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Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 5-Speed Manual T\bansaxle - MTX75
- T\bansmissi\fn—1.8L Du\bat\f\bq-TDCi
(Lynx) DieselS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Installati\fn
Special T\f\fl(s)
Ma
te\bials
Gene\bal Equipment CAUTION: Make su\be that the tw\f guide sleeves a\be installed.
303-290-13\f
Ad\bpter\ffor\f303-290A
\f
303-290A-15\f
Ad\bpter\ffür\f303-290A
\f
303-290B\f
Support\fB\br,\fEngine\f
303-290B-16\f
Ad\bpter\ffor\f303-290B
\f
NameSpec\bf\bcat\bo\f
Gre\bse\fK-HTESD-M1C220-A\f/\fA88SX1C220AA
T\bansmissi\fn jack
1. Refer\fto:\f He\blth\f\bnd\fS\bfety\fPrec\butions\f(100-00\f
Gen
er\bl\fInform\btion,\fDescription\f\bnd\fOper\btion).
\f
2. Apply\f\b\fthin\fco\bting\fof\fgre\bse\fto\fthe\finput\fsh\bft\f splines.\f
Material\b Gre\bse\fK-HT\f(ESD-M1C220-A\f/\f
A88
SX1C220AA) \f
3. Gen
eral \fquipment\b Tr\bnsmission\fj\bck \f
\f
\f
\f
\f
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Page 2106 of 4402
4. Perform\fthis\f\bnd\fthe\ffollowing\foper\btion\fsimult\bneously.\f
Special Tool(s)\b 303-290A-15\f
To r
que\b 48\fNm
\f
5. Special Tool(s)\b 303-290A-15\f
Tor
que\b 48\fNm
\f
6. Remove\fthe\ftr\bnsmission\fj\bck.\f
7. Special Tool(s)\b 303-290B,\f303-290-13 ,\f303-
29 0
A-15 ,\f303-290B-16 \f
8. To
rque\b 80\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Page 2107 of 4402
9. Do\fnot\ftighten\fthe\fnew\fbolt\fof\fthe\fre\br\fengine\fmounting\fyet.\f
10. Refer\fto:\fKupplungssystem\fentlüften\f(308-00,\f Gener\bl\fProcedures).\f
11. Special Tool(s)\b 303-290A-15\f
To r
que\b 48\fNm
\f
12. Special Tool(s)\b 303-290A-15\f
To r
que\b 48\fNm
\f
13. Special Tool(s)\b 303-290A-15\f
Tor
que\b 48\fNm
\f
\f\f
\f\f
\f\f
\f\f
\f\f
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Page 2108 of 4402
14. Remove\fthe\fspeci\bl\ftool.\fSpecial Tool(s)\b 303-290B,\f303-290-13 ,\f303-
29 0
A-15 ,\f303-290B-16 \f
15.
Inst\bll\fthe\ffollowing\fitems:\f 1. C\bt\blyst\f
Refer\fto:\f C\bt\blytic\fConverter \f(309-00D\f
Exh
\bust\fSystem\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\f
Inst\bll\btion).\f
2. Drivesh\bfts\f
Refer\fto:\f Front\fH\blfsh\bft\fLH \f(205-04\fFront\f
Dri
ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
Refer\fto:\f Front\fH\blfsh\bft\fRH \f(205-04\fFront\f
Dr i
ve\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
3. Subfr\bme\f
Refer\fto:\f Front\fSubfr\bme \f(502-00\fUni-
Bod
y,\fSubfr\bme\f\bnd\fMounting\fSystem,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
16. Torque\b 40\fNm
\f
17. Torque\b 48\fNm
\f
\f\f
\f\f
\f\f
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Page 2109 of 4402
18.Torque\b 25\fNm\f
19. Torque\b 24\fNm
\f
20. \f\f 1.Torque\b 25\fNm
\f
2. Torque\b 48\fNm
\f
3. Torque\b 148\fNm
\f
21. Torque\b 25\fNm
\f
22. \f
\f\f
\f\f
\f\f
\f\f
\f\f
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Page 2110 of 4402

23. Adjust\fthe\fselector\fc\bble.\fRefer\fto:\f Ge\brshift\fC\bble\fAdjustment\f-\fVehicles\f
Wi t
h:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f(MTX-75) \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. B\bttery\fc\brrier\f
Refer\fto:\f B\bttery\f(414-01\fB\bttery,\f
Mou
nting\f\bnd\fC\bbles,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. Air\ffilter\f
Refer\fto:\f Air\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\f
Inst\bll\btion).\f
25. Check\fthe\flevel\fof\fthe\ftr\bnsmission\ffluid.\f
Refer\fto:\f Tr\bnsmission\fDr\bining\f\bnd\fFilling \f(308-
03A
\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\f
Gener\bl\fProcedures).\f
26. \f
27. Initi\blize\fthe\fwindow\fregul\btor\fmotors.\f
Refer\fto:\f Door\fWindow\fMotor\fIniti\bliz\btion \f(501-
11 \f
Gl\bss,\fFr\bmes\f\bnd\fMech\bnisms,\fGener\bl\f
Procedures).\f
\f\f
\f\f
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Page 2111 of 4402

Manual T\bansmissi\fn/T\bansaxle - Vehicles With: 6-Speed Manual T\bansaxle - MMT6 -
Specificati\fns
Capacities
Sh
im thickness calculati\fns
T\bansmissi\fn Rati\fs
* The final d\bive \bati\f f\f\b \beve\bse gea\b is calculated by multiplying the inte\bnal gea\bb\fx \bati\f f\f\b 1st gea\b by the final d\bive \bati\f \ff the 5th/6th and \beve\bse gea\b \futput shaft.
Transmissi\bn fl\fid (0- 5 mm bel\bw the l\bwer edge \bf the inspecti\bn h\ble)
Type1st\b–\b4th\b\fear\boutput\bshaft
Meas\fring shims (mm)-
Meas\fred end fl\bat (example) (mm)+1,56
Additi\bn val\fe (mm) t\b \bbtain c\brrect bearing pre-l\bad+0,17
Req\fired shim thickness (example) (mm)= 1,73
Available shims (mm)1.44 -2.16 (in 0.02 mm steps)
2.0L\bdiesel\ben\fineInternal\bGearbox\bRatio(s)
1. gear3.583
2. gear1.952
3. gear1.241
4. gear0.868
5. gear0.943
6. gear0.789
Reverse gear1.423
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Page 2112 of 4402
Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - MMT6 -
Manual T\bansmissi\fnS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Desc\bipti\fn and Ope\bati\fn
C\fnst\bucti\fn featu\bes \fn the diffe\bential side
\f\f
Desc\bipti\fn
Differenti\bl\f
Reverse\fge\br\fidler\f
1st\fge\br\fwheel\f
1st/2nd\fge\br\fsynchronizer\fclutch\f
2nd\fge\br\fwheel\f
3rd\fge\br\fwheel\f
3rd/4th\fge\br\fsynchronizer\fclutch\f
4th\fge\br\fwheel\f
Output\fsh\bft\f1st/4th\fge\br\f
Input\fsh\bft\f
Output\fsh\bft\f5th/6th/reverse\fge\br\f
6th\fge\br\fwheel\f
5th/6th\fge\br\fsynchronizer\fclutch\f
5th\fge\br\fwheel\f
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
\f
Pa\bt Numbe\b -
-
-
-
-
-
-
-
-
-
-
-
-
-
-
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