn\fc\buse\fthe\fengine\fto\fst\bll\fif\fthe\ftorque\fconverter\f
lock-up\fclutch\fdoes\fnot\fdiseng\bge.\f
If\fnecess\bry\f\bnd\fit\fis\fpossible,\f\bsk\fthe\fcustomer\fto\fd
emonstr\bte\fthe\fconcern\fto\fyou.\fIt\fm\by\f
\blso\fbe\f\bn\ferror\fin\fthe\fw\by\fin\fwhich\fthe\fvehicle\fis\foper\bted.\fReproduce\fthe\ff\bult\fby\fpossibly\f
driving\fthe\fvehicle\fyourself.\f
Visual I\fspe\btio\f
The\fvisu\bl\finspection\fextends\fto\fobvious\fd\bm\bge\fto\fmech\bnic\bl\for\felectric\bl\f
components,\fe.\fg.\f

Electric\bl\fconnectors\f\bnd\fc\bble\fconnections\f\f

E\bse\fof\foper\btion\fof\fthe\fselector\flever\f\f

Selector\flever\fposition\f\bnd\fselector\flever\fdispl\by\f\f

Fluid\fle\bk\bge\f\f

Tr\bnsmission\ffluid\flevel\fcheck\f\f

Tr\bnsmission\ffluid\fqu\blity\fcheck\f\f

Modific\btions/retrofitting/tuning\f\f

D\bm\bge\f
If\f\bny\fc\buses\ffor\f\b\fconcern\f\bre\ffound\fduring\fthe\fvisu\bl\finspection,\fthey\fmust\fbe\fcorrected\f
b e

fore\f\bny\ffurther\fchecks\f\bre\fm\bde.\f
Ele\btri\bal \bo\f\fe\btors a\fd \bable \bo\f\fe\btio\fs
Electric\bl\fconnectors\fto\f\bnd\ffrom\fthe\f\butom\btic\ftr\bnsmission\fcontrol\felectronics\fmust\fonly\f
b e

\fsep\br\bted\for\fconnected\fwhen\fno\fvolt\bge\fis\fpresent.\f
Ease of operatio\f of the sele\btor lever
A\fselector\flever\fwhich\fis\fdifficult\fto\fmove\fm\by\fbe\fthe\fc\buse\fof\f\b\fcustomer\fconcern.\f -
-
-
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Vehicles\fwith\f2.3L\fengine\f
Vehicles\fwith\fdiesel\fengine\f
6. Collect\fthe\f\butom\btic\ftr\bnsmission\ffluid\f(ATF)\fin\f
\b\fs

uit\bble\fcont\biner.\f
7. Dr\bin\foff\f\butom\btic\ftr\bnsmission\ffluid.\f
8. Dr\bin\foff\f\butom\btic\ftr\bnsmission\ffluid.\f
9. Torque:\b 47\fNm
\f
10. Torque:\b 47\fNm
\f
11. Torque:\b 8\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
Стр. 2 из
3
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G860303&gui...procarmanuals.com
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All\fvehicles\f
Vehicles\fwith\f2.3L\fengine\f
Vehicles\fwith\fdiesel\fengine\f
All\fvehicles\f
12. Fill\fthe\ftr\bns\bxle\fwith\f\butom\btic\ftr\bnsmission\f
fl

uid.\f
Refer\fto:\f Specific\btions \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,\fSpecific\btions).\f
Mater\fal:\b Autom\btic\fTr\bnsmission\fOil\fE-AW\f
(WS

S-M2C924-A\f/\f4U7J-M2C924-AA) \f
13.

\f
14. Torque:\b 40\fNm
\f
15. Refer\fto:\f Tr\bnsmission\fFluid\fLevel\fCheck \f(307-
01\f
Autom\btic\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f6-Speed\fAutom\btic\fTr\bns\bxle\f-\fAWF21,\f
Gener\bl\fProcedures).\f
\f\f
\f\f
\f\f
Стр. 3 из
3
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G860303&gui...procarmanuals.com
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Distribution\f\bnd\fFiltering\f-\f2.0L\fDur\btec-HE\f
(107kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4/2.3L\f
Dur\btec-HE\f(118kW/160PS)\f-\fMI4,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. B\bttery\fconsole\f
Refer\fto:\f B\bttery\f(414-01\fB\bttery,\f
Mou

nting\f\bnd\fC\bbles,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
4. CAUTION:\fThe\fge\brshift\fc\bbles\fmust\fnot\f
be

\fkinked\for\ftwisted.\f
5. Torque: 15\fNm\f
6. Torque: 48\fNm
\f
7. Remove\fthe\ffollowing\fitems:\f 1. Subfr\bme\f
Refer\fto:\f Front\fSubfr\bme \f(502-00\fUni-
Bo d

y,\fSubfr\bme\f\bnd\fMounting\fSystem,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
2. Drive\fsh\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
Dri

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. St\brter\fmotor\f
Refer\fto:\f St\brter\fMotor \f(303-06A\fSt\brting\f
Sy s

tem\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f
\f\f
\f\f
\f\f
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05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G860290&gui...procarmanuals.com
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