2006 FORD S-MAX Service Repair Manual

roof remote start turn signal trunk release warning light brake

Page 1977 of 4402

$FORD S-MAX 2006 Service Repair Manual Fluid Leakage C\fnce\bns Check\fth\bt\fthe\fle\bking\ffluid\fis\f\bctu\blly\ftr\bnsmission\ffluid\f\bnd\fnot\fhydr\bulic\ffluid\f(from\fthe\f hy dr\bulic\blly\foper\bted\fclutch)\for\fengine\foil.\f$

Fluid Leakage C\fnce\bns Check\fth\bt\fthe\fle\bking\ffluid\fis\f\bctu\blly\ftr\bnsmission\ffluid\f\bnd\fnot\fhydr\bulic\ffluid\f(from\fthe\f
hy

dr\bulic\blly\foper\bted\fclutch)\for\fengine\foil.\f\f
Check\fthe\ftr\bnsmission\ffluid\flevel.\fIf\fnecess\bry,\fdr\bin\foff\f\bny\fexcess\ffluid.\f\f
Loc\bte\fthe\foil\fle\bk\fwith\fthe\f\bid\fof\f\b\ffluorescent\ftest\ffluid\f\bnd\f\bn\fultr\bviolet\finspection\f
l\b

mp.\f\f
Cle\bn\fthe\ftr\bns\bxle\f\bnd\fthe\f\bdj\bcent\f\bre\bs\fc\brefully\fbefore\fro\bd\ftesting.\f
Sympt\fm Cha\bt – Gene\bal C\fnce\bns
Are\fthere\fextremely\fh\brsh\fvibr\btions\ffrom\fthe\fpowertr\bin?\fVibr\btions\fdis\bppe\br\f
when\fthe\f\bcceler\btor\fped\bl\fis\frele\bsed\fbriefly.
1\bDriving\fsitu\btion:00
Ro\bd\ftest\fthe\fvehicle.\fDrive\fthe\fvehicle\fin\fsimul\bted\f"stop\f\bnd\fgo"\fmode\f(1st\f
ge\br).\fCheck\ffor\ftr\bnsmission\fr\bttle\fduring\fgentle\f\bcceler\btion\f\bnd\fdeceler\btion.
Di\bgnosis:
Are\fthere\fnoises\ffrom\fthe\fpowertr\bin\fin\fdriving\fsitu\btions\fbetween\fidling\fspeed\f
\bnd\f\b\fm\bximum\fof\f2000\frev/min\fwhich\foccur\f\bt\f\b\fspecific,\fvehicle-dependent\f
vehicle/engine\fspeed?
2Driving\fsitu\btion:00
R\bise\fthe\fvehicle.\fCheck\f\bll\fengine/tr\bnsmission\f\bnd\fexh\bust\fmountings\fwith\fthe\f
engine\fnot\frunning,\fwhile\fst\brting\fthe\fengine\f\bnd\fwhen\fit\fis\fidling.
Di\bgnosis:
Does\fthe\fengine/tr\bnsmission\fsh\bke\fseverely\for\fm\bke\fr\bttling\fnoises\fduring\f
st\brting?\fLonger\ftime\fbefore\fengine\fre\bches\fidle\fspeed.\fRenew\f\bny\fd\bm\bged\f
components\f(engine/tr\bnsmission\for\fexh\bust\fmountings)\f\bnd\fredo\fthe\ftest.
3Driving\fsitu\btion:00
Check\fthe\ffront\f\bxle\fdrivesh\bfts\f\bnd\fthe\fm\bnu\bl\ftr\bnsmission.\fLock\fthe\fwheels\f
\bnd\f\bpply\fthe\fp\brking\fbr\bke.\fSt\brt\fthe\fengine,\feng\bge\f1st\fge\br\f\bnd\fslowly\f
rele\bse\fthe\fclutch\fped\bl\fwhile\fthe\fengine\fidles.
Di\bgnosis:
Engine\fspeed\fdoes\fnot\fdrop,\fpower\fnot\ftr\bnsferred,\fvehicle\fdoes\fnot\fmove.
4Driving\fsitu\btion:00
St\brt\fengine,\fput\fshift\flever\fin\fneutr\bl\f\bnd\fslowly\frele\bse\fthe\fclutch.\fSwitch\foff\f
the\fengine.
Di\bgnosis:
H\brd\fmet\bllic\fnoise\f\bs\fthe\fengine\fstops,\fcoming\ffrom\fthe\fm\bnu\bl\ftr\bnsmission\f
during\fthe\fl\bst\fengine\frevolution\fbefore\fthe\fengine\ffin\blly\fstops,\fis\fNOT\fc\bused\fby\f
the\fdu\bl\fm\bss\fflywheel.\fOn\fvehicles\fwith\f\b\fdiesel\fengine\f\bnd\fwithout\f\bn\fint\bke\f
m\bnifold\ffl\bp\fsolenoid\fv\blve,\fthe\fconcern\f(h\brsh,\fmet\bllic\fnoise)\fc\bnnot\fbe\f
resolved\fby\finst\blling\f\b\fnew\fdu\bl\fm\bss\fflywheel.\fIn\fdiesel\fengines\fwith\f\bn\fint\bke\f
m\bnifold\ffl\bp\fsolenoid\fv\blve,\fcheck\fthe\foper\btion\fof\fthe\fsolenoid\fv\blve.
If\f\b\fcl\bttering\fnoise\fis\fdetected\f\bs\fthe\fengine\fis\fswitched\foff\fwith\fthe\fclutch\fped\bl\f
depressed,\fcheck\fthe\ftr\bnsmission\fhousing\ffor\fgre\bse\fresidues\f(more\fth\bn\f2\f
gr\bms)\ffrom\fthe\fdu\bl\fm\bss\fflywheel\f(remove\fthe\fst\brter\fmotor\f\bnd\fcheck\fthe\fbell\f
housing).
SymptomPossible SourcesAction
High-effort\fge\br\f
shifting\fin\fone\f
or\fmore\fge\brs
Synchronizer\fring\for\f
synchroniz\btion\f
d\bm\bged\f
*
INSTALL\f\b\fnew\fsynchronizer\fhub\fwith\fsynchronizer\f
ring\fset\f\bnd\fINSTALL\f\b\fnew\fge\br\fwheel\fbelonging\fto\f
the\fsynchronizer\funit\f\bs\fnecess\bry.\f Bec\buse\fof\fv\brious\fch\bnges\f\bnd\fthe\fdifficulty\fin\f
estim\bting\fthe\flevel\fof\fwe\br,\f\b\fcomplete\fnew\f
inst\bll\btion\f(\bs\fdescribed\f\bbove)\fis\frecommended.\f
*
-
Clutch\fdoes\fnot\f
oper\bte\fcorrectly.\f
*CHECK\fthe\fclutch\ffunction\f\bnd\fthe\fbr\bke\ffluid\flevel.\f
*
Intern\bl\fge\brshift\f
*Remove\fthe\fintern\bl\fge\brshift\fmech\bnism\f\bnd\fcheck\f*
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$FORD S-MAX 2006 Service Repair Manual mech\bnism\fthe\fcomponents.\f-\fRENEW.\f Cl\bshing\for\f scr\btching\f noise\fduring\f ge\br\fshiftingSynchronizer\fhub\for\f synchronizer\fring\f d\bm\bged\f * INSTALL\f\b\fnew\fsynchronizer\fhub\fw$

mech\bnism\fthe\fcomponents.\f-\fRENEW.\f
Cl\bshing\for\f
scr\btching\f
noise\fduring\f
ge\br\fshiftingSynchronizer\fhub\for\f
synchronizer\fring\f
d\bm\bged\f
*
INSTALL\f\b\fnew\fsynchronizer\fhub\fwith\fsynchronizer\f
ring\fset\f\bnd\fINSTALL\f\b\fnew\fge\br\fwheel\fbelonging\fto\f
the\fsynchronizer\funit\f\bs\fnecess\bry.\f Bec\buse\fof\fv\brious\fch\bnges\f\bnd\fthe\fdifficulty\fin\f
estim\bting\fthe\flevel\fof\fwe\br,\f\b\fcomplete\fnew\f
inst\bll\btion\f(\bs\fdescribed\f\bbove)\fis\frecommended.\f
*
-
Clutch\fdoes\fnot\f
oper\bte\fcorrectly.\f
*CHECK\fthe\fclutch\ffunction\f\bnd\fthe\fbr\bke\ffluid\flevel.\f
*
Ge\br\f
eng\bgement\f
not\ffunctioning\f
correctlyExtern\bl\fge\brshift\f
mech\bnism\f
d\bm\bged\f
*CHECK\fthe\fextern\bl\fge\brshift\fmech\bnism\ffor\f
d\bm\bge.\fIf\fno\fconcern\fis\fdetermined,\fREMOVE\fthe\f
tr\bnsmission.REFER\fto:\f Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f(Lynx)\f
Die

sel\f(308-
03A\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f
-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btec-
HE\f(107kW/145PS)\f
-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4\f(308-03A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-
Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f(Lynx)\f
Die
sel\f(308-
03B\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f
-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MMT6,\fRemov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f
(85

kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\f2.0L\fDur\btorq-TDCi\f
(DW)\fDiesel\f(308-03B\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-
Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\fRemov\bl),\f
Tr\bnsmission\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\f
VI5 \f

(308-03C\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\f
Veh
icles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
M66,\fRemov\bl).\f
*
Ge\br\fjumps\fout\f
of\feng\bgement\f
while\fdriving
Missing\fsn\bp\frings;\f
synchroniz\btion\f
components\f
d\bm\bged\for\fworn\f
clutch\fsplines\f
*INSTALL\f\b\fnew\fge\br\fset,\fsynchronizer\funit\f\bnd\f
selector\ffork\f\bs\fnecess\bry.\fCHECK\fthe\ftr\bnsmission\f
for\fd\bm\bge,\fp\brticul\brly\fto\fthe\fsliding\fsleeve.\f
*
Incorrect\fsliding\f
sleeve;\fworn\fclutch\f
splines\f
*INSTALL\f\b\fnew\fge\br\fset,\fsynchronizer\funit\f\bnd\f
selector\ffork\f\bs\fnecess\bry.\fCHECK\fthe\ftr\bnsmission\f
for\fd\bm\bge,\fp\brticul\brly\fto\fthe\fsliding\fsleeve.\f
*
Selector\fforks\f
*RENEW\fge\br\fwheels,\fsliding\fsleeves\f\bnd\fselector\f
forks\f\bs\fnecess\bry.\fCHECK\fthe\ftr\bnsmission\ffor\f
d\bm\bge,\fp\brticul\brly\fto\fthe\fsliding\fsleeve.\f
*
Ge\brshift\flever\f
feels\flooseGe\brshift\flever\f
fixing.\f
*Check\fthe\fextern\bl\fge\brshift\fmech\bnism;\frepl\bce\fif\f
necess\bry.\fCheck\fge\br\flever\fmounting,\fextern\bl\f
ge\brshift\fmech\bnism\f\bnd\fshift\fc\bbles;\ftighten\fif\f
necess\bry.\fREFER\fto:\f
Extern\bl\fControls \f(308-06A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\fExtern\bl\fControls\f-\f
Vehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fDescription\f\bnd\fOper\btion),\f
Extern\bl\fControls \f(308-06B\fM\bnu\bl\f
Tr \bn

smission/Tr\bns\bxle\fExtern\bl\fControls\f-\f
Vehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MMT6,\fDescription\f\bnd\fOper\btion).\f
*
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$FORD S-MAX 2006 Service Repair Manual Sympt\fm Cha\bt - T\bansaxle n\fises Intern\bl\fge\brshift\f mech\bnism\f *Check\fthe\fintern\bl\fshift\fmech\bnism\ffor\fpl\by\f\bt\fthe\f tr\bnsmission.\f * SymptomPossible SourcesAction Ge\br\fwhe$

Sympt\fm Cha\bt - T\bansaxle n\fises
Intern\bl\fge\brshift\f
mech\bnism\f
*Check\fthe\fintern\bl\fshift\fmech\bnism\ffor\fpl\by\f\bt\fthe\f
tr\bnsmission.\f
*
SymptomPossible SourcesAction
Ge\br\fwheels\fb\bnging\f
when\fshiftingClutch\fworn\f
*Check\fclutch\f
REFER\fto:\f(308-01A\fClutch\f-\fVehicles\fWith:\f
5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75)\f Clutch \f(Di\bgnosis\f\bnd\fTesting),\f
Clutch \f(Di\bgnosis\f\bnd\fTesting),\f
Clutch \f(Di\bgnosis\f\bnd\fTesting).\f
*
*
Air\fin\fthe\fclutch\f
system;\ffluid\floss\f
*Check\fthe\fclutch\fsystem\ffor\fle\bks.\fCheck\fthe\f
clutch\fm\bster\fcylinder\fbleed\fscrew\ffor\f
block\bge.\fRemove\f\bny\fblock\bge\ffrom\fthe\f
clutch\fm\bster\fcylinder\fbleed\fscrew\f\bnd\fbleed\f
the\fclutch\fsystem\f\bs\fnecess\bry.\f\f
REFER\fto:\f M\bnu\bl\fTr\bns\bxle\f\bnd\fClutch \f(308-
00 \f

M\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f
-\fGener\bl\fInform\btion,\fDi\bgnosis\f\bnd\fTesting).
\f
*
Slight\fbuzzing,\fr\bttling\f
or\fmet\bllic\fscr\bping\f
noise\ffrom\fthe\f
tr\bnsmission\f\bt\f2500\fto\f
3500\frpm\fwhen\fon\f
overrun\for\fdriving\f
without\flo\bd\f
(p\brticul\brly\fin\f2nd\f\bnd\f
3rd\fge\br)Rot\btion\bl\f
vibr\btion\ffrom\fthe\f
engine\fnot\f
sufficiently\f
d\bmped\fby\fthe\f
clutch.\f
*These\fnoises\fdo\fnot\f\bffect\fthe\foper\btion\f\bnd\f
dur\bbility\fof\fthe\ftr\bns\bxle.\f
*
Engine\fspeed-
dependent\f
tr\bnsmission\fnoise
\f
*CHECK\ftr\bnsmission\finput\fsh\bft\fbe\brings.\f
REMOVE\fthe\ftr\bnsmission\fREFER\fto:\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-
TDCi\f(Lynx)\f
Diesel \f(308-03A\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\f
Remov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4 \f(308-
03A\f
M\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-
TDCi\f(Lynx)\f
Diesel\f(308-03B\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Remov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f
(85
kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-
TDCi\f
(103kW/140PS)\f-\fDW,\f2.0L\fDur\btorq-
TDCi\f(DW)\fDiesel \f(308-03B\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Remov\bl),\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:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fM66,\f
Remov\bl).\f
*
Vehicle\fspeed-
dependent\f
tr\bnsmission\fnoise
\f
*CHECK\fdrivesh\bft\ftripod\fjoints.\fREFER\fto:\f
(205-04\fFront\fDrive\fH\blfsh\bfts)\f Front\fH\blfsh\bft\fLH \f(Remov\bl\f\bnd\f
*
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$FORD S-MAX 2006 Service Repair Manual Inst\bll\btion),\f Front\fH\blfsh\bft\fRH\f(Remov\bl\f\bnd\f Ins t\bll\btion).\f Steering\f\bngle- dependent\f tr\bnsmission\fnoise \f *CHECK\fdifferenti\bl\fsplines\ffor\fd\bm\bge.\fTurn\f the\fdiff$

Inst\bll\btion),\f
Front\fH\blfsh\bft\fRH\f(Remov\bl\f\bnd\f
Ins

t\bll\btion).\f
Steering\f\bngle-
dependent\f
tr\bnsmission\fnoise
\f
*CHECK\fdifferenti\bl\fsplines\ffor\fd\bm\bge.\fTurn\f
the\fdifferenti\bl\fbevel\fge\brs\f\bg\binst\fone\f
\bnother.\fFor\fthis\fpurpose,\fREMOVE\fthe\f
differenti\bl.\f\f
REFER\fto:\f Front\fH\blfsh\bft\fLH \f(205-04\fFront\f
Dri

ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion)\f/\f
\f
Front\fH\blfsh\bft\fRH \f(205-04\fFront\fDrive\f
H\blf
sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
The\fengine\f\bnd\f
tr\bns\bxle\f
\bssembly\fis\fin\f
cont\bct\fwith\fthe\f
body.\f
*Look\ffor\fpoints\fof\fcont\bct\f\bnd\fREPAIR\f\bs\f
necess\bry.\f
*
Coll\br\fscrews\f–\f
engine/ge\brbox\f
*TIGHTEN\fthe\ftr\bnsmission\fbolts.REFER\fto:\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-
TDCi\f(Lynx)\f
Diesel \f(308-03A\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\f
Inst\bll\btion),\f
Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4 \f(308-
03A\f
M\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fInst\bll\btion),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-
TDCi\f(Lynx)\f
Diesel\f(308-03B\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Inst\bll\btion),\f
Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f
(85
kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-
TDCi\f
(103kW/140PS)\f-\fDW \f(308-03B\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Inst\bll\btion),\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:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fM66,\f
Inst\bll\btion).\f
*
Tr\bns\bxle\ffluid\f
level\flow.\f
*Check\fthe\ftr\bnsmission\ffluid\flevel.\f
*
Tr\bns\bxle\f
be\brings\f\bnd\fge\br\f
wheels\f(usu\blly\fon\f
high-mile\bge\f
vehicles).\f
*
REMOVE\fthe\ftr\bns\bxle.\fCHECK\fthe\fbe\brings\f
\bnd\fge\br\fwheels\f\bnd\fINSTALL\fnew\f
components\f\bs\fnecess\bry.REFER\fto:\f Tr\bnsmission\f-\f1.8L\fDur\btorq-
TDCi\f(Lynx)\f
Diesel \f(308-03A\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\f
Remov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f
(1 0

7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4 \f(308-
03A\f
M\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
*
Стр. 5 из
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Page 1981 of 4402

$FORD S-MAX 2006 Service Repair Manual Sympt\fm Cha\bt - Oil leakage Sympt\fm Cha\bt - Clutch MTX75,\fRemov\bl),\f Tr\bnsmission\f-\f1.8L\fDur\btorq- TDCi\f(Lynx)\f Diesel\f(308-03B\fM\bnu\bl\f Tr\bn smission/Tr\bns\bxle\f-\fVehicles\fWi$

Sympt\fm Cha\bt - Oil leakage
Sympt\fm Cha\bt - Clutch
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-
TDCi\f(Lynx)\f
Diesel\f(308-03B\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Remov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f
(85
kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-
TDCi\f
(103kW/140PS)\f-\fDW,\f2.0L\fDur\btorq-
TDCi\f(DW)\fDiesel \f(308-03B\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Remov\bl),\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:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fM66,\f
Remov\bl).\f
R\bttling\for\fvibr\btion\f
noises.Extern\bl\fselector\f
mech\bnism\f
*CHECK\fthe\fextern\bl\fge\brshift\fmech\bnism.\f
*
Front\for\fre\br\f
engine\fmounting\f
defective\f
*CHECK\ffront\for\fre\br\fengine\fmounting;\fRENEW\f
if\fnecess\bry.\f
*
SymptomPossible SourcesAction
Fluid\f
Le\bk\bgeOil\fse\bls\for\fO-ring\fse\bls\f
*CHECK\fthe\fm\bting\fsurf\bces\f\bnd\fINSTALL\f\b\fnew.\f
*
Fluid\fle\bk\fbetween\fthe\f
clutch-side\f\bnd\f
tr\bnsmission-side\fhousing\f
h\blves.\f
*DISASSEMBLE\fthe\ftr\bnsmission\f\bnd\fcle\bn\fthe\f
m\bting\ff\bces.\fCHECK\fthe\fsurf\bces\ffor\fd\bm\bge.\f
Se\bl\fthe\ftr\bnsmission\fusing\fWSK-M2G348-A5\f
se\bler.\f
*
Fluid\fle\bk\f\bt\ftr\bnsmission\f
housing\fbolt\f
*Tighten\ftr\bnsmission\fhousing\fbolts\fto\fspecified\f
tightening\ftorque.\f
*
SymptomPossible SourcesAction
Clutch\fslippingNo\fclutch\fped\bl\ffree\fpl\by\f
Clutch\fdi\bphr\bgm\fsprings\fbroken\f
Clutch\fdisc\ff\bcing\fbroken\f
H\brdened\for\foiled\fclutch\fdisc\ff\bcing\f
surf\bce.\f
*
*
*
*GO\fto\f
Pinpoint\fTest\f
A.\f \f
*
Clutch\fch\btter\for\fshudderEngine\fmounting\fdefective\f
Tilted\fclutch\fdisc\f
*
*GO\fto\f
Pinpoint\fTest\f
B.\f \f
*
Clutch\fdiseng\bges\ftoo\fl\bte\for\fnot\f
\bt\f\bll;\fhigh-effort\fge\br\fshiftingInsufficient\ffluid.\f
Air\fin\fhydr\bulic\fsystem.\f
Excessive\fclutch\fped\bl\ffree\fpl\by\f
Clutch\fdi\bphr\bgm\fsprings\fbroken\f
Clutch\fdisc\fdeformed\for\fbroken\f
Corrosion\fon\fclutch\fdisc\fsplines\f
Insufficient\for\fno\fgre\bse\fon\fthe\f
tr\bnsmission\finput\fsh\bft\f\bnd\fclutch\fdisc\f
splines\f
*
*
*
*
*
*
*GO\fto\f
Pinpoint\fTest\f
C.\f \f
*
Clutch\fped\bl\fpuls\btingUneven\fdi\bphr\bgm\fspring\ffingers\f
Frequency\fmodul\btor\fdefective\f(if\f
present)\f
*
*GO\fto\f
Pinpoint\fTest\f
D.\f \f
*
Excessive\fnoiseRele\bse\fbe\bring\fdefective\f
*GO\fto\f*
Стр. 6 из 20
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Page 1982 of 4402

$FORD S-MAX 2006 Service Repair Manual Pinp\fint test Drivesh\bft\fguide\fbe\bring\f Excessive\fcr\bnksh\bft\fend\fpl\by.\f * *Pinpoint\fTest\f E.\f \f Fluid\fLe\bk\bgeClutch\fm\bster\fcylinder\f Clutch\fsl\bve\fcylinder\f Hydr\bulic\flin$

Pinp\fint test
Drivesh\bft\fguide\fbe\bring\f
Excessive\fcr\bnksh\bft\fend\fpl\by.\f
*
*Pinpoint\fTest\f
E.\f
\f
Fluid\fLe\bk\bgeClutch\fm\bster\fcylinder\f
Clutch\fsl\bve\fcylinder\f
Hydr\bulic\flines\fin\f\bre\b\fof\fengine\f\bnd\f
tr\bnsmission\f
*
*
*GO\fto\f
Pinpoint\fTest\f
F.\f \f
*
PINPOINT TEST A : CLUTCH SLIPPING
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
A1: TEST CLUTCH SLIPPAGE
Lock\fthe\fwheels\f\bnd\f\bpply\fthe\fp\brking\fbr\bke.\f1
Ignition\fswitch\fin\fposition\fIII.\f2
St\brt\fthe\fengine,\fdepress\fthe\fclutch\fped\bl\f\bnd\feng\bge\ffourth\fge\br.\f3
Run\fthe\fengine\f\bt\f\bpprox.\f2000\frpm.\f4
Rele\bse\fthe\fclutch\fped\bl\fslowly.\f5
Does\fthe\fengine\fst\bll\fwhen\fthe\fclutch\fped\bl\fis\ffully\frele\bsed?\f
Yes Clutch\fOK.\f
N\f GO\fto\fA2.\f\f
A2: CHECK CLUTCH PEDAL FREE PLAY
Me\bsure\fthe\fclutch\fped\bl\ffree\fpl\by.\f1
Depress\fthe\fclutch\fped\bl\fby\fh\bnd\funtil\f\bn\fincre\bse\fin\fresist\bnce\fis\fcle\brly\f
felt,\fthen\frele\bse\fthe\fclutch\fped\bl\f\bg\bin.\f2
Is\fthe\fclutch\fped\bl\ffree\fpl\by\f\bpprox.\f10\fmm?\f
Yes Clutch\fped\bl\ffree\fpl\by\fOK.\f
N\f GO\fto\fA3.\f\f
A3: CHECK THE CLUTCH DIAPHRAGM SPRING
Remove\fthe\ftr\bnsmission.\fCHECK\fthe\fclutch\fdi\bphr\bgm\fspring.\fREFER\fto:\f
Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0
L\fDur\btec-
HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4 \f(308-03A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel \f(308-03A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.
0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\f2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f(308-03B\f
M\bnu

\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fMMT6,\fRemov\bl),\f Tr\bnsmission\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
M66,\fRemov\bl).\f
1
Is\fthe\fclutch\fdi\bphr\bgm\fspring\fbroken?\f
Yes
Renew\fthe\fclutch\fset.\f
N\f GO\fto\fA4.\f\f
A4: TEST CLUTCH FRICTION DISK
Remove\fthe\fclutch\fdisc\f\bnd\fclutch\fpressure\fpl\bte.\f\f1
Is\fthe\fclutch\fdisc\fcont\bmin\bted\fwith\foil\for\fthe\fclutch\fpressure\fpl\bte\fbroken?\f
Стр. 7 из 20
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Page 1983 of 4402

$FORD S-MAX 2006 Service Repair Manual Yes CHECK\fthe\fengine\f\bnd\ftr\bnsmission\ffor\fle\bks.INSTALL\f\b\fnew\fclutch\fdisc\f \bnd\fpressure\fpl\bte.\f N\f CHECK\fsystem\foper\btes\fcorrectly\f PINPOINT TEST B : CLUTCH CHATTER OR SHUDD$

Yes CHECK\fthe\fengine\f\bnd\ftr\bnsmission\ffor\fle\bks.INSTALL\f\b\fnew\fclutch\fdisc\f
\bnd\fpressure\fpl\bte.\f
N\f
CHECK\fsystem\foper\btes\fcorrectly\f
PINPOINT TEST B : CLUTCH CHATTER OR SHUDDER
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
B1: TEST CLUTCH CHATTER OR SHUDDER
Ignition\fswitch\fin\fposition\fIII.\f1
St\brt\fthe\fengine,\fdepress\fthe\fclutch\f\bnd\feng\bge\ffirst\fge\br.\f2
Run\fthe\fengine\f\bt\fbetween\f1200\frpm\f\bnd\f1500\frpm.\f3
Rele\bse\fthe\fclutch\fped\bl\fslowly.\f4
Does\fthe\fvehicle\fjerk\fwhen\fit\fst\brts\foff?\f
Yes GO\fto\fB2.\f\f
N\f C

lutch\fOK.\f
B2: TEST ENGINE/TRANSAXLE ISOLATOR, ROLL RESISTOR
Check\fthe\fengine/tr\bns\bxle\fmountings\fisol\btor\f\bnd\froll\fresistor\ffor\f
d\bm\bge\for\floose\fbolts.\f1
Is\fthe\fengine/tr\bns\bxle\fisol\btor\for\froll\frestrictor\floose\for\fd\bm\bged?\f
Yes TIGHTEN\fthe\fbolts\for\fINSTALL\fnew\fbolts\f\bs\fnecess\bry.\fCHECK\fsystem\f
oper\btes\fcorrectly\f
N\f GO\fto\fB3.\f\f
B3: TEST CLUTCH PRESSURE PLATE
Remove\fclutch\fpressure\fpl\bte.\f1
Is\fthe\fclutch\fpressure\fpl\bte\fd\bm\bged?\f
Yes
RENEW\fthe\fclutch\fset.\f
N\f GO\fto\fB4.\f\f
B4: TEST CLUTCH FRICTION DISK
CHECK\fthe\fclutch\fdisc.\f1
Does\fthe\fclutch\fdisc\fshow\fevidence\fof\fd\bm\bge\fdue\fto\ftilting?\f
Yes
RENEW\fthe\fclutch\fset.\f
N\f CHECK\fflywheel.\f
PINPOINT TEST C : CLUTCH DISENGAGES TOO LATE OR NOT AT ALL
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
C1: CHECK FLUID LEVEL
Check\fbr\bke\ffluid\flevel\f1
Is\fthe\fbr\bke\ffluid\flevel\fbetween\fthe\fMAX\f\bnd\fMIN\fm\brks\fon\fthe\fbr\bke\ffluid\f
reservoir?\f
Yes GO\fto\fC2 .\f\f
N\f F

ill\fwith\fbr\bke\ffluid,\fCHECK\fthe\fbr\bke\f\bnd\fclutch\fsystems\ffor\fle\bks.\f
C2: CLUTCH DISENGAGES TOO LATE OR NOT AT ALL
Bleed\fthe\fclutch\fsystem.\f1
Does\fthe\fclutch\fshow\fimproved\fdiseng\bging\fch\br\bcteristics\ffollowing\fbleeding\fof\f
Стр. 8 из 20
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Page 1984 of 4402

$FORD S-MAX 2006 Service Repair Manual the\fsystem?\f Yes Clutch\fOK.\f N\f GO\fto\fC3 .\f\f C3: CHECK CLUTCH PEDAL FREE PLAY Me\bsure\fthe\fclutch\fped\bl\ffree\fpl\by.\f1 Depress\fthe\fclutch\fped\bl\fby\fh\bnd\funtil\f\bn\fincre\bse\f$

the\fsystem?\f
Yes Clutch\fOK.\f
N\f
GO\fto\fC3 .\f\f
C3: CHECK CLUTCH PEDAL FREE PLAY
Me\bsure\fthe\fclutch\fped\bl\ffree\fpl\by.\f1
Depress\fthe\fclutch\fped\bl\fby\fh\bnd\funtil\f\bn\fincre\bse\fin\fresist\bnce\fis\fcle\brly\f
felt,\fthen\frele\bse\fthe\fclutch\fped\bl\f\bg\bin.\f2
Is\fthe\fclutch\fped\bl\ffree\fpl\by\f\bpprox.\f10\fmm?\f
Yes
GO\fto\fC4 .\f\f
N\f
C

HECK\fth\bt\fthe\fclutch\fped\bl\fmoves\ffreely;\fremove\fif\fnecess\bry.\f
C4: CHECK THE CLUTCH DIAPHRAGM SPRING
Remove\fthe\ftr\bnsmission\f\bnd\fCHECK\fthe\fclutch\fdi\bphr\bgm\fspring.REFER\f
to:\f Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel \f(308-03A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0
L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4\f(308-03A\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel \f(308-03B\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MMT6,\fRemov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.
0L\fDur\btorq-
TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f(103kW/140PS)\f-\fDW,\f
2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f(308-03B\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MMT6,\fRemov\bl),\f
Tr\bnsmission\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
M66,\fRemov\bl).\f
1
Is\fthe\fclutch\fdi\bphr\bgm\fspring\fbroken?\f
Yes
RENEW\fthe\fclutch\fset.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
N\f GO\fto\fC5 .\f\f
C5: TEST CLUTCH FRICTION DISK
Remove\fthe\fclutch\fdisc.\f1
Is\fthe\fclutch\fdisc\fbent\for\fbroken?\f
Yes
RENEW\fthe\fclutch\fset.\f
N\f GO\fto\fC6 .\f\f
C6: CHECK THE SPLINES ON THE CLUTCH DISC FOR INSUFFICIENT LUBRICATION
AND/OR SIGNS OF CORROSION
CAUTION:\fDo\fnot\fuse\fsolvent\fcle\bners\fto\fcle\bn\fthe\finside\fof\fthe\fclutch\fhousing\for\f
the\ftr\bnsmission\finput\fsh\bft.\fA\flint-free\fd\bmp\fcloth\fshould\fbe\fused\ffor\fcle\bning.\fF\bilure\f
to\ffollow\fthis\finstruction\fm\by\fresult\fin\fincorrect\fclutch\foper\btion.\f
CHECK\fthe\fsplines\fon\fthe\fclutch\fdisc\ffor\finsufficient\for\fno\fgre\bse\f\bnd/or\f
signs\fof\fcorrosion.\f1
Is\fthere\finsufficient\for\fno\fgre\bse\f\bnd/or\fsigns\fof\fcorrosion\fon\fthe\fsplines\fof\fthe\f
clutch\fdisc?\f
Yes CLEAN\fthe\fsplines\fof\fthe\fclutch\fdisc.\f GO\fto\fC7.\f\f
Стр. 9 из 20
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