2006 FORD S-MAX boot

Inst\fll\ft\bon 5. \f
1.

\f
2. S\fecial Tool(s): 204-169\f
To r

que: 21\fNm
\f
3. S\fecial Tool(s): 308-046\f
4. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
i
n

st\blled.\f
5. \f\f
Fill\fthe\fCV\fjoint\fwith\fgre\bse.\f
Mat

erial: Gre\bse\fFD-R\f(WSS-M1C259-A1\f/\f
3M 5

J-M1C259-AA) \f

Insert\f\b\fsm\bll\fscrewdriver\funder\fthe\fboot\f
\f\f
\f\f
\f\f
\f\f
\f\f
Стр. 2 из
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04.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G543339&gui...procarmanuals.com
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Front Dr\bve H\flfsh\ffts - Outer Const\fnt
Veloc\bty (CV) Jo\bnt BootS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\fl \fnd Inst\fll\ft\bon
Spec\b\fl Tool(s)
Remov\fl
In

st\fll\ft\bon
204-169\f
Cl\bmping\fTool,\fBoot\fRet\bining\fCl\bmp
\f
1. Remove\fthe\finner\fCV\fjoint\fboot.\f Refer\fto:\f Inner\fConst\bnt\fVelocity\f(CV)\fJoint\fBoot \f
(20

5-04\fFront\fDrive\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. \f
1. \f\f
Fill\fthe\fCV\fjoint\fwith\fgre\bse.\f

Insert\f\b\fsm\bll\fscrewdriver\funder\fthe\fboot\f
se

\bt\fto\f\bllow\fthe\f\bir\fto\fesc\bpe.\f
2. Special\bTool(\f):\b 204-169\f
Tor

que:\b 21\fNm
\f
3. Inst\bll\fthe\finner\fCV\fjoint\fboot.\f Refer\fto:\f Inner\fConst\bnt\fVelocity\f(CV)\fJoint\fBoot \f
(2 0

5-04\fFront\fDrive\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
\f
\f\f
\f\f
\f\f
Стр. 1 из 1
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Tie\fRod\b1. 1.\b
Noises\fsuch\f\bs\fknocks,\fwhich\fm\by\f\bppe\br\fto\forigin\bte\ffrom\fthe\fsteering\flink\bge,\f
m
\by\f\blso\fbe\fgener\bted\fby\ffront\fsuspension\fcomponents.\f\f
REFER\fto:\fNoise,\fVibr\btion\f\bnd\fH\brshness\f(NVH)\f(100-04\fNoise,\fVibr\btion\f\bnd\f
H\brshness,\fDi\bgnosis\f\bnd\fTesting).\f
2. 2.\b
R\bise\f\bnd\fsupport\fthe\fvehicle.\f\f
R
EFER\fto:\fLifting\f(100-02\fJ\bcking\f\bnd\fLifting,\fDescription\f\bnd\fOper\btion).\f
3. 3.\b
Firmly\fgr\bsp\fthe\fro\bd\fwheel\f\bnd\f\bpply\f\b\frocking\fmotion\fchecking\ffor\f\bny\ffree\fpl\by\f
i
n\fthe\fwheel\fbe\bring\for\fsuspension\fcomponents.\f
4. 4.\b
Turn\fthe\fsteering\fwheel\fto\fposition\fthe\fsteering\flink\bge\f\bg\binst\fthe\fright-h\bnd\f
s
teering\flock\fstop.\f
5. 5.\b
With\fthe\f\bid\fof\f\bnother\ftechnici\bn\fholding\fthe\fsteering\flink\bge\f\bg\binst\fthe\fright-
h
\bnd\fsteering\flock\fstop,\ffirmly\fgr\bsp\fthe\fro\bd\fwheel\f\bnd\f\bpply\f\b\frocking\fmotion\f
checking\ffor\f\bny\ffree\fpl\by\fin\fthe\fsteering\flink\bge.\f
6. 6.\b
Det\bch\fthe\fsteering\fge\br\fboot\ffrom\fthe\fsteering\fge\br\fbody\f\bnd\fcheck\ffor\ffree\fpl\by\f
\b
t\fthe\ftie-rod\finner\fb\bll\fjoint.\f \f\f
\f\f
\f\f
Стр. 5 из
8
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7.7.\b
If\fthere\fis\ffree\fpl\by\f\bt\fthe\ftie-rod\finner\fb\bll\fjoint,\finst\bll\f\b\fnew\ftie-rod.\f\f
R EFER\fto:\fTie\fRod\f(211-03\fSteering\fLink\bge,\fRemov\bl\f\bnd\fInst\bll\btion).\f
8. 8.\b
Check\fthe\ftie-rod\fend\ffor\ffree\fpl\by.\fInst\bll\f\b\fnew\ftie-rod\fend\fif\fnecess\bry.\f\f
R
EFER\fto:\fTie\fRod\fEnd\f(211-03\fSteering\fLink\bge,\fRemov\bl\f\bnd\fInst\bll\btion).\f
9. 9.\b
Turn\fthe\fsteering\fwheel\fto\fposition\fthe\fsteering\flink\bge\f\bg\binst\fthe\fleft-h\bnd\f
s
teering\flock\fstop.\f
10. 10.\b
With\fthe\f\bid\fof\f\bnother\ftechnici\bn\fholding\fthe\fsteering\f\bg\binst\fthe\fleft-h\bnd\f
s
teering\flock\fstop,\ffirmly\fgr\bsp\fthe\fro\bd\fwheel\f\bnd\f\bpply\f\b\frocking\fmotion\fchecking\f
for\f\bny\ffree\fpl\by\fin\fthe\fsteering\flink\bge.\f
11. 11.\b
Det\bch\fthe\fsteering\fge\br\fboot\ffrom\fthe\fsteering\fge\br\fbody\f\bnd\fcheck\ffor\ffree\f
p
l\by\f\bt\fthe\ftie-rod\finner\fb\bll\fjoint.\f
12. 12.\b
If\fthere\fis\ffree\fpl\by\f\bt\fthe\ftie-rod\finner\fb\bll\fjoint,\finst\bll\f\b\fnew\ftie-rod.\f\f
R
EFER\fto:\fTie\fRod\f(211-03\fSteering\fLink\bge,\fRemov\bl\f\bnd\fInst\bll\btion).\f
13. 13.\b
Check\fthe\ftie-rod\fend\ffor\ffree\fpl\by.\fInst\bll\f\b\fnew\ftie-rod\fend\fif\fnecess\bry.\f\f
R
EFER\fto:\fTie\fRod\fEnd\f(211-03\fSteering\fLink\bge,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Turning\bEffort\bTest\b
1. 1.\b
Before\fc\brrying\fout\fthe\fturning\feffort\ftest,\fm\bke\fsure\fth\bt\fthe\ffollowing\f\bre\f
s
ervice\bble:\f

Suspension\fcomponents.\f\f

Steering\fcolumn.\f\f

Toe\f\bdjustment.\f\f
RE

FER\fto:\f Front\fToe\fAdjustment \f(204-00\fSuspension\fSystem\f-\fGener\bl\fInform\btion,\f
Ge n

er\bl\fProcedures).\f

Tire\fpressures.\f
2 . 2.\b
P\brk\fthe\fvehicle\fon\f\b\fdry,\feven\fsurf\bce\f\bnd\f\bpply\fthe\fp\brking\fbr\bke.\f \f
\f
\f\f
Стр. 6 из
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Steering\bSystem\b\f\bGeneral\bInformation\b\f\b
Power\bSteering\bSystem\bBleedingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General\bProcedures\b
Special\bTool(s)\b
Mat

erials\b
211-189\f
Ad\bpter,\fPower\fSteering\fBleeding\f
416-D001\f
H\bnd\fV\bcuum\fPump/Pressure\fPump
\f
NameSpec\bf\bcat\bo\f
Hydr\bulic\fFluid\fDP-PSWSS-M2C204-A2\f/\f5U7J-M2C204-AA 1. Fill\fthe\fpower\fsteering\ffluid\freservoir\fto\fthe\fMAX\fm\brk.\f
Material\b Hydr\bulic\fFluid\fDP-PS\f(WSS-M2C204-
A2\f

/\f5U7J-M2C204-AA) \f
2. R

\bise\fthe\fvehicle\funtil\fthe\fro\bd\fwheels\f\bre\fcle\br\f
of\fthe\ffloor.\fSupport\fthe\fvehicle.\f
Refer\fto:\f Lifting\f(100-02\fJ\bcking\f\bnd\fLifting,\f
Des

cription\f\bnd\fOper\btion).\f
3. St\brt\fthe\fengine\f\bnd\fslowly\fturn\fthe\fsteering\f wheel\ffrom\flock\fto\flock\f\bnd\f\bdd\fpower\fsteering\f
fluid\funtil\fthe\fpower\fsteering\ffluid\fin\fthe\fpower\f
steering\ffluid\freservoir\fdoes\fnot\fdrop.\f\f
4. Switch\fOFF\fthe\fengine\f\bnd\fex\bmine\fthe\fpower\f steering\fhose\fconnections,\fsteering\fge\br\fboots,\f
power\fsteering\fv\blve\fbody\f\bnd\fpower\fsteering\f
pump\ffor\fextern\bl\fle\bks.\f
5. Check\fthe\fpower\fsteering\ffluid\flevel.\fFill\fthe\f power\fsteering\ffluid\freservoir\fto\fthe\fMAX\fm\brk.\f
Material\b Hydr\bulic\fFluid\fDP-PS\f(WSS-M2C204-
A2 \f

/\f5U7J-M2C204-AA) \f
6. W

hen\fbleeding\fthe\fpower\fsteering\fsystem\fthe\f
v\bcuum\fwill\fdecre\bse.\fUsing\fthe\fspeci\bl\ftools,\f
m\bint\bin\f\b\fsufficient\fv\bcuum\fof\f38cm-Hg.\fIf\fthe\f
v\bcuum\fdecre\bses\fby\fmore\fth\bn\f5cm-Hg\fin\f5\f
minutes,\fthe\fsystem\fshould\fbe\fchecked\ffor\fle\bks.
\f
Spe\fial Tool(s)\b 211-189,\f416-D001\f
7. \f
\f 1. St\brt\fthe\fengine\f\bnd\fslowly\fturn\fthe\f
steering\fwheel\ffrom\flock\fto\flock\fonce;\fthen\f
turn\fthe\fsteering\fwheel\fto\fthe\fright,\fjust\f
off\fthe\fstop.\f
\f
\f
\f\f
Стр. 1 из 2
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Steering\bLinkage\b\f\bSteering\bLinkageS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description\band\bOperation\b
\f\f
Description\b
Tie-rod\fend\fnut\f
Tie-rod\fend\f
Tie-rod\fend\flocknut\f
Steering\fge\br\f
Steering\fge\br\fboot\f\f
Tie-rod\f\f
Item
1
2
3
4
5
6
\f
Part\bNumber -
-
-
-
-
-
Стр. 1 из 1
04.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G549208&gui...procarmanuals.com
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Steering\bLinkage\b\f\bTie\bRodS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Removal\band\bInstallation\b
Special\bTool(s)\b
Gen

eral\bEquipment\b
Removal\b
N O

TE:\fRemov\bl\fsteps\fin\fthis\fprocedure\fm\by\fcont\bin\finst
\bll\btion\fdet\bils.\f
204-169\f
Cl\bmping\fTool,\fBoot\fRet\bining\fCl\bmp
\f
211-245\f
Socket,\fSteering\fGe\br\fTie-Rod\f
Vise
Vise\fj\bw\fprotectors
1. Refer\fto:\fSteering\fGe\br \f(211-02\fPower\fSteering,\f
Rem

ov\bl\f\bnd\fInst\bll\btion).\f
2. NOTE:\fM\bke\fsure\fth\bt\fthe\ftie\frod\fend\fis\f
in

st\blled\fwith\fthe\fs\bme\fnumber\fof\fturns\f\bs\f
when\fremoved.\f
Torque:\b 90\fNm
\f
3. NOTE:\fNote\fthe\fposition\fof\fe\bch\fcomponent\f
b
e

fore\fremov\bl.\f
4. \f
5. Ge

nera\f\bEquipment:\b Vise\f
Ge n

era\f\bEquipment:\b Vise\fj\bw\fprotectors \f
\f
\f
\f\f
\f\f
\f\f
Стр. 1 из 2
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systems\fh\bs\fbeen\ftested.\f\f

T\bke\finto\f\bccount\fthe\floc\btion\fof\f\bir\fcurt\bins\f\bnd\fshoulder\f\birb\bgs.\f
Protection of the vehicle
Pro
tect\f\bffected\f\bre\bs\ffrom\fweld\fsp\btter\f\bnd\fdust\fduring\f\bll\fwelding\f\bnd\fgrinding\fwork\fon\f
the\fvehicle.\fIf\fmet\bllic\fdust\fst\bys\fon\fthe\fvehicle\ffor\fsome\ftime,\fthere\fis\fthe\flikelihood\fof\f
film\frust\fform\btion.\fGrinding\for\fs\bnding\fwork\fproduce\ftiny\fspots\fof\fd\bm\bge\fto\fthe\fp\bint\f
surf\bce,\fwhich\fm\by\fc\buse\fcorrosion.\f\f
For\fthis\fre\bson,\fm\bke\fsure\fto:\f

Use\fc\brbon\ffibre\fbl\bnkets\fto\fprotect\fthe\fvehicle\fbody.\f\f

Use\fcovering\ffilm\fto\fprotect\fthe\fvehicle\fbody\ffrom\fs\bnding\fdust\f\bnd\fmet\bl\fdust.\f\f

T\bke\f\bppropri\bte\fme\bsures\fto\fprotect\fthe\finterior\fequipment\fof\fthe\fvehicle\fduring\f\bny\f
re

p\bir\fwork.\f\f
In\f\bddition,\ft\bke\finto\f\bccount:\f
Remove\ffuel\fsupply\fcomponents\f\bs\fnecess\bry.\f\f

Protect\fworking\f\bre\bs\fwhich\f\bre\fin\fd\bnger\fof\fc\btching\ffire\fwith\f\b\ffireproof\fbl\bnket.\f\f

The\fwelding\fmust\fnot\fc\buse\fcomponents\fof\fthe\f\bir\fconditioning\fsystem\fto\fbecome\f
he

\bted.\f\f

Remov\bl\fof\f\bny\f\btt\bched\fcomponents\fin\fthe\fsp\bce\f\bdjoining\fthe\frep\bir\f\bre\b.\f\f

Use\fcovering\fp\bper\fto\fprotect\fthe\finterior\ffrom\fgrinding\fdust.\f\f

Cre\bte\f\b\fdefinite\fb\brrier\fbetween\fthe\fwork\f\bre\b\f\bnd\fthe\finterior\fby\fusing\f\b\fc\brbon\ffibre\f
bl

\bnket.\f\f
Protective equi\bment
Th
e\ffollowing\fprotective\fequipment\fmust\f\blw\bys\fbe\fused:\f

Protective\fhelmet\for\fwelding\fm\bsk.\f\f

E\br\fdefenders\f\bnd\fbre\bthing\fprotection.\f\f

Protective\fgloves\f\bnd\fs\bfety\fboots.\f\f

Welding\ffume\fextr\bction.\f
Electronic com\bonent\f
I n

cre\bsed\fuse\fof\fcomfort\f\bnd\fs\bfety\felectronics\fin\fmodern\fmotor\fvehicles\f\blso\frequires\fthe\f
gre\btest\f\bttention\fto\fbe\fp\bid\fduring\fbody\fwork.\fOvervolt\bges\fproduced\fduring\fwelding\f\bnd\f
in\f\blignment\fwork\fduring\fbodyshell\frectific\btion\fm\by\fc\buse\felectronic\fsystems\fto\fbe\f
d\bm\bged.\fIn\fp\brticul\br,\fthe\fs\bfety\finstructions\ffor\fperforming\fwelding\fwork\fon\fvehicles\fwith\f
\birb\bg\fsystems\fmust\fbe\f\bdhered\fto.\f\f
NOTE:\fAfter\fdisconnecting\fthe\fpower\fsupply\f\bnd\fbefore\f
performing\ffurther\fwork,\f\b\fw\bit\f
time\fof\fup\fto\f15\fminutes\fmust\fbe\fm\bint\bined,\fdepending\fon\fthe\fvehicle.\fWork\fon\f\birb\bg\f
systems\fm\by\fonly\fbe\fperformed\fby\fpersons\fwho\fh\bve\f\b\frelev\bnt\fcertific\bte\fof\f
competence.\f
P\by\f\bttention\fto\fthe\ffollowing\fpoints:\f

Disconnect\fthe\fb\bttery\fneg\btive\fcl\bmp\f\bnd\fcover\fthe\fb\bttery\ftermin\bl.\f\f

Disconnect\fthe\felectric\bl\fconnector\f\bt\fthe\f\birb\bg\fcontrol\fmodule.\f\f

If\fwelding\fis\fto\fbe\fperformed\fdirectly\fne\br\f\b\fcontrol\fmodule,\fit\fmust\fbe\fremoved\f
be

foreh\bnd.\f\f

Never\fconnect\fthe\fneg\btive\fc\bble\fof\fthe\fwelder\fne\br\f\bn\f\birb\bg\for\f\b\fcontrol\fmodule.\f\f

Connect\fthe\fneg\btive\fc\bble\fof\fthe\fwelder\fclose\fto\fthe\floc\btion\fof\fthe\fweld.\f\f
For\f\bddition\bl\finform\btion,\frefer\fto:\f(501-20B\fSupplement\bl\fRestr\bint\fSystem)\f\f
Стр. 2 из 4
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