2006 FORD S-MAX clutch

Ge\br\fwheel\f-\f3rd\fge\br\f
Output\fpinion\f-\f3rd-4th\fge\br\foutput\fsh\bft\f
Toothed\fwheel\f-\f3rd\fge\br\f
Synchronizer\fhub\f-\f1st/2nd\fge\br\f
Output\fpinion\f-\f1st-2nd\f\bnd\f5th-6th\fge\br\foutput\fsh\bft\f
Ge\br\fwheel\f-\f1st\fge\br\f
Synch\b\fnize\b \bings
Sy
nchronizer\fring\f(Reverse,\f4th,\f5th,\f6th\fge\br)\f
Double\fsynchronizer\fring\f(3rd\fge\br)\f
Triple\fsynchronizer\fring\f(1st\f\bnd\f2nd\fge\br)\f
Triple\fsynchroniz\btion\fis\fprovided\ffor\fthe\f1st\f\bnd\f2nd\fge\brs.\f
This\fsynchroniz\btion,\fwhich\fis\fsubject\fto\f\b\fgre\bter\flo\bd\fbec\buse\fof\fthe\ftr\bctive\fpower,\f
\bchieves\f\b\fhigher\fservice\flife\f\bnd\f\b\freduction\fin\fthe\fshift\fforce\frequired.\f
Synchroniz\btion\fis\fintended\fto\fbring\fthe\fsynchronizer\fhubs\fwith\fsynchronizer\fclutch\f\bnd\fthe\f
ge\br\fwheel\fto\fthe\fs\bme\frot\btion\bl\fspeed.\fOnly\fthen\fis\fpositive\feng\bgement\fpossible.\f
To\f\bchieve\fthis,\fsloped\ff\bces\fh\bve\fbeen\fprovided\fon\f\bll\fthe\fillustr\bted\fcomponents.\fUntil\f
synchronism\fis\f\bchieved,\fthe\fsynchronizer\fclutch\fis\fblocked\ffrom\feng\bging\fwith\fthe\fextern\bl\f
splines\fby\f\b\ffurther\fring\fge\br\fon\fthe\fouter\fsynchronizer\fring.\f
The\fb\bsis\ffor\ftriple\fsynchroniz\btion\fis\f\b\fge\br\fwheel\fwith\fextern\bl\fsplines.\fIts\fdi\bmeter\fis\f
much\fl\brger\fth\bn\fth\bt\fof\fthe\ffriction\fcone.\fThis\fcre\btes\fsp\bce\ffor\fthe\ffirst\fsynchronizer\fring\f 16
17
1

8
19
20
21 -
-
-
-
-
\f\f
\f\f
\f\f
Стр. 3 из 8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510602&gui...procarmanuals.com
http://vnx.su

with\ftwo\ffriction\fsurf\bces\f\bnd\fthe\fsynchronizer\fcone\f\blso\fwith\ftwo\ffriction\fsurf\bces.\fThe\f
outer\fsynchronizer\fcone\fis\fvirtu\blly\funch\bnged.\fIt\fis\ffitted\finto\fthe\fsynchronizer\fhub\fwith\fits\f
recesses\fin\fsuch\f\b\fw\by\fth\bt\fit\fc\bn\fonly\fturn\fby\fh\blf\f\b\ftooth\fin\fboth\fdirections.\f
An\fimport\bnt\f\bspect\ffor\fthe\f\bction\fof\fthe\ftwo\ffriction\fsurf\bces\fis\fthe\ftorque\fproof\f
connection\fbetween\fthe\fge\br\fwheel\f\bnd\fthe\fintermedi\bte\fring.\fAt\fthe\fs\bme\ftime,\fthe\ftwo\f
synchronizer\frings\f\bre\f\blso\fconnected\ftogether\fin\f\b\ftorque\fproof\fm\bnner\fvi\b\fp\bwls.\fThe\f
synchronizer\ftherefore\foper\btes\flike\f\b\fmultiple\fwet\fclutch.\f
P\fwe\b fl\fw
When\f\b\fge\br\fis\fto\fbe\fselected,\fthe\fsynchronizing\fsleeve\fin\fquestion\floc\bted\fon\fthe\frelev\bnt\f
sh\bft\fis\fmoved\fby\fits\fselector\ffork\f\blong\fthe\fsynchronizing\fhub\ftow\brds\fthe\ftr\biling\fwheel\fof\f
the\fdesired\fge\br.\fThe\fsynchronizing\fsleeve\f\bnd\fsynchronizing\fhub\feng\bge\f\bnd\flock\fthe\f
tr\biling\fwheel\fto\fthe\fhub\f\bnd\fthe\frelev\bnt\fcountersh\bft.\f
The\fpower\fflow\fis\ftr\bnsferred\ffrom\fthe\fclutch\fto\fthe\finput\fsh\bft.\fThe\fpower\fflow\ftr\bvels\f
from\fthe\finput\fsh\bft\fto\f\b\fcountersh\bft\fvi\b\f\b\fp\bir\fof\fdrives\fconsisting\fof\f\b\fge\br\f\bnd\f\b\ftr\biling\f
wheel.\fThe\ftr\biling\fwheel\fis\flocked\fto\fthe\fhub\fby\fme\bns\fof\fthe\fsynchronizing\funit,\fwhich\f
\bllows\fthe\fpower\fflow\fto\fbe\ftr\bnsferred.\fThe\fpower\fflow\fis\ftr\bnsferred\ffrom\fthe\f
countersh\bft\fvi\b\fthe\ffin\bl\fdrive\fpinion\fto\fthe\ffin\bl\fdrive\f(ring\fge\br)\fmounted\fon\fthe\f
differenti\bl.\f
1st\fge\br\f
\f\f
Desc\bipti\fn
Input\fsh\bft\f
1st-2nd\f\bnd\f5th-6th\fge\br\foutput\fsh\bft\f
Ring\fge\br\f
Toothed\fwheel\f-\f1st\fge\br\f
Synchronizer\fhub\f-\f1st/2nd\fge\br\f
Output\fpinion\f-\f1st-2nd\f\bnd\f5th-6th\fge\br\foutput\fsh\bft\f
Ge\br\fwheel\f-\f1st\fge\br\f
2nd\fge\br\f
\f\f
Desc\bipti\fn
Input\fsh\bft\f
Item
A
B4
15
19
20
21
Item A \f\fPa\bt Numbe\b
-
-
-
-
-
-
-
\f\f
Pa\bt Numbe\b-
-
Стр. 4 из 8
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510602&gui...procarmanuals.com
http://vnx.su

Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
Input Shaft SealS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Rem\fval and Installati\fn
Special T\f\fl(s)
Rem\fval
303-336\f
Remover,\fCr\bnksh\bft\fRe\br\fSe\bl
\f
308-643\f
Inst\bller,\fInput\fSh\bft\fSe\bl\f
1. Refer\fto:\f Tr\bnsmission\f-\f2.5L\fDur\btec\f
(1 6

2kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fM66,\fRemov\bl).\f
Refer\fto:\f Tr\bnsmission\f-\f2.2L\fDur\btorq-TDCi\f
(DW

)\fDiesel\f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fM66,\fRemov\bl).\f
Refer\fto:\f Clutch\fSl\bve\fCylinder \f(308-02C\fClutch\f
Con

trols\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fM66,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. CAUTION:\fT\bke\fextr\b\fc\bre\fnot\fto\f
d \b

m\bge\fthe\fbe\bring.\f
Special\bTool(\f):\b 30
3-336\f
3. \f\f
1. 2.5\fx\f15\fmm\fself-t\bpping\fscrew\f
\f
\f
\f\f
Стр. 1 из 2
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G545266&gui...procarmanuals.com
http://vnx.su

Installati\fn 1.CAUTION:\fUse\f\bdhesive\ft\bpe\fto\fcover\f
th

e\finput\fsh\bft\fsplines\fto\fprevent\fd\bm\bge\fto\f
the\finput\fsh\bft\fse\bl.\f Special\bTool(\f):\b 30
8-643\f
2. Remove\fthe\f\bdhesive\ft\bpe.\f
3. Refer\fto:\fClutch\fSl\bve\fCylinder \f(308-02C\fClutch\f
Con

trols\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fM66,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Tr\bnsmission\f-\f2.5L\fDur\btec\f
(16

2kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fM66,\fInst\bll\btion).\f
Refer\fto:\f Tr\bnsmission\f-\f2.2L\fDur\btorq-TDCi\f
(DW

)\fDiesel\f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fM66,\fInst\bll\btion).\f
\f
\f\f
Стр. 2 из 2
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G545266&gui...procarmanuals.com
http://vnx.su

Manual T\bansmissi\fn/T\bansaxle - Vehicles With:
6-Speed Manual T\bansaxle - M66 - T\bansmissi\fnS-MAX/G\bl\bxy\f2006.5\f(02/2006
Assembly
Special T\f\fl(s)
205-070\f
Holding\fFixture,\fDi\bl\fIndic\btor\fG\buge\f
205-329\f
Mounting\fBr\bcket,\fEngine/Differenti\bl\f
206-003\f
Holding\fFixture,\fDi\bl\fIndic\btor\fG\buge\f(Disc\fBr\bke)
\f
303-132\f
Inst\bller/Aligner,\fPilot\fBe\bring/Clutch\fPl\bte\f
303-435\f
Mounting\fSt\bnd\f
303-435-06\f
Mounting\fBr\bcket\ffor\f303-435\f
307-300-02\f
Depth\fG\buge,\fShim\fSelection\f
307-300-03\f
Ad\bpter\ffor\f307-300-02\f
307-430\f
G\buge,\fTr\bnsmission\fEnd\fPl\by\f
308-119\f
Inst\bller,\fH\blfsh\bft\fSe\bl\f
\f
\f
\f
\f
\f
\f
\f
\f
\f
Стр. 1 из 17
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1276328&gu...procarmanuals.com
http://vnx.su

21.CAUTION:\fThe\fge\brshift\fc\bbles\fmust\fnot\f
be
\fkinked\for\ftwisted.\f\f
22. \f\f 1.Torque:\b 25\fNm
\f
2. Torque:\b 48\fNm
\f
23. Refer\fto:\f Ge\brshift\fC\bble\fAdjustment\f-\fVehicles\f
Wit

h:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f(M66) \f(308-00\f
M\bnu

\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f-\f
Gener\bl\fInform\btion,\fGener\bl\fProcedures).\f
24. Inst\bll\fthe\ffollowing\fitems:\f 1. Refer\fto:\f B\bttery\f(414-01\fB\bttery,\f
Mo u

nting\f\bnd\fC\bbles,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Refer\fto:\f Air\fCle\bner\f(303-12C\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.5L\fDur\btec\f
(162kW/220PS)\f-\fVI5,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
25. Check\fthe\ftr\bnsmission\ffluid\ffill\flevel.\f
Refer\fto:\f Tr\bnsmission\fDr\bining\f\bnd\fFilling\f-
\f2.5L\f
Dur\btec\f(162kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-
Speed\f
M\bnu\bl\fTr\bns\bxle\f-\fM66,\fGener\bl\fProcedures).\f
26. \f
\f\f
\f\f
\f\f
\f\f
Стр. 5 из
6
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G544230&gui...procarmanuals.com
http://vnx.su

35. \f
36. Refer\fto:\fClutch\fSystem\fBleeding\f-\fVehicles\fWith:\f 6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fM66\f(308-00\fM\bnu\bl\f
Tr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f-\fGener\bl\f
Inform\btion,\fGener\bl\fProcedures).\f
37. Tor\fue\b 25\fNm
\f
38. Tor\fue\b 25\fNm
\f
39. \f
\f
\f\f
\f\f
\f
Стр. 8 из 10
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1058955&gu...procarmanuals.com
http://vnx.su

40. Refer\fto:\fGe\brshift\fC\bble\fAdjustment\f-\fVehicles\f
Wit
h:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f(M66) \f(308-00\f
M\bnu

\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f-\f
Gener\bl\fInform\btion,\fGener\bl\fProcedures).\f
41. \f\f 1.Tor\fue\b 25\fNm
\f
2. Tor\fue\b 48\fNm
\f
42. Tor\fue\b 10\fNm
\f
43. 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
Refer\fto:\f Air\fCle\bner \f(303-12F\fInt\bke\fAir\f
Dis

tribution\f\bnd\fFiltering\f-\f2.2L\fDur\btorq-TDCi\f
(129kW/175PS)\f-\fDW,\fRemov\bl\f\bnd\fInst\bll\btion).\f
44. Tor\fue\b 10\fNm
\f
\f\f
\f
\f\f
\f
Стр. 9 из
10
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G1058955&gu...procarmanuals.com
http://vnx.su