Page 2153 of 4402
Vehicles\fbuilt\fup\fto\f10/2005\finclusive\f
Vehicles\fbuilt\ffrom\f11/2005\f
Assembly All\fvehicles\f
CAUTION:\fM\bke\fsure\fvice\fj\bw\fprotectors\f\bre\fused.\f 10.
NOTE:\fM\bke\f\b\fnote\fof/m\brk\fthe\finst\blled\f
po
sitions\fof\fthe\fcomponents\fbefore\fremov\bl.\f
1. Sliding\fcoll\br\f
2.
Blocker\fb\brs\f
3. Synchronizer\fhub\f
11. This\fstep\fis\fonly\fnecess\bry\fif\fthe\foil\fring\fis\f d\bm\bged.\f
12. Ensure\fth\bt\fno\foil\fring\fis\finst\blled.\f
13. Cl\bmp\fthe\foutput\fsh\bft\fin\fthe\fvice.\f
14. Co\bt\f\bll\frunning\fsurf\bces\fwith\fcle\bn\ftr\bnsmission\f fluid\fbefore\f\bssembly.\f
Material:\b Tr\bnsmission\fOil\f75W\fFE\f(WSS-
M2 C
200-D2\f/\f7U7J-M2C200-BA) \f
\f
\f\f
\f\f
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Page 2158 of 4402

Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - MMT6 -
5th-6th and Reve\bse Gea\b Output ShaftS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Disassembly and Assembly \ff Subassemblies
Special T\f\fl(s)
Mat
e\bials
Gene\bal Equipment
Disassembly CA
UTION:\fUse\fprotective\fcovers.\f All\fvehicles\f
204-050\f
Inst\bller,\fFront\fWheel\fHub\fBe\bring\fCup/Se\bl\f
205-071-01\f
Ad\bpter\ffor\f205-071\f(Thrust\fP\bd)\f
205-295\f
Remover,\fBe\bring\f(M\bin\fTool)\f
308-046\f
Inst\bller,\fTr\bnsmission\fExtension\fHousing\fBushing/Se\bl
\f
308-196\f
Collet\ffor\f205-295\f
308-197\f
Collet\ffor\f205-295\f
308-604\f
Inst\bller,\fOutput\fDrive\fFl\bnge\fSe\bl\f
NameSpec\bf\bcat\bo\f
Tr\bnsmission\fOil\f75W\fFEWSS-M2C200-D2\f/\f7U7J-M2C200-BA
Hot\f\bir\fgun
1. Cl\bmp\fthe\foutput\fsh\bft\fin\f\b\fvise.\f
2.Special\bTool(\f):\b 205-071-01,\f205-295,\f 308-197\f
\f
\f
\f
\f
\f
\f
\f
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Page 2159 of 4402
3.NOTE:\fLeft-h\bnd\fthre\bd\f
He\bt\fthe\ftr\bnsmission-side\ft\bper\froller\fbe\bring\f
re
t\bining\fbolt\fto\f\bpprox.\f90\f°C\fusing\f\b\fhot\f\bir\f
gun\f\bnd\fdisc\brd.\f
General\bEquipment:\b Hot\f\bir\fgun\f
4. NOTE:\fUse\f\b\fsuit\bble\fw\bsher\f\bs\f\b\fthrust\f
e
l
ement.\f
Special\bTool(\f):\b 20
5-295,\f308-196\f
5. D
isc\brd\fthe\fsn\bp\fring.\f
6. NOTE:\fM\bke\f\b\fnote\fof/m\brk\fthe\finst\blled\f
p
o
sitions\fof\fthe\fcomponents\fbefore\fremov\bl.\f
1. Sliding\fcoll\br\f
2.
Blocker\fb\br\f
3. Synchronizer\fhub\f
\f\f
\f\f
\f\f
\f
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Page 2161 of 4402
Vehicles\fbuilt\fup\fto\f10/2005\finclusive\f
Vehicles\fbuilt\ffrom\f11/2005\f
Assembly All\fvehicles\f
CAUTION:\fUse\fprotective\fcovers.\f
All\fvehicles\f
10. This\fstep\fis\fonly\fnecess\bry\fif\fthe\foil\fring\fis\f
d\bm
\bged.\f
11. Ensure\fth\bt\fno\foil\fring\fis\finst\blled.\f
12. Cl\bmp\fthe\foutput\fsh\bft\fin\f\b\fvise.\f
13. Co\bt\f\bll\frunning\fsurf\bces\fwith\fcle\bn\ftr\bnsmission\f fluid\fbefore\f\bssembly.\f
Material:\b Tr\bnsmission\fOil\f75W\fFE\f(WSS-
M2 C
200-D2\f/\f7U7J-M2C200-BA) \f
14.
\f
\f\f
\f\f
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Page 2165 of 4402
Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - MMT6 -
Diffe\bentialS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Disassembly and Assembly \ff Subassemblies
Special T\f\fl(s)
Gen
e\bal Equipment
Disassembly CA
UTION:\fM\bke\fsure\fvice\fj\bw\fprotectors\f\bre\fused.\f
205-071-01\f
Ad\bpter\ffor\f205-071\f(Thrust\fP\bd)
\f
205-081\f
Inst\bller,\fDifferenti\bl\fBe\bring\f
205-295\f
Remover,\fBe\bring\f(M\bin\fTool)\f
308-197\f
Collet\ffor\f205-295\f
Hydr\bulic\fpress
1. Cl\bmp\fthe\fdifferenti\bl\fin\fthe\fvice.\f
2.Special\bTool(\f):\b 205-071-01,\f205-295,\f 308-197\f
3. Sp
ecial\bTool(\f):\b 205-071-01,\f205-295,\f 308-197\f
4. R
emove\fthe\ffollowing\fitems:\f 1. Loo\fen:\b Four\fturn(s)
\f
\f
\f
\f
\f
\f\f
\f
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Page 2166 of 4402
Assembly CAUTION:\fM\bke\fsure\fvice\fj\bw\fprotectors\f\bre\fused.\f 2. \f
3
.
S\bve\fthree\fbolts\ffor\fre\bssembly\fthe\fring\f
ge\br.\f
5. \f\f
6. Cl\bmp\fthe\fdifferenti\bl\fin\fthe\fvice.\f 7. Inst\bll\fthe\fthree\fbolts\fs\bved\fduring\fdis\bssembly.
\f
Torque:\b 82\fNm\f
8. \f\f
\f
\f
\f
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Page 2194 of 4402

Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
Manual T\bansmissi\fnS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Desc\bipti\fn and Ope\bati\fn
Ove\bview
Th
e\fm\bnu\bl\ftr\bns\bxle\f(M66)\fw\bs\fdesigned\ffor\fuse\fin\ffront-wheel\f\bnd\ffour-wheel\fdrive\f
vehicles\f\bnd\ffor\fhigh\ftorques.\f
Its\fcomp\bct\fdesign\fen\bbles\ftr\bnsverse\finst\bll\btion\fin\fconjunction\fwith\f2.5L\fDur\btec-ST\f
(VI5)\fengine\f(\bnd\f2.2L\fDur\btorq-TDCi\f(DW)\fDiesel\fengine).\f
The\ftr\bns\bxle\fis\fequipped\fwith\fsix\fforw\brd\fge\brs.\f
The\fbenefits:\f
Optimized\fgr\bdu\btion\fof\fspeed\fst\bges\f
Lower\ffuel\fconsumption\f
Less\fnoise\femission\fdue\fto\flower\fengine\fspeeds\f
The\ftr\bns\bxle\fdesign\fis\fb\bsed\fon\ffour\fsh\bfts\f(one\finput\fsh\bft\f\bnd\fthree\foutput\fsh\bfts.\fSee\f
\b l
so\fillustr\btion\fon\fnext\fp\bge).\f
All\fthe\fge\brs,\fincluding\fthe\freverse\fge\br,\f\bre\fsynchronized:\f
Single\fsynchroniz\btion\f-\f4th/5th/6th\f\bnd\freverse\fge\br\f
Du\bl\fsynchroniz\btion\f-\f3rd\fge\br\f
Triple\fsynchroniz\btion\f-\f1st/2nd\fge\br\f
The\ftr\bns\bxle\fh\bs\f\b\flifetime\ffilling\fof\fsynthetic\foil.\f
A n
\f\bperture\fis\fprovided\ffor\fchecking\fthe\flevel\f\bnd\ftopping\fup.\f
\f
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Page 2195 of 4402

Ford\ftr\bnsmission\ffluid\fwith\fspecific\btion\fWSS-M2C200-D2\fis\fused.\f
The\ftot\bl\ffilling\fc\bp\bcity\fis\f2.0\fliters.\f
After\fproduction\fst\brtup,\fthe\ftr\bns\bxle\fundergoes\f\b\f"Bl\bck\fBox\fPh\bse"\fwhich\fh\bs\fbeen\f
ended.\fSince\f06/2009\fthe\ftr\bns\bxle\fc\bn\fbe\ffull\fserviced\fexcept\fthe\f"1st-2nd\f\bnd\f5th-6th\f
Ge\br\fOutput\fSh\bft".\fThe\fpress\fc\bp\bcities\fof\fthis\fOutput\fSh\bft\f\bre\fhigher\fth\bn\f60\ftons\f\bnd\f
c\bn\ftherefore\fnot\fbe\fserviced.\fOnly\fthe\fouter\fbe\brings\fc\bn\fbe\frenewed.\f
Inte\bnal C\fmp\fnents
\f\f
Desc\bipti\fn
Input\fsh\bft\f
1st-2nd\f\bnd\f5th-6th\fge\br\foutput\fsh\bft\f
3rd-4th\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
Ge\br\fwheel\f-\f2nd\fge\br\f
Toothed\fwheel\f-\f5th\fge\br\f
Toothed\fwheel\f-\f6th\fge\br\f
Ge\br\fwheel\f-\f6th\fge\br\f
Synchronizer\fhub\f-\f5th/6th\fge\br\f
Ge\br\fwheel\f-\f4th\fge\br\f
Ge\br\fwheel\f-\f5th\fge\br\f
Synchronizer\fhub\f-\f3rd/4th\fge\br\f
Toothed\fwheel\f-\f4th\fge\br\f
Toothed\fwheel\f-\f2nd\fge\br\f
Toothed\fwheel\f-\f1st\fge\br\f
ItemA
B
C
D 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
\f
Pa\bt Numbe\b -
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
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