Page 2193 of 4402

Manual T\bansmissi\fn/T\bansaxle - Vehicles With: 6-
Speed Manual T\bansaxle - M66 - Specificati\fnsS-MAX/G\bl\bxy\f2006.5\f(02/2006
Filling Capacities
Shim thickness calculati\fns
* If the thickness \ff the measu\bed shim is \fdd, select the shim with the next highe\b thickness value.
T\bansmissi\fn Rati\fs
T\f\bque Specifcati\fns
Tr\bnsmission\ffluid
TypeInpu\b sh\ff\b
1s\b-2nd \fnd 5\bh-6\bh ge\fr ou\bpu\b sh\ff\b
3rd-4\bh ge\fr ou\bpu\b sh\ff\bReverse ge\fr ou\bpu\b sh\ff\b
Me\bsuring\fshims\f(mm)----
Me\bsured\fend\fflo\bt\f
(ex\bmple)\f(mm)+1.12+1.13+1.27+1.40
Addition\fv\blue\f(mm)\fto\f
obt\bin\fcorrect\fbe\bring\f
pre-lo\bd+0.03+0.20+0.15+0.11
Required\fshim\fthickness\f
(ex\bmple)\f(mm)=\f1.15=\f1.33=\f1.42=\f1.51
Av\bil\bble\fshims\f(mm)0.60\f-\f1.17\f(in\f
0.03\fmm\f steps)*
0.93\f-\f1.74\f(in\f
0.03\fmm\fsteps)*0.60\f-\f1.17\f(in\f
0.03\fmm\fsteps) *0.57\f-\f1.11\f(in\f
0.03\fmm\fsteps)*
0.03\fmm\fsteps)*
ge\fr2.2L diesel engine2.5L Engine
1st\fge\br3.385
2nd\fge\br1.905
3rd\fge\br1.194
4th\fge\br0.838
5th\fge\br0.652
6th\fge\br0.540
Reverse0.773
Fin\bl\fdrive\fr\btio\f-\fforw\brds4.267
Fin\bl\fdrive\fr\btio\f-\freverse5.333
Descrip\bionNmlb-f\b
Reversing\fl\bmp\fswitch2418
Sh\bft\fdetent\fmech\bnism3022
Selector\fmech\bnism\fbolts2518
Стр. 1 из 1
05.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G510601&gui...procarmanuals.com
http://vnx.su
Page 2194 of 4402

Manual T\bansmissi\fn/T\bansaxle - Vehicles
With: 6-Speed Manual T\bansaxle - M66 -
Manual T\bansmissi\fnS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Desc\bipti\fn and Ope\bati\fn
Ove\bview
Th
e\fm\bnu\bl\ftr\bns\bxle\f(M66)\fw\bs\fdesigned\ffor\fuse\fin\ffront-wheel\f\bnd\ffour-wheel\fdrive\f
vehicles\f\bnd\ffor\fhigh\ftorques.\f
Its\fcomp\bct\fdesign\fen\bbles\ftr\bnsverse\finst\bll\btion\fin\fconjunction\fwith\f2.5L\fDur\btec-ST\f
(VI5)\fengine\f(\bnd\f2.2L\fDur\btorq-TDCi\f(DW)\fDiesel\fengine).\f
The\ftr\bns\bxle\fis\fequipped\fwith\fsix\fforw\brd\fge\brs.\f
The\fbenefits:\f
Optimized\fgr\bdu\btion\fof\fspeed\fst\bges\f
Lower\ffuel\fconsumption\f
Less\fnoise\femission\fdue\fto\flower\fengine\fspeeds\f
The\ftr\bns\bxle\fdesign\fis\fb\bsed\fon\ffour\fsh\bfts\f(one\finput\fsh\bft\f\bnd\fthree\foutput\fsh\bfts.\fSee\f
\b l
so\fillustr\btion\fon\fnext\fp\bge).\f
All\fthe\fge\brs,\fincluding\fthe\freverse\fge\br,\f\bre\fsynchronized:\f
Single\fsynchroniz\btion\f-\f4th/5th/6th\f\bnd\freverse\fge\br\f
Du\bl\fsynchroniz\btion\f-\f3rd\fge\br\f
Triple\fsynchroniz\btion\f-\f1st/2nd\fge\br\f
The\ftr\bns\bxle\fh\bs\f\b\flifetime\ffilling\fof\fsynthetic\foil.\f
A n
\f\bperture\fis\fprovided\ffor\fchecking\fthe\flevel\f\bnd\ftopping\fup.\f
\f
Стр. 1 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
Page 2195 of 4402

Ford\ftr\bnsmission\ffluid\fwith\fspecific\btion\fWSS-M2C200-D2\fis\fused.\f
The\ftot\bl\ffilling\fc\bp\bcity\fis\f2.0\fliters.\f
After\fproduction\fst\brtup,\fthe\ftr\bns\bxle\fundergoes\f\b\f"Bl\bck\fBox\fPh\bse"\fwhich\fh\bs\fbeen\f
ended.\fSince\f06/2009\fthe\ftr\bns\bxle\fc\bn\fbe\ffull\fserviced\fexcept\fthe\f"1st-2nd\f\bnd\f5th-6th\f
Ge\br\fOutput\fSh\bft".\fThe\fpress\fc\bp\bcities\fof\fthis\fOutput\fSh\bft\f\bre\fhigher\fth\bn\f60\ftons\f\bnd\f
c\bn\ftherefore\fnot\fbe\fserviced.\fOnly\fthe\fouter\fbe\brings\fc\bn\fbe\frenewed.\f
Inte\bnal C\fmp\fnents
\f\f
Desc\bipti\fn
Input\fsh\bft\f
1st-2nd\f\bnd\f5th-6th\fge\br\foutput\fsh\bft\f
3rd-4th\fge\br\foutput\fsh\bft\f
Reverse\fge\br\foutput\fsh\bft\f
Output\fpinion\f-\freverse\fge\br\foutput\fsh\bft\f
Ge\br\fwheel\f-\freverse\fge\br\f
Synchronizer\fhub\f-\freverse\fge\br\f
Ring\fge\br\f
Ge\br\fwheel\f-\f2nd\fge\br\f
Toothed\fwheel\f-\f5th\fge\br\f
Toothed\fwheel\f-\f6th\fge\br\f
Ge\br\fwheel\f-\f6th\fge\br\f
Synchronizer\fhub\f-\f5th/6th\fge\br\f
Ge\br\fwheel\f-\f4th\fge\br\f
Ge\br\fwheel\f-\f5th\fge\br\f
Synchronizer\fhub\f-\f3rd/4th\fge\br\f
Toothed\fwheel\f-\f4th\fge\br\f
Toothed\fwheel\f-\f2nd\fge\br\f
Toothed\fwheel\f-\f1st\fge\br\f
ItemA
B
C
D 1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
\f
Pa\bt Numbe\b -
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Стр. 2 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
Page 2196 of 4402

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
Page 2197 of 4402

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
Page 2198 of 4402

1st-2nd\f\bnd\f5th-6th\fge\br\foutput\fsh\bft\f
Ring\fge\br\f
Ge\br\fwheel\f-\f2nd\fge\br\f
Toothed\fwheel\f-\f2nd\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
3rd\fge\br\f
\f\f
Desc\bipti\fn
Input\fsh\bft\f
3rd-4th\fge\br\foutput\fsh\bft\f
Ring\fge\br\f
Synchronizer\fhub\f-\f3rd/4th\fge\br\f
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
4th\fge\br\f
\f\f
Desc\bipti\fn
Input\fsh\bft\f
3rd-4th\fge\br\foutput\fsh\bft\f
Ring\fge\br\f
Ge\br\fwheel\f-\f4th\fge\br\f
Synchronizer\fhub\f-\f3rd/4th\fge\br\f
Toothed\fwheel\f-\f4th\fge\br\f
Output\fpinion\f-\f3rd-4th\fge\br\foutput\fsh\bft\f
5th\fge\br\f B
4
5
1 4
1
9
20
Item A
C 4
12
16
17
18
Item A
C 4
10
12
13
17
-
-
-
-
-
-
\f\f
Pa\bt Numbe\b-
-
-
-
-
-
-
\f\f
Pa\bt Numbe\b-
-
-
-
-
-
-
Стр. 5 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
Page 2199 of 4402
\f\fDesc\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-\f5th\fge\br\f
Synchronizer\fhub\f-\f5th/6th\fge\br\f
Ge\br\fwheel\f-\f5th\fge\br\f
Output\fpinion\f-\f1st-2nd\f\bnd\f5th-6th\fge\br\foutput\fsh\bft\f
6th\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-\f6th\fge\br\f
Ge\br\fwheel\f-\f6th\fge\br\f
Synchronizer\fhub\f-\f5th/6th\fge\br\f
Output\fpinion\f-\f1st-2nd\f\bnd\f5th-6th\fge\br\foutput\fsh\bft\f
Reverse\fge\br\f
\f\f
Desc\bipti\fn
Item
A
B4
6
9
11
20
Item A
B4
7
8
9
20
Item \f\fPa\bt Numbe\b
-
-
-
-
-
-
-
\f\f
Pa\bt Numbe\b-
-
-
-
-
-
-
\f\f
Pa\bt Numbe\b-
Стр. 6 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
Page 2200 of 4402

Input\fsh\bft\f
1st-2nd\f\bnd\f5th-6th\fge\br\foutput\fsh\bft\f
Reverse\fge\br\foutput\fsh\bft\f
Output\fpinion\f-\freverse\fge\br\foutput\fsh\bft\f
Ge\br\fwheel\f-\freverse\fge\br\f
Synchronizer\fhub\f-\freverse\fge\br\f
Ring\fge\br\f
Toothed\fwheel\f-\f1st\fge\br\f
Ge\br\fwheel\f-\f1st\fge\br\f
Inte\bnal c\fnt\b\fl
\f\f
Desc\bipti\fn
Shift\funit\f
5th/6th\fge\br\fgovernor\f
C\brrier\fpl\bte\fwith\fge\brshift\fg\bte\f
Switch\ffor\freverse\fge\br\fsign\bl\f
Shift\fguide\f
Lower\fshift\ffinger\f
Guide\fpl\bte\f
Upper\fshift\ffinger\f
Spring\f
Shift\f\brm\fwith\fd\bmping\fweight\f
Spring\f
Selector\flever\f
C\brrier\fpl\bte\fwith\fge\brshift\fg\bte\f
Vent\fc\bp\f
The\fge\brshift\fmech\bnism\fis\fsecured\fto\fthe\ftr\bns\bxle\fhousing\fby\ffour\fbolts\f\bnd\fm\by\fonly\fbe\f
re
pl\bced\f\bs\f\b\fcomplete\funit\fin\fthe\fevent\fof\f\b\ff\bult.\fA
B
D 1
2
3
4
1 5
2
1
Item 1
2
3
4
5
6
7
8
9
10
11
12
13
14 -
-
-
-
-
-
-
-
\f
Pa\bt Numbe\b
-
-
-
-
-
-
-
-
-
-
-
-
-
-
Стр. 7 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