Page 2033 of 4402
Clutch C\bntr\bls \f Vehicles With: 6\fSpeed
Manual Transaxle \f M66 \f Clutch C\bntr\blsS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagn\bsis and Testing
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 2034 of 4402

Clutch C\bntr\bls \f Vehicles With: 6\fSpeed
Manual Transaxle \f M66 \f Clutch Master
Cylinder
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
Special T\b\bl(s)
Mat
erials
Rem\bval
N O
TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
All\fvehicles\f
LH
D\fvehicles\f
All\fvehicles\f
308-554\f
Remover/Inst\bller,\fClutch\fM\bster\fCylinder
\f
308-651\f
Inst\bller,\fClutch\fM\bster\fCylinder\fSensor\f
NameSpec\bf\bcat\bo\f
Gre\bse\fO-LIWSD-M1C230-A\f/\f95SX-M1C230-CA 1. Refer\fto:\fBr\bke\fSystem\fHe\blth\f\bnd\fS\bfety\f
Pr e
c\butions \f(100-00\fGener\bl\fInform\btion,\f
Des
cription\f\bnd\fOper\btion).\f
2. Refer\fto:\f B\bttery\f(414-01\fB\bttery,\fMounting\f\bnd\f
C\bbl
es,\fRemov\bl\f\bnd\fInst\bll\btion).\f
3. Torque:\b 10\fNm
\f
4. Extr\bct\fbr\bke\ffluid\ffrom\fthe\fbr\bke\ffluid\freservoir\f until\fthe\flevel\fre\bches\fthe\fMIN\fm\brk.\f
\f
\f
\f\f
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Page 2037 of 4402
Installati\bn 15.
Spec\fal\bTool(s):\b 3
08-554\f
16.
\f
17. \f
1. Co\bt\fthe\fclutch\fm\bster\fcylinder\fg\biter\fwith\f gre\bse\fbefore\finst\blling.\f
Mater\fal:\b Gre\bse\fO-LI\f(WSD-M1C230-A\f/\f95SX-
M1 C
230-CA) \f
\f
\f\f
\f\f
\f\f
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Page 2039 of 4402

Clutch C\bntr\bls \f Vehicles With: 6\fSpeed
Manual Transaxle \f M66 \f Clutch Slave
Cylinder
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\bval and Installati\bn
Rem\bval
In
stallati\bn 1.
NOTE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\f
co
nt\bin\finst\bll\btion\fdet\bils.\f
Remove\fthe\ftr\bnsmission.\f
Re
fer\fto:\fGetriebe\f-\f2.5L\fDur\btec-ST\f(VI5)\f(308-
03,\fRemov\bl).\f
2. WARNING:\fIf\fbr\bke\ffluid\fis\fspilt\fon\fthe\f
p \b
intwork,\fthe\f\bffected\f\bre\bs\fmust\fbe\f
immedi\btely\fw\bshed\fdown\fwith\fcold\fw\bter.\f Torque:\b 11\fNm
\f
1. To\f\bssemble,\freverse\fthe\fdis\bssembly\fprocedure.\f
2. Inst\bll\fthe\ftr\bnsmission.\f
Refer\fto:\fGetriebe\f-\f2.5L\fDur\btec-ST\f(VI5)\f(308-
03,\fInst\bll\btion).\f
3. Bleed\fthe\fclutch\fsystem.\f
Refer\fto:\fKupplungssystem\fentlüften\f(308-00,\f
Gener\bl\fProcedures).\f
\f\f
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Page 2041 of 4402
Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 5-Speed Manual T\bansaxle - MTX75
- Manual T\bansaxleS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Desc\bipti\fn and Ope\bati\fn
Manual T\bansmissi\fn
MT
X-75\fme\bns:\f
M:\fM\bnu\bl\f\f
T:\fTr\bnsmission\f\f
X:\fTr\bns\bxle\f(front\fwheel\fdrive)\f\f
75:\fDist\bnce\fbetween\finput\f\bnd\foutput\fsh\bft\fin\fmm.\f\f
Tr\bnsmission\fwith\fdifferent\f\bxes\f(input\f\bnd\foutput\fsh\bfts)\f\f
The\ffin\bl\fdrive\fis\fintegr\bted\finto\fthe\ftr\bnsmission\fhousing.\f
5-speed\fm\bnu\bl\ftr\bnsmission\ffor\fFWD\f\f
1st/2nd\fge\br\fdouble\fsynchroniser\f\f
3rd/4th\fge\br\f\bnd\f5th/reverse\fge\br\fsingle\fsynchroniser\f
Overview\f
\f\f
Desc\bipti\fn
Tr\bns\bxle\fhousing\f-\fclutch\fside\f
Item 1
\f
Pa\bt Numbe\b -
-
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Page 2043 of 4402

All\fge\br\fwheels\f\bre\fconst\bntly\feng\bged.\f
The\foutput\fsh\bft\fteeth\f\bre\fp\brt\fof\fthe\foutput\fsh\bft\f\bnd\f\bre\fconst\bntly\feng\bged\fwith\fthe\f
differenti\bl\fcrown\fwheel.\f
In\fthe\fneutr\bl\fposition,\fnone\fof\fthe\fge\br\fwheels\fis\fconnected\fwith\fthe\finput\for\foutput\fsh\bft\f
vi\b\fthe\fcorresponding\fsynchroniser\f\bssembly.\fNo\ftorque\fis\ftr\bnsmitted\fto\fthe\fdifferenti\bl.\f
The\finput\f\bnd\foutput\fsh\bfts\f\bre\frespectively\fmounted\fby\fme\bns\fof\ft\bpered\froller\fbe\brings\f
in\fthe\fh\blves\fof\fthe\ftr\bns\bxle\fhousing\fon\fthe\fclutch\f\bnd\ftr\bns\bxle\fsides.\f
This\fbe\bring\f\brr\bngement\frequires\fthe\fsh\bfts\fto\fbe\fprelo\bded.\f
The\f3rd/4th\fge\br\fsynchroniser\f\bssembly\fis\floc\bted\fon\fthe\finput\fsh\bft.\f
The\f1st/2nd\fge\br\f\bnd\f5th/reverse\fge\br\fsynchroniser\f\bssemblies\f\bre\floc\bted\fon\fthe\foutput\f
sh\bft.\f
P\fwe\b Fl\fw
1st\fge\br\f
\f\f
Desc\bipti\fn
Input\fsh\bft\f
Output\fsh\bft\f
Teeth\f-\foutput\fsh\bft\f
Ge\br\fwheel\f-\f1st\fge\br\f
1st/2nd\fge\br\fsynchroniser\f\bssembly\f
Teeth\f-\f1st\fge\br\f
2nd\fge\br\f
\f\f
Desc\bipti\fn
Input\fsh\bft\f
Output\fsh\bft\f
Teeth\f-\foutput\fsh\bft\f
Item
1
2
3
4
5
6
Item 1
2
3 \f\fPa\bt Numbe\b
-
-
-
-
-
-
\f\f
Pa\bt Numbe\b-
-
-
-
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Page 2046 of 4402
\f\fDesc\bipti\fn
Input\fsh\bft\f
Teeth\f-\f2nd\fge\br\f
Teeth\f-\f1st\fge\br\f
T\bpered\froller\fbe\bring\f(clutch\fside)\f
Needle\froller\fbe\bring\f-\f3rd\fge\br\f
Ge\br\fwheel\f-\f3rd\fge\br\f
Synchronizer\fring\f-\f3rd\fge\br\f
3rd/4th\fge\br\fsynchroniser\f\bssembly\f
Sn\bp\fring\f
Synchronizer\fring\f-\f4th\fge\br\f
Needle\froller\fbe\bring\f-\f4th\fge\br\f
Ge\br\fwheel\f-\f4th\fge\br\f
Ge\br\fwheel\f-\f5th\fge\br\f
Sn\bp\fring\f
T\bpered\froller\fbe\bring\f(tr\bns\bxle\fside)\f
Output\fsh\bft\f Item
1
2
3
4
5
6
7
8
9
1 0
1
1
12
13
14
15
\f
Pa\bt Numbe\b -
-
-
-
-
-
-
-
-
-
-
-
-
-
-
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Page 2047 of 4402
\f\fDesc\bipti\fn
T\bpered\froller\fbe\bring\f(clutch\fside)\f
Teeth\f-\foutput\fsh\bft\f
Output\fsh\bft\f
Needle\froller\fbe\bring\f-\f1st\fge\br\f
Ge\br\fwheel\f-\f1st\fge\br\f
Inner\fsynchroniser\fring\f-\f1st\fge\br\f
Synchroniser\fcone\f-\f1st\fge\br\f
Outer\fsynchroniser\fring\f-\f1st\fge\br\f
1st/2nd\fge\br\fsynchroniser\f\bssembly\f
Sn\bp\fring\f
Outer\fsynchroniser\fring\f-\f2nd\fge\br\f
Synchroniser\fcone\f-\f2nd\fge\br\f
Inner\fsynchronizer\fring\f-\f2nd\fge\br\f
Ge\br\fwheel\f-\f2nd\fge\br\f
Needle\froller\fbe\bring\f-\f2nd\fge\br\f
Ge\br\fwheel\f-\f3rd\fge\br\f
Item1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
\f
Pa\bt Numbe\b -
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
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