clutch FORD S-MAX 2006 Service Manual PDF

Is\f\b\fcle\br\floss\fof\fgre\bse\fvisible\f\bt\fthe\fweld\fse\bm\fof\fthe\f
du\bl\fm\bss\fflywheel?\f
Yes INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
N\f
GO\fto\fE28 .\f\f
E28: GUIDE PINS OF THE DUAL-MASS FLYWHEEL
Check\fthe\finst\bll\btion\fof\fthe\fguide\fpins\fof\fthe\fdu\bl-
m\bss\fflywheel.\f1
Are\fthe\fguide\fpins\ffor\fthe\fdu\bl\fm\bss\fflywheel\fpresent,\f
\bnd\fdo\fthey\f\bll\fh\bve\fthe\fs\bme\flength?\f
Yes
The\fdu\bl\fm\bss\fflywheel\fis\fOK.\f
N\f INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
E29: 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\fE31 .\f\f
E30: ROTATION OF THE DUAL-MASS FLYWHEEL
Secure\fthe\fprim\bry\fside.\fTwist\fthe\fsecond\bry\fside\f
in\f\b\fclockwise\fdirection\funtil\fspring\fresist\bnce\fis\f1
\f\f
\f\f
\f\f
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INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
N\f GO\fto\fE34 .\f\f
E34: GUIDE PINS OF THE DUAL-MASS FLYWHEEL
Check\fthe\finst\bll\btion\fof\fthe\fguide\fpins\fof\fthe\fdu\bl-
m\bss\fflywheel.\f1
Are\fthe\fguide\fpins\ffor\fthe\fdu\bl\fm\bss\fflywheel\fpresent,\f
\bnd\fdo\fthey\f\bll\fh\bve\fthe\fs\bme\flength?\f
Yes
The\fdu\bl\fm\bss\fflywheel\fis\fOK.\f
N\f INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
PINPOINT TEST F : FLUID LEAKAGE
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
F1: CHECK THE CLUTCH SLAVE CYLINDER
Check\fthe\fclutch\fm\bster\fcylinder\ffor\fle\bks.\f1
Is\fthe\fclutch\fm\bster\fcylinder\fOK?\f
Yes GO\fto\fF2 .\f\f
N\f R

ENEW\fthe\fclutch\fm\bster\fcylinder.\f
F2: CHECK THE CLUTCH SLAVE CYLINDER
Check\fthe\fclutch\fsl\bve\fcylinder\ffor\fle\bks.\f1
Is\fthe\fclutch\fsl\bve\fcylinder\fOK?\f
Yes GO\fto\fF3 .\f\f
N\f I

NSTALL\f\b\fnew\fclutch\fsl\bve\fcylinder.\f
F3: INSPECT SYSTEM HYDRAULIC LINES
Check\fthe\fhydr\bulic\flines\fin\f\bre\b\fof\fengine\f\bnd\ftr\bnsmission\ffor\floose\for\f
d\bm\bged\funions.\f
1
Are\fthe\fclutch\fhydr\bulic\flines\fOK?\f
Yes CARRY\fOUT\f\b\fro\bd\ftest\fto\fverify\fthe\fcustomer\fconcern.\f
N\f REPAIR\for\fINSTALL\fnew\fcomponents\f\bs\fnecess\bry.\fCARRY\fOUT\f\b\fro\bd\f
test.\f \f\f
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Manual T\bansmissi\fn/T\bansaxle and
Clutch - Gene\bal Inf\f\bmati\fn - Gea\bshift
Cable Adjustment—Vehicles With: 5-
Speed Manual T\bansaxle (MTX-75)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Gene\bal P\b\fcedu\bes
Special T\f\fl(s)
308-640\f
Aligner,\fGe\brshift\fLever
\f
1. \f
2. 4th\fge\br\fon\fthe\ftr\bnsmission\fmust\fbe\feng\bged.\f
3. \f
4.Special\bTool(\f):\b 308-640\f
5. \f
\f
\f\f
\f\f
\f\f
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Manual T\bansmissi\fn/T\bansaxle and
Clutch - Gene\bal Inf\f\bmati\fn - Gea\bshift
Cable Adjustment—Vehicles With: 6-
Speed Manual T\bansaxle (MMT6)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Gene\bal P\b\fcedu\bes
Special T\f\fl(s)
Gen

e\bal Equipment All\fVehicles\f
Ve

hicles\fbuilt\fup\fto\f10/2007\f
308-640\f
Aligner,\fGe\brshift\fLever
\f
2.5\fmm\fdrill\fbit 1. Refer\fto:\fAir\fCle\bner\f(303-12D\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
Refer\fto:\f Air\fCle\bner \f(303-12E\fInt\bke\fAir\f
Dis
tribution\f\bnd\fFiltering\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,\fEmission\fRequirements:\f
St\bge\fIV/St\bge\fV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. CAUTION:\fGe\brshift\fc\bbles\fmust\fnot\fbe\f
k i

nked\for\fbent.\f
3. \f\f 1. X\f=\f44\fmm.\f
General \bqui\fment: 2.5\fmm\fdrill\fbit\f
2. NOTE:\fEnsure\fth\bt\f4th\fge\br\fis\f
en

g\bged.\f
\f
\f\f
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Manual T\bansmissi\fn/T\bansaxle and
Clutch - Gene\bal Inf\f\bmati\fn - Gea\bshift
Cable Adjustment—Vehicles With: 6-
Speed Manual T\bansaxle (M66)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Gene\bal P\b\fcedu\bes
Special T\f\fl(s)
308-640\f
Aligner,\fGe\brshift\fLever
\f
1. \f
2. CAUTION:\fGe\brshift\fc\bbles\fmust\fnot\fbe\f
ki

nked\for\fbent.\f
3. \f\f 2.NOTE:\fEnsure\fth\bt\f4th\fge\br\fis\f
en

g\bged.\f
4. \f
\f
\f\f
\f\f
\f
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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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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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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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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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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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