weight FORD S-MAX 2006 Service Repair Manual

Instruction\fsymbols\f\bre\fused\fto\f\bpply\fse\bler,\flubric\bnt,\fweight,\ft\bpe\for\fcle\bning\fdetergent\f
to\f\b\fcomponent.\f
Loc\btion\fsymbols\f\bre\fused\fto\fshow\fthe\floc\btion\fof\f\b\fcomponent\for\fsystem\fwithin\fthe\f
vehicle.\f
\f
\f
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Suspensi\bn Syste\f - General Inf\br\fati\bn
- Specificati\bnsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Fr\bnt Wheel Align\fent (at curb weight)
Rear Wheel Align\fent (at curb weight)
Descrip\bionTo\ferance Range Se\b\bing or
Nomina\f Maximum Variance Lef\b or Righ\b
C\bster\f\bngle\fDegrees\f\bnd\fminutes4°25'\fto\f2°22'3°23'1°00'
Decim\bl\fdegrees4.42°\fto\f2.36°3.39°1.00°
C\bmber\f\bngle\fDegrees\f\bnd\fminutes0°35'\fto\f-1°57'-0°41'1°15'
Decim\bl\fdegrees0.59°\fto\f-1.95°-0.68°1.25°
Tot\bl\ftoemm1.4\fToe-in\f±\f2.51.4\fToe-in\f±\f1.0-
Degrees\f\bnd\f
minutes0°12'\fToe-in\f±\f 0°21'0°12'\fToe-in\f±\f0°08'-
Decim\bl\fdegrees0.20°\fToe-in\f±\f0.35°0.20°\fToe-in\f±\f0.14°-
Kingpin\fAngle\f@\fDMDecim\bl\fdegrees-13.61°-
Descrip\bionTo\ferance Range Se\b\bing or
Nomina\f Maximum Variance Lef\b or
Righ\b
C\bmber\f \bngle\fDegrees\f\bnd\f minutes-0°21'\fto\f-2°53'-1°37'1°15'
Decim\bl\fdegrees-0.35°\fto\f-2.89°-1.62°1.25°
Tot\bl\ftoemm2.8\fToe-in\f±\f2.52.8\fToe-in\f±\f1.0-
Degrees\f\bnd\fminutes0°24'\fToe-in\f±\f0° 21'0°24'\fToe-in\f±\f0°08'-
Decim\bl\fdegrees0.40°\fToe-in\f±\f0.35°\f0.40°\fToe-in\f±\f0.14°-
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shock\f\bbsorbers\fmust\fbe\finst\blled.\fREFER\fto:\f\fShock\fAbsorber\f\bnd\fSpring\fAssembly \f(
204-01\fFront\fSuspension,\fRemov\bl\f\bnd\f
Ins
t\bll\btion),\f
Re\br\fShock\fAbsorber \f(204-02\fRe\br\fSuspension,\fRemov\bl\f\bnd\fInst\bll\btion).\f
L\bad-Levelling Sh\bck Abs\brber
1. 1.
With\fthe\fvehicle\funl\bden,\fme\bsure\f\bnd\fnote\fthe\fdimensions\fbetween\fthe\fb\bse\fof\f
t
he\fwheel\frim\f\bnd\fthe\ftop\fof\fthe\fre\br\ffender\fon\fboth\fsides.\f\f

The\fme\bsurements\fon\fboth\fsides\fshould\fbe\f\bpproxim\btely\fequ\bl.\f\f
2. 2.
With\f\b\flo\bd\fof\f4\f\bver\bge\fsize\f\bdults\f\bnd\f\b\f100\fkg\fweight,\fme\bsure\f\bnd\fnote\fthe\f
d
imensions\fbetween\fthe\fb\bse\fof\fthe\fwheel\frim\f\bnd\fthe\ftop\fof\fthe\fre\br\ffender\fon\f
both\fsides.\f\f
3. NOTE:\fDue\fto\fthe\fintern\bl\fr\btchet\fmech\bnism\fof\fthe\fsuspension\fcomponents,\fthe\f
he

ight\fof\fthe\fre\br\fof\fthe\fvehicle\fshould\frise\fduring\fthe\fro\bd\ftest.\f\f
3. With\f\b\flo\bd\fof\f4\f\bver\bge\fsize\f\bdults\f\bnd\f\b\f100\fkg\fweight,\fdrive\fthe\fvehicle\ffor\f3\f
km
\fon\f\b\fro\bd\fof\fnorm\bl\fcondition.\f\f
4. 4.
With\f\b\flo\bd\fof\f4\f\bver\bge\fsize\f\bdults\f\bnd\f\b\f100\fkg\fweight,\fme\bsure\f\bnd\fnote\fthe\f
d
imensions\fbetween\fthe\fb\bse\fof\fthe\fwheel\frim\f\bnd\fthe\ftop\fof\fthe\fre\br\ffender\fon\f
both\fsides.\f\f
5. 5.
If\fthe\fdimensions\fon\fboth\fsides\f\bre\fno\flonger\f\bpproxim\btely\fequ\bl,\finst\bll\fnew\flo\bd\f
levelling\fshock\f\bbsorbers.\f\f
REFER\fto:\f
Re\br\fShock\fAbsorber \f(204-02\fRe\br\fSuspension,\fRemov\bl\f\bnd\f
Ins

t\bll\btion).\f
6. NOTE:\fDue\fto\fthe\fintern\bl\fr\btchet\fmech\bnism\fof\fthe\fsuspension\fcomponents,\fthe\f
he

ight\fof\fthe\fre\br\fof\fthe\fvehicle\fshould\frise\fduring\fthe\fro\bd\ftest.\f\f
6.
If\fthe\fdimensions\f\bre\f\bpproxim\btely\fequ\bl,\funlo\bd\fthe\fvehicle\f\bnd\fdrive\fthe\fvehicle\f
for\f3\fkm\fon\f\b\fro\bd\fof\fnorm\bl\fcondition.\f\f
7. 7.
With\fthe\fvehicle\funl\bden,\fme\bsure\f\bnd\fnote\fthe\fdimensions\fbetween\fthe\fb\bse\fof\f
t
he\fwheel\frim\f\bnd\fthe\ftop\fof\fthe\fre\br\ffender\fon\fboth\fsides.\fCheck\fthe\ffin\bl\f
dimensions\fwith\fthe\forigin\bl\fdimensions\ft\bken\fin\fthe\funl\bden\fcondition.\f\f
8. 8.
If\fthe\ffin\bl\fdimensions\fdo\fnot\f\bpproxim\btely\fequ\bl\fthe\forigin\bl\fdimensions,\finst\bll\f
n
ew\flo\bd\flevelling\fshock\f\bbsorbers.\f\f
REFER\fto:\f Re\br\fShock\fAbsorber \f(204-02\fRe\br\fSuspension,\fRemov\bl\f\bnd\f
Ins

t\bll\btion).\f
9. 9.
If\fthe\ffin\bl\fdimensions\f\bpproxim\btely\fequ\bl\fthe\forigin\bl\fdimensions,\fverify\fthe\f
c
ustomer\fconcern.\f\f
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Wheels a\bd Ti\fes - Wheels a\bd Ti\fesS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Desc\fiptio\b a\bd Ope\fatio\b
Vehicles equipped with a ti\fe p\fessu\fe se\bso\f
C\b

re\fmust\fbe\ft\bken\fwhen\fremoving\f\bnd\finst\blling\ftires\fto\fm\bke\fsure\fth\bt\fthe\ftire\fpressure\f
sensor\fis\fnot\fd\bm\bged.\f
CAUTION:\fTo\f\bvoid\fcont\bct\fwith\fthe\ftr\bck\frod\fend,\fonly
\f\bdhesive\fweights\fm\by\fbe\f
used\fon\fthe\finside\fof\f17\finch\f\bluminium\fwheels.\f
\f\f
Desc\fiptio\b
Tire\fv\blve\f\bnd\fpressure\fsensor\f
Tire\fremov\bl/inst\bll\ftool\fst\brting\fposition\f
Tire\f\bnd\fbe\bd\fhigh\ftension\f\bre\b\f
Tire\f\bnd\fbe\bd\flow\ftension\f\bre\b\f
When\fremoving\fthe\ftire,\fthe\fbe\bd\fbre\bker\fmust\fnot\fbe\fused\fwithin\f90\fdegrees\fof\fthe\ftire\f
v\b
lve\fin\fe\bch\fdirection.\f
When\fusing\fthe\ftire\fremov\bl\fm\bchine,\fthe\ffitting\f\brm\fst\brt\fposition\fmust\fbe\f\bs\fshown.\fThe\f
wheel\fc\bn\fthen\fbe\frot\bted\fthrough\f180\fdegrees\fin\f\b\fcounterclockwise\fdirection.\fThis\fwill\f
rele\bse\fthe\fhigh\ftension\ffrom\fthe\ftire\fbe\bd\f\bllowing\fthe\frem\bining\f180\fdegrees\fof\fthe\ftire\f
to\fbe\fm\bnu\blly\frele\bsed\ffrom\fthe\fwheel\frim.\f
When\finst\blling\fthe\ftire,\fposition\fthe\ffitting\f\brm\f\bs\fshown.\fRot\bte\fthe\ftire\fin\f\b\fclockwise\f
direction\ft\bking\fc\bre\fth\bt\fthe\fbe\bd\fon\fthe\fside\fof\fthe\ftire\fexperiencing\flow\ftension\fdoes\fnot\f
d\bm\bge\fthe\fsensor.\f
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Brake S\bstem \f General Information \f
Brake S\bstemS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagnosis and Testing
Principles of Operation
Th

e\fbr\bke\fsystem\foper\btes\fby\ftr\bnsferring\feffort\f\bpplied\fto\fthe\fbr\bke\fped\bl\fby\fthe\fdriver\fto\f
the\fbr\bkes\f\bt\fe\bch\fwheel.\f
The\fbr\bking\feffort\fis\fdistributed\fto\fe\bch\fwheel,\fusing\f\bn\fhydr\bulic\fsystem.\fThe\fsystem\fis\f
\bssisted\fusing\f\b\fv\bcuum\fbr\bke\fbooster\fth\bt\freduces\fped\bl\feffort\f\bnd\fincre\bses\fhydr\bulic\f
pressure.\fThe\fp\brking\fbr\bke\foper\btes\fon\fthe\fre\br\fwheels\f\bnd\fis\f\bpplied\fusing\f\b\fh\bnd\f
oper\bted\fcontrol.\f
Inspection and Verification
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\fd\bm\bge.\f
V

isual Inspection Chart
3. 3.
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
4. 4.
If\fthe\fconcern\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\f
S
ymptom\fCh\brt.\f
Road Test
C\brry\fout\f\b\fro\bd\ftest\fto\fcomp\bre\f\bctu\bl\fvehicle\fbr\bking\fperform\bnce\fwith\fthe\fperform\bnce\f
st\bnd\brds\fexpected\fby\fthe\fdriver.\fThe\f\bbility\fof\fthe\ftest\fdriver\fto\fm\bke\fv\blid\fcomp\brison\f
\bnd\fdetect\fperform\bnce\fdeficiencies\fwill\fdepend\fon\fexperience.\f
The\fdriver\fshould\fh\bve\f\b\fthorough\fknowledge\fof\fbr\bke\fsystem\foper\btion\f\bnd\f\bccepted\f
gener\bl\fperform\bnce\fguidelines\fto\fm\bke\fgood\fcomp\brisons\f\bnd\fdetect\fperform\bnce\f
concerns.\f
An\fexperienced\fbr\bke\ftechnici\bn\fwill\f\blw\bys\fest\bblish\f\b\froute\fth\bt\fwill\fbe\fused\ffor\f\bll\fbr\bke\f
di\bgnosis\fro\bd\ftests.\fThe\fro\bds\fselected\fwill\fbe\fre\bson\bbly\fsmooth\f\bnd\flevel.\fGr\bvel\for\f
bumpy\fro\bds\f\bre\fnot\fsuit\bble\fbec\buse\fthe\fsurf\bce\fdoes\fnot\f\bllow\fthe\ftires\fto\fgrip\fthe\fro\bd\f
equ\blly.\fCrowned\fro\bds\fshould\fbe\f\bvoided\fbec\buse\fof\fthe\fl\brge\f\bmount\fof\fweight\fshifted\fto\f
the\flow\fset\fof\fwheels\fon\fthis\ftype\fof\fro\bd.\fOnce\fthe\froute\fis\fest\bblished\f\bnd\fconsistently\f
used,\fthe\fro\bd\fsurf\bce\fv\bri\bble\fc\bn\fbe\felimin\bted\ffrom\fthe\ftest\fresults.\f
Before\f\b\fro\bd\ftest,\fobt\bin\f\b\fcomplete\fdescription\fof\fthe\fcustomer\fconcerns\for\fsuspected\f
condition.\fFrom\fthe\fdescription,\fthe\ftechnici\bn's\fexperience\fwill\f\bllow\fthe\ftechnici\bn\fto\f
m\btch\fpossible\fc\buses\fwith\fsymptoms.\fCert\bin\fcomponents\fwill\fbe\ft\bgged\f\bs\fpossible\f
suspects\fwhile\fother\fwill\fbe\felimin\bted\fby\fthe\fevidence.\fMore\fimport\bntly,\fthe\fcustomer\f
description\fc\bn\freve\bl\funs\bfe\fconditions\fwhich\fshould\fbe\fchecked\for\fcorrected\fbefore\fthe\f
ro\bd\ftest.\fThe\fdescription\fwill\f\blso\fhelp\fform\fthe\fb\bsic\f\bppro\bch\fto\fthe\fro\bd\ftest\fby\f
n\brrowing\fthe\fconcern\fto\fspecific\fcomponents,\fvehicle\fspeed\for\fconditions.\f
Mechanica\b

Tire\fpressure\f\f

Wheels\f\bnd\ftires\f\f

Fluid\fle\bk\ffrom\fbr\bke\fline(s)\f\f

Fluid\flevel\f\f

Fluid\fcont\bmin\btion\f
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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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Input\fsh\bft\f
1st-2nd\f\bnd\f5th-6th\fge\br\foutput\fsh\bft\f
Reverse\fge\br\foutput\fsh\bft\f
Output\fpinion\f-\freverse\fge\br\foutput\fsh\bft\f
Ge\br\fwheel\f-\freverse\fge\br\f
Synchronizer\fhub\f-\freverse\fge\br\f
Ring\fge\br\f
Toothed\fwheel\f-\f1st\fge\br\f
Ge\br\fwheel\f-\f1st\fge\br\f
Inte\bnal c\fnt\b\fl
\f\f
Desc\bipti\fn
Shift\funit\f
5th/6th\fge\br\fgovernor\f
C\brrier\fpl\bte\fwith\fge\brshift\fg\bte\f
Switch\ffor\freverse\fge\br\fsign\bl\f
Shift\fguide\f
Lower\fshift\ffinger\f
Guide\fpl\bte\f
Upper\fshift\ffinger\f
Spring\f
Shift\f\brm\fwith\fd\bmping\fweight\f
Spring\f
Selector\flever\f
C\brrier\fpl\bte\fwith\fge\brshift\fg\bte\f
Vent\fc\bp\f
The\fge\brshift\fmech\bnism\fis\fsecured\fto\fthe\ftr\bns\bxle\fhousing\fby\ffour\fbolts\f\bnd\fm\by\fonly\fbe\f
re
pl\bced\f\bs\f\b\fcomplete\funit\fin\fthe\fevent\fof\f\b\ff\bult.\fA
B
D 1
2
3
4
1 5
2

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Manual T\bansmissi\fn/T\bansaxle Exte\bnal
C\fnt\b\fls - Vehicles With: 5-Speed Manual
T\bansaxle - MTX75 - Exte\bnal C\fnt\b\fls
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Desc\bipti\fn and Ope\bati\fn
Ge\br\fselector\funit\f\bnd\fge\brshift\fc\bble\f
\f\f
Desc\bipti\fn
Shift\funit\f
Ge\brshift\fc\bbles\fret\bining\fbr\bckets\f
Shift\f\brm\fwith\fd\bmping\fweight\f
Selector\fc\bble\f\bdjusting\fmech\bnism\f
Selector\fc\bble\f
Shift\fc\bble\f
Shift\flever\f
Adjustment\ftool,\fge\brshift\flever\f
The\flength\fof\fthe\fselector\fc\bble\fc\bn\fbe\f\bdjusted.\f
Th

e\fspring\fin\fthe\fge\brshift\flever\fpulls\fthe\fselector\fc\bble\finto\fthe\fneutr\bl\fposition\fof\fthe\fg\bte\f
for\f3rd/4th\fge\br.\f
The\fge\brshift\flever\fis\flocked\fin\fthis\fposition\fusing\f\bn\f\bdjustment\ftool.\f
The\f\bdjustment\fmech\bnism\fis\floc\bted\f\bt\fthe\fend\fne\brest\fthe\ftr\bnsmission.\f Item
1
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Стр. 1 из 1
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Manual T\bansmissi\fn/T\bansaxle Exte\bnal
C\fnt\b\fls - Vehicles With: 6-Speed Manual
T\bansaxle - MMT6 - Exte\bnal C\fnt\b\fls
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Desc\bipti\fn and Ope\bati\fn
Ge\br\fselector\funit\f\bnd\fge\brshift\fc\bble\f
\f\f
Desc\bipti\fn
Shift\funit\f
Ge\brshift\fc\bble\fret\bining\fbr\bckets\f
Shift\f\brm\fwith\fd\bmping\fweight\f
Selector\fc\bble\f\bdjusting\fmech\bnism\f
Selector\fc\bble\f
Shift\fc\bble\f
Shift\flever\f
Adjustment\ftool,\fge\brshift\flever\f
The\flength\fof\fthe\fselector\fc\bble\fc\bn\fbe\f\bdjusted.\f
Th

e\fspring\fin\fthe\fge\brshift\flever\fpulls\fthe\fselector\fc\bble\finto\fthe\fneutr\bl\fposition\fof\fthe\fg\bte\f
for\f3rd/4th\fge\br.\f
The\fge\brshift\flever\fis\flocked\fin\fthis\fposition\fusing\f\bn\f\bdjustment\ftool.\f
The\f\bdjustment\fmech\bnism\fis\floc\bted\f\bt\fthe\fend\fne\brest\fthe\ftr\bnsmission.\f Item
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05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G837189&gui...procarmanuals.com
http://vnx.su

Manual T\bansmissi\fn/T\bansaxle Exte\bnal
C\fnt\b\fls - Vehicles With: 6-Speed Manual
T\bansaxle - M66 - Exte\bnal C\fnt\b\fls
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Desc\bipti\fn and Ope\bati\fn
Ge\br\fselector\funit\f\bnd\fge\brshift\fc\bbles\f
\f\f
Desc\bipti\fn
Shift\funit\f
Ge\brshift\fc\bbles\fret\bining\fbr\bckets\f
Shift\f\brm\fwith\fd\bmping\fweight\f
Selector\fc\bble\f\bdjusting\fmech\bnism\f
Selector\fc\bble\f
Shift\fc\bble\f
Ge\brshift\flever\f
Adjustment\ftool,\fge\brshift\flever\f
The\flength\fof\fthe\fselector\fc\bble\fc\bn\fbe\f\bdjusted.\f
Th

e\fspring\fin\fthe\fge\brshift\flever\fpulls\fthe\fselector\fc\bble\finto\fthe\fneutr\bl\fposition\fof\fthe\fg\bte\f
for\f3rd/4th\fge\br.\f
The\fge\brshift\flever\fis\flocked\fin\fthis\fposition\fusing\f\bn\f\bdjustment\ftool.\f
The\f\bdjustment\fmech\bnism\fis\floc\bted\f\bt\fthe\fend\fne\brest\fthe\ftr\bnsmission.\f Item
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Стр. 1 из 1
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510630&gui...procarmanuals.com
http://vnx.su