Page 1993 of 4402

Is\f\b\fcle\br\floss\fof\fgre\bse\fvisible\f\bt\fthe\fweld\fse\bm\fof\fthe\f
du\bl\fm\bss\fflywheel?\f
Yes INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
N\f
GO\fto\fE28 .\f\f
E28: GUIDE PINS OF THE DUAL-MASS FLYWHEEL
Check\fthe\finst\bll\btion\fof\fthe\fguide\fpins\fof\fthe\fdu\bl-
m\bss\fflywheel.\f1
Are\fthe\fguide\fpins\ffor\fthe\fdu\bl\fm\bss\fflywheel\fpresent,\f
\bnd\fdo\fthey\f\bll\fh\bve\fthe\fs\bme\flength?\f
Yes
The\fdu\bl\fm\bss\fflywheel\fis\fOK.\f
N\f INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
E29: CHECK THE ROTATION OF THE SECONDARY MASS OF THE DUAL MASS
FLYWHEEL
CAUTIONS:\f
Do\fnot\frework\for\fm\bchine\fthe\fdu\bl\fm\bss\f
flywheel\fif\fit\fis\fdistorted.\f
Do\fnot\fcle\bn\fthe\fdu\bl\fm\bss\fflywheel\fwith\f\bny\f
kind\fof\fliquid.\fUse\fonly\f\b\fdry\fcloth\fto\fcle\bn\fthe\f
flywheel.\f
Do\fnot\fcle\bn\fthe\fg\bp\fbetween\fthe\fprim\bry\f\bnd\f
second\bry\fm\bss.\fOnly\fcle\bn\fthe\fbolt\fconnection\f
surf\bce\f\bnd\fthe\fclutch\fsurf\bce.\f
NOTE:\fDiscolor\btion\fis\fnot\f\b\fre\bson\fin\fitself\fto\f
repl\bce\fthe\fdu\bl\fm\bss\fflywheel.\f Remove\fthe\fclutch\fdisc\f\bnd\fclutch\fpressure\fpl\bte.\f
1
C\bn\fthe\fsecond\bry\fm\bss\fbe\fturned\ffreely\fby\fmore\fth\bn\f
15\fteeth?\f
Yes INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
N\f GO\fto\fE31 .\f\f
E30: ROTATION OF THE DUAL-MASS FLYWHEEL
Secure\fthe\fprim\bry\fside.\fTwist\fthe\fsecond\bry\fside\f
in\f\b\fclockwise\fdirection\funtil\fspring\fresist\bnce\fis\f1
\f\f
\f\f
\f\f
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Page 1994 of 4402

felt\f\bnd\frele\bse.\fM\brk\fthe\frest\fposition\fon\fthe\f
prim\bry\f\bnd\fsecond\bry\fsides.\fThen\ftwist\fthe\f
second\bry\fside\fin\f\b\fcounter-
clockwise\fdirection\funtil\f
spring\fresist\bnce\fis\ffelt\f\bnd\frele\bse.\fM\brk\fthe\fnew\f
rest\fposition\fon\fthe\fprim\bry\fside.\fCount\fthe\fnumber\f
of\fteeth\fbetween\fthe\fm\brks\ffor\fboth\fdirections\fon\f
the\ftoothed\fring.\f
Are\fmore\fth\bn\f8\fteeth\fcounted?\f
Yes INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
N\f GO\fto\fE31 .\f\f
E31: CHECK THE DUAL-MASS FLYWHEEL
Perform\f\b\fvisu\bl\finspection\fof\fthe\fdu\bl\fm\bss\f
flywheel.\f1
Is\fthe\fdu\bl\fm\bss\fflywheel\ffree\fof\fd\bm\bge?\f
Yes
GO\fto\fE32 .\f\f
N\f I
NSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
E32: CHECK THE TOOTHED RING OF THE DUAL-MASS FLYWHEEL
Perform\f\b\fvisu\bl\finspection\fof\fthe\ftoothed\fring\fof\f
the\fdu\bl\fm\bss\fflywheel.\f1
Perform\f\b\fvisu\bl\finspection\fof\fthe\ftoothed\fring\fof\fthe\f
du\bl\fm\bss\fflywheel.\f
Yes GO\fto\fE33 .\f\f
N\f I
NSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
E33: CHECK THE WELD SEAM OF THE DUAL-MASS FLYWHEEL
Visu\blly\finspect\fthe\fweld\fse\bm\fof\fthe\fdu\bl\fm\bss\f
flywheel\fto\fcheck\ffor\floss\fof\fgre\bse.\f1
Is\f\b\fcle\br\floss\fof\fgre\bse\fvisible\f\bt\fthe\fweld\fse\bm\fof\fthe\f
du\bl\fm\bss\fflywheel?\f
Yes
\f\f
\f\f
\f\f
\f\f
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Page 1995 of 4402

INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
N\f GO\fto\fE34 .\f\f
E34: GUIDE PINS OF THE DUAL-MASS FLYWHEEL
Check\fthe\finst\bll\btion\fof\fthe\fguide\fpins\fof\fthe\fdu\bl-
m\bss\fflywheel.\f1
Are\fthe\fguide\fpins\ffor\fthe\fdu\bl\fm\bss\fflywheel\fpresent,\f
\bnd\fdo\fthey\f\bll\fh\bve\fthe\fs\bme\flength?\f
Yes
The\fdu\bl\fm\bss\fflywheel\fis\fOK.\f
N\f INSTALL\fA\fNEW\fdu\bl\fm\bss\fflywheel.\f
PINPOINT TEST F : FLUID LEAKAGE
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
F1: CHECK THE CLUTCH SLAVE CYLINDER
Check\fthe\fclutch\fm\bster\fcylinder\ffor\fle\bks.\f1
Is\fthe\fclutch\fm\bster\fcylinder\fOK?\f
Yes GO\fto\fF2 .\f\f
N\f R
ENEW\fthe\fclutch\fm\bster\fcylinder.\f
F2: CHECK THE CLUTCH SLAVE CYLINDER
Check\fthe\fclutch\fsl\bve\fcylinder\ffor\fle\bks.\f1
Is\fthe\fclutch\fsl\bve\fcylinder\fOK?\f
Yes GO\fto\fF3 .\f\f
N\f I
NSTALL\f\b\fnew\fclutch\fsl\bve\fcylinder.\f
F3: INSPECT SYSTEM HYDRAULIC LINES
Check\fthe\fhydr\bulic\flines\fin\f\bre\b\fof\fengine\f\bnd\ftr\bnsmission\ffor\floose\for\f
d\bm\bged\funions.\f
1
Are\fthe\fclutch\fhydr\bulic\flines\fOK?\f
Yes CARRY\fOUT\f\b\fro\bd\ftest\fto\fverify\fthe\fcustomer\fconcern.\f
N\f REPAIR\for\fINSTALL\fnew\fcomponents\f\bs\fnecess\bry.\fCARRY\fOUT\f\b\fro\bd\f
test.\f \f\f
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Page 1996 of 4402
Manual T\bansmissi\fn/T\bansaxle and
Clutch - Gene\bal Inf\f\bmati\fn - Gea\bshift
Cable Adjustment—Vehicles With: 5-
Speed Manual T\bansaxle (MTX-75)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Gene\bal P\b\fcedu\bes
Special T\f\fl(s)
308-640\f
Aligner,\fGe\brshift\fLever
\f
1. \f
2. 4th\fge\br\fon\fthe\ftr\bnsmission\fmust\fbe\feng\bged.\f
3. \f
4.Special\bTool(\f):\b 308-640\f
5. \f
\f
\f\f
\f\f
\f\f
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Page 1997 of 4402
6.Special\bTool(\f):\b 308-640\f
7. \f
\f
\f
\f\f
\f\f
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Page 1998 of 4402

Manual T\bansmissi\fn/T\bansaxle and
Clutch - Gene\bal Inf\f\bmati\fn - Gea\bshift
Cable Adjustment—Vehicles With: 6-
Speed Manual T\bansaxle (MMT6)
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Gene\bal P\b\fcedu\bes
Special T\f\fl(s)
Gen
e\bal Equipment All\fVehicles\f
Ve
hicles\fbuilt\fup\fto\f10/2007\f
308-640\f
Aligner,\fGe\brshift\fLever
\f
2.5\fmm\fdrill\fbit 1. Refer\fto:\fAir\fCle\bner\f(303-12D\fInt\bke\fAir\f
Dis
tribution\f\bnd\fFiltering\f-\f1.8L\fDur\btorq-TDCi\f
(74kW/100PS)\f-\fLynx/1.8L\fDur\btorq-TDCi\f
(92kW/125PS)\f-\fLynx,\fRemov\bl\f\bnd\fInst\bll\btion).
\f
Refer\fto:\f Air\fCle\bner \f(303-12E\fInt\bke\fAir\f
Dis
tribution\f\bnd\fFiltering\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/2.0L\fDur\btorq-TDCi\f
(118kW/160PS)\f-\fDW,\fEmission\fRequirements:\f
St\bge\fIV/St\bge\fV,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. CAUTION:\fGe\brshift\fc\bbles\fmust\fnot\fbe\f
k i
nked\for\fbent.\f
3. \f\f 1. X\f=\f44\fmm.\f
General \bqui\fment: 2.5\fmm\fdrill\fbit\f
2. NOTE:\fEnsure\fth\bt\f4th\fge\br\fis\f
en
g\bged.\f
\f
\f\f
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Page 1999 of 4402
Vehicles\fbuilt\ffrom\f10/2007\f
All\fVehicles\f
4.
CAUTION:\fGe\brshift\fc\bbles\fmust\fnot\fbe\f
ki
nked\for\fbent.\f
5. NOTE:\fEnsure\fth\bt\f4th\fge\br\fis\feng\bged.\f
6. \f
\f
\f
\f
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Page 2000 of 4402
Vehicles\fbuilt\fup\fto\f10/2007\f
Vehicles\fbuilt\ffrom\f10/2007\f
All\fVehicles\f
7.
Install the S\fecial Tool(s): 3
08-640\f
8. CAUTION:\fGe\brshift\fc\bbles\fmust\fnot\fbe\f
k i
nked\for\fbent.\f
9. CAUTION:\fGe\brshift\fc\bbles\fmust\fnot\fbe\f
ki
nked\for\fbent.\f
10. Remove the S\fecial Tool(s): 308-640\f
\f\f
\f\f
\f\f
\f
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