2006 FORD S-MAX Service Repair Manual

airbag off oil filter AUX width emergency towing key fob battery

Page 353 of 4402

$FORD S-MAX 2006 Service Repair Manual \f\fDescription\b Power\fsteering\ffluid\freturn\fline\f Steering\fge\br\fpressure\fline\f\bnd\freturn\fline\f Power\fsteering\ffluid\fpressure\fline\f Power\fsteering\fpump\f Power\fsteering\fpressur$

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$FORD S-MAX 2006 Service Repair Manual Power\fsteering\ffluid\freservoir\f Power\fsteering\ffluid\fpressure\fline\f Steering\fge\br\fpressure\fline\f\bnd\freturn\fline\f Power\fsteering\ffluid\freturn\fline\f Power\fsteering\fpump\f 2.5L\f$

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$FORD S-MAX 2006 Service Repair Manual Steering\bSystem\b\f\bGeneral\bInformation\b\f\b Steering\bSystemS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Diagnosis\band\bTesting\b Special\bTool(s)\b Gen eral\bEquipment\b Inspection\band\bVerif$

Steering\bSystem\b\f\bGeneral\bInformation\b\f\b
Steering\bSystemS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagnosis\band\bTesting\b
Special\bTool(s)\b
Gen

eral\bEquipment\b
Inspection\band\bVerification\b 1. 1.\b
Verify\fthe\fcustomer\fconcern.\f
2

. 2.\b
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V

isual\bInspection\bChart\b
3. 3.\b
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
4. 4.\b
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Symptom\bChart\b Symptom\bChart\b
Alignment\fPins,\fSubfr\bme\f
205-316\f(15-097A)\f\f
Simul\btor,\fDriver\f\bnd\fP\bssenger\fAir\fB\bgs\f\bnd\fSide\fAir\fCurt\bins\f
501-073\f(40-016)\f
Worldwide\fDi\bgnostic\fSystem\f(WDS)
Mechanica\bE\bectrica\b
Tire\fpressure(s)\f\f
Accessory\fdrive\fbelt\f\f
Loose\ftie-rod\fend(s)\f\f
Tie-rod(s)\f\f
Steering\fge\br\fhousing\f\f
Loose\fstrut\f\bnd\fspring\f\bssemblies\f
or

\fb\bll\fjoints\f\f
Loose\fpinch\fbolts\fon\fsteering\f
co

lumn\fsh\bft\fflexible\fcoupling\f\f
Wheels\f\bnd\ftires\f\f
Power\fsteering\flines\ffluid\fle\bks\f\f
Steering\fge\br\fbellows\f
B\bttery\f\f
B\bttery\fc\bbles\f\f
Electro-hydr\bulic\fpower\fsteering\fpump\fcontrol\f
mo

dule\felectric\bl\fconnectors\f\f
Electro-hydr\bulic\fpower\fsteering\fpump\fcontrol\f
mo

dule\fground\fc\bble\f\f
Electro-hydr\bulic\fpower\fsteering\fpump\fcontrol\f
mo

dule\fground\fc\bble\fret\bining\fscrew\f\f
Fuses\f\f
Power\fsteering\fpressure\f(PSP)\fswitch\f
\fymptomPossib\be \fourcesAction
Drift\fleft\for\frightVehicle\f\bttitude\f
incorrect\f(front\for\f
re\br\fis\fhigh\for\flow).\f
*CHECK\ffor\f\bbnorm\bl\flo\bding,\fcoil\fspring\fs\bg\for\f
non-st\bnd\brd\fsprings.\f
*
Incorrect\fwheel\f
\blignment.\f
*CHECK\fthe\fwheel\f\blignment\f\bnd\fADJUST\fif\f
necess\bry.\fREFER\fto:\f(204-00\fSuspension\f
System\f-\fGener\bl\fInform\btion)\f
Front\fToe\fAdjustment \f(Gener\bl\fProcedures),\f
Re\br\fToe\fAdjustment \f(Gener\bl\fProcedures).\f
*
\f\f
\f\f
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$FORD S-MAX 2006 Service Repair Manual Incorrect\ffront\f subfr\bme\f\blignment.\f *Using\fthe\fspeci\bl\ftool\f\bnd\f\b\fsuit\bble\fw\bsher,\f CHECK\fthe\ffront\fsubfr\bme\f\blignment.\f\f REFER\fto:\f Front\fSubfr\bme \f(502-00\fUni-Body$

Incorrect\ffront\f
subfr\bme\f\blignment.\f
*Using\fthe\fspeci\bl\ftool\f\bnd\f\b\fsuit\bble\fw\bsher,\f
CHECK\fthe\ffront\fsubfr\bme\f\blignment.\f\f
REFER\fto:\f Front\fSubfr\bme \f(502-00\fUni-Body,\f
Sub

fr\bme\f\bnd\fMounting\fSystem,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
*
Worn\ffront\fwheel\f
be\brings.\f
*CHECK\f\bnd\fINSTALL\fnew\fwheel\fbe\brings\f\bs\f
necess\bry.\f\f
REFER\fto:\f Front\fWheel\fBe\bring \f(204-01\fFront\f
Sus

pension,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
Br\bke\fsystem.\f
*CHECK\fthe\fbr\bke\fsystem.\f\f
REFER\fto:\f Br\bke\fSystem\f(206-00\fBr\bke\fSystem\f-
\f
Gener\bl\fInform\btion,\fDi\bgnosis\f\bnd\fTesting).\f
*
Steering\flink\bge.\f
*CARRY\fOUT\fthe\fSteering\fLink\bge\fComponent\f
Test.\fREFER\fto\fSteering\fLink\bge\fComponent\fTest.
\f
*
Steering\fge\br.\f
*CARRY\fOUT\fthe\fSteering\fLink\bge\fComponent\f
Test.\fREFER\fto\fSteering\fLink\bge\fComponent\fTest.
\f
*
Wheels\f\bnd\ftires.\f
*REFER\fto:\f Wheels\f\bnd\fTires\f(204-04\fWheels\f\bnd\f
Tir
es,\fDi\bgnosis\f\bnd\fTesting).\f
*
Steering\fwheel\f
off\fcenterVehicle\f\bttitude\f
incorrect\f(front\for\f
re\br\fis\fhigh\for\flow).\f
*CHECK\ffor\f\bbnorm\bl\flo\bding,\fcoil\fspring\fs\bg\for\f
non-st\bnd\brd\fsprings.\f
*
Incorrect\fwheel\f
\blignment.\f
*CHECK\fthe\fwheel\f\blignment\f\bnd\fADJUST\fif\f
necess\bry.\f\f
REFER\fto:\f Front\fToe\fAdjustment \f(204-00\f
Sus

pension\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
*
Suspension\flower\f
\brm\fb\bll\fjoint.\f
*CARRY\fOUT\fthe\fB\bll\fJoint\fInspection\fComponent\f
Test.\f\f
*
Steering\flink\bge.\f
*CARRY\fOUT\fthe\fSteering\fLink\bge\fComponent\f
Test.\fREFER\fto\fSteering\fLink\bge\fComponent\fTest.
\f
*
Steering\fge\br.\f
*CARRY\fOUT\fthe\fSteering\fLink\bge\fComponent\f
Test.\fREFER\fto\fSteering\fLink\bge\fComponent\fTest.
\f
*
Vibr\btionIncorrect\fwheel\f
\blignment.\f
*CHECK\fthe\fwheel\f\blignment\f\bnd\fADJUST\fif\f
necess\bry.\f\f
REFER\fto:\f Front\fToe\fAdjustment \f(204-00\f
Su s

pension\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
*
Wheels\f\bnd\ftires.\f
*CHECK\fthe\fwheels\f\bnd\ftires.\fBALANCE\for\f
INSTALL\fnew\fwheels\f\bnd\ftires\f\bs\fnecess\bry.\f\f
REFER\fto:\f Wheels\f\bnd\fTires\f(204-04\fWheels\f\bnd\f
Tir

es,\fDi\bgnosis\f\bnd\fTesting).\f
*
D\bm\bged\for\fworn\f
front\fwheel\fbe\brings.\f
*CHECK\f\bnd\fINSTALL\fnew\fwheel\fbe\brings\f\bs\f
necess\bry.\f\f
REFER\fto:\f Front\fWheel\fBe\bring \f(204-01\fFront\f
Sus

pension,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
Front\fstrut\f\bnd\f
spring\f\bssemblies.\f
*CHECK\f\bnd\fINSTALL\fnew\fsuspension\fcomponents\f
\bs\fnecess\bry.\f\f
*
D\bm\bged\ffront\f
suspension\flower\f\brm
(s).\f
*CHECK\f\bnd\fINSTALL\fnew\fsuspension\fcomponents\f
\bs\fnecess\bry.\f\f
*
Steering\flink\bge.\f
*CARRY\fOUT\fthe\fSteering\fLink\bge\fComponent\f
Test.\fREFER\fto\fSteering\fLink\bge\fComponent\fTest.
\f
*
Steering\feffort\fis\f
high/lowPower\fsteering\fhose\f
restriction.\f
*CHECK\fthe\fpower\fsteering\fhoses\ffor\fd\bm\bge,\f
kinks\for\frestrictions.\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\f\f
*
Power\fsteering\ffluid\f
cont\bmin\btion.\f
*FLUSH\fthe\fpower\fsteering\fsystem.\f\f
REFER\fto:\f Power\fSteering\fSystem\fFlushing \f(211-
00 \f

Steering\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
*
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Page 357 of 4402

$FORD S-MAX 2006 Service Repair Manual Aer\btion\fof\fthe\fpower\f steering\ffluid.\f * BLEED\fthe\fpower\fsteering\fsystem.\f\f REFER\fto:\f Power\fSteering\fSystem\fBleeding \f(211- 00\f Steering\fSystem\f-\fGener\bl\fInform\btion,\f Ge$

Aer\btion\fof\fthe\fpower\f
steering\ffluid.\f
*
BLEED\fthe\fpower\fsteering\fsystem.\f\f
REFER\fto:\f Power\fSteering\fSystem\fBleeding \f(211-
00\f

Steering\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
*
Steering\fge\br\ffloor\f
se\bl\ftouch\fcondition.\f
*CHECK\fthe\finst\bll\btion\fof\fthe\ffloor\fse\bl.\f
*
Steering\fcolumn.\f
*CHECK\fif\fthe\ffloor\fcovering\fis\fobstructing\fthe\f
steering\fge\br\fpinion.\f\f
CHECK\fthe\finst\bll\btion\fof\fthe\ffloor\fse\bl.\f
CARRY\fOUT\fthe\fSteering\fColumn\fUnivers\bl\fJoint\f
Component\fTest.\fREFER\fto\fSteering\fColumn\f
Univers\bl\fJoint\fComponent\fTest.\f
*
*
*
Steering\flink\bge.\f
*CARRY\fOUT\fthe\fSteering\fLink\bge\fComponent\f
Test.\fREFER\fto\fSteering\fLink\bge\fComponent\fTest.
\f
*
Steering\fge\br.\f
*CARRY\fOUT\fthe\fSteering\fLink\bge\fComponent\f
Test.\fREFER\fto\fSteering\fLink\bge\fComponent\fTest.
\f
*
Worn\fpower\fsteering\f
pump.\f
*INSTALL\f\b\fnew\fpower\fsteering\fpump.\fREFER\fto:\f
(211-02\fPower\fSteering)\f Power\fSteering\fPump\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4\f(Remov\bl\f\bnd\f
Ins

t\bll\btion),\f
Power\fSteering\fPump\f-\f2.5L\fDur\btec-ST\f
(VI5)\f(Remov\bl\f\bnd\fInst\bll\btion),\f
Power\fSteering\fPump\f-\f1.8L\fDur\btorq-TDCi\f
(Kent)\fDiesel\f(Remov\bl\f\bnd\fInst\bll\btion),\f
Power\fSteering\fPump\f-\f2.0L\fDur\btorq-TDCi\f
(DW)\fDiesel,\fVehicles\fWith:\fElectro-
Hydr\bulic\f
Power\fSteering\f(EHPS)\f(Remov\bl\f\bnd\f
Inst\bll\btion).\f
*
Excessive\fnoisePower\fsteering\f
oper\btion\fnoise.\f
*CARRY\fOUT\fthe\fPower\fSteering\fOper\btion\fNoise\f
Check.\f\f
REFER\fto:\fNoise,\fVibr\btion\f\bnd\fH\brshness\f(NVH)\f
(100-04\fNoise,\fVibr\btion\f\bnd\fH\brshness,\f
Di\bgnosis\f\bnd\fTesting).\f
*
Aer\btion\fof\fthe\fpower\f
steering\ffluid.\f
*
BLEED\fthe\fpower\fsteering\fsystem.\f\f
REFER\fto:\f Power\fSteering\fSystem\fBleeding \f(211-
00\f

Steering\fSystem\f-\fGener\bl\fInform\btion,\f
Gener\bl\fProcedures).\f
*
Power\fsteering\flines.\f
*CHECK\fth\bt\fthe\fpower\fsteering\fline\fcl\bmps\f\bre\f
secure.\f\f CHECK\fthe\fpower\fsteering\flines\ffor\fcle\br\bnce\f
from\fthe\fvehicle\fbody,\fsubfr\bme\f\bnd\fsteering\f
ge\br.\f
CHECK\fthe\fsteering\fge\br\ftr\bnsfer\flines\ffor\f
cle\br\bnce\ffrom\fthe\fsteering\fge\br.\f
*
*
*
Loose\fsteering\fge\br\f
ret\bining\fbolts.\f
*CHECK\f\bnd\fINSTALL\fnew\fbolts\f\bs\fnecess\bry.\f\f
REFER\fto:\fSteering\fGe\br\f(211-
02\fPower\fSteering,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Power\fsteering\f
pump.\f
*INSTALL\f\b\fnew\fpower\fsteering\fpump.\fREFER\fto:\f
(211-02\fPower\fSteering)\f
Power\fSteering\fPump\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\fFlex\f
Fuel\f(107kW/145PS)\f-\fMI4/2.3L\fDur\btec-HE\f
(118kW/160PS)\f-\fMI4\f(Remov\bl\f\bnd\f
In s

t\bll\btion),\f
Power\fSteering\fPump\f-\f2.5L\fDur\btec-ST\f
(VI5)\f(Remov\bl\f\bnd\fInst\bll\btion),\f
Power\fSteering\fPump\f-\f1.8L\fDur\btorq-TDCi\f
*
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Page 358 of 4402

$FORD S-MAX 2006 Service Repair Manual Components\bTests\b Steering\bLinkage\b1. 1.\b Gr\bsp\fthe\fsteering\fwheel\ffirmly\f\bnd\fmove\fit\fup\f\bnd\fdown\f\bnd\fto\fthe\fleft\f\bnd\fright\f w ithout\fturning\fthe\fsteering\fwheel\fto\fch$

Components\bTests\b
Steering\bLinkage\b1. 1.\b
Gr\bsp\fthe\fsteering\fwheel\ffirmly\f\bnd\fmove\fit\fup\f\bnd\fdown\f\bnd\fto\fthe\fleft\f\bnd\fright\f
w
ithout\fturning\fthe\fsteering\fwheel\fto\fcheck\fthe\fsteering\fcolumn\fbe\bring\ffor\fwe\br,\f
steering\fcolumn\fsh\bft\ffor\fwe\br,\fsteering\fwheel\ffor\flooseness\f\bnd\fsteering\fcolumn\f
for\flooseness.\fIf\fthe\fsteering\fcolumn\fbe\bring\for\fthe\fsteering\fcolumn\fsh\bft\fis\fworn\f
inst\bll\f\b\fnew\fsteering\fcolumn.\f\f
REFER\fto:\fSteering\fColumn\f(211-04\fSteering\fColumn,\fRemov\bl\f\bnd\fInst\bll\btion).\f
If\fthe\fsteering\fwheel\for\fthe\fsteering\fcolumn\fis\floose,\ftighten\fthe\fsteering\fwheel\for\f
the\fsteering\fcolumn\fret\bining\fbolts.\f\f
2. 2.\b
With\fthe\fro\bd\fwheels\fin\fthe\fstr\bight\f\bhe\bd\fposition,\fgently\fturn\fthe\fsteering\fwheel\f
t
o\fthe\fleft\f\bnd\fthe\fright\fto\fcheck\ffor\ffree\fpl\by\fin\fthe\fsteering\flink\bge.\f
3. 3.\b
There\fshould\fbe\fno\fexcessive\ffree\fpl\by\f\bt\fthe\fsteering\fwheel\frim.\fIf\fthere\fis\f
e
xcessive\ffree\fpl\by,\fCHECK\fthe\ftie-rod\finner\f\bnd\fouter\fb\bll\fjoints,\fREFER\fto\fTie-Rod\f
Component\fTest\fin\fthis\fprocedure.\fCHECK\fthe\fsteering\fcolumn\funivers\bl\fjoint,\f
REFER\fto\fSteering\fColumn\fUnivers\bl\fJoint\fComponent\fTest\fin\fthis\fprocedure.\fIf\f
there\fis\fno\ffree\fpl\by\fin\fthe\ftie-rod\f\bnd\fthe\fsteering\fcolumn,\finst\bll\f\b\fnew\fsteering\f
ge\br.\f\f
REFER\fto:\fSteering\fGe\br\f(211-02\fPower\fSteering,\fRemov\bl\f\bnd\fInst\bll\btion).\f
(Kent)\fDiesel\f(Remov\bl\f\bnd\fInst\bll\btion),\f
Power\fSteering\fPump\f-\f2.0L\fDur\btorq-TDCi\f
(DW)\fDiesel,\fVehicles\fWith:\fElectro-
Hydr\bulic\f
Power\fSteering\f(EHPS)\f(Remov\bl\f\bnd\f
Inst\bll\btion).\f
Tie-rod.\f
*CARRY\fOUT\fthe\fTie-Rod\fComponent\fTest.\fREFER\f
to\fTie-Rod\fComponent\fTest.\f
*
Steering\fdoes\fnot\f
v\bry\fwith\f
incre\bsed\fwheel\f
rot\btion
Worn\ftie-rod\fends.\f
*INSTALL\fnew\fcomponents\f\bs\fnecess\bry.\f\f
REFER\fto:\fTie\fRod\fEnd\f(211-
03\fSteering\fLink\bge,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Worn\ffront\f
suspension\fbushings.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\f\f
*
Worn\fsuspension\fb\bll\f
joints.\f
*
CARRY\fOUT\fthe\fB\bll\fJoint\fInspection\fComponent\f
Test.\f\f
*
Steering\fge\br\f
insul\btor\fbushings\f
worn\for\fperished.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\f\f
*
Loose\fsteering\fge\br\f
ret\bining\fbolts.\f
*CHECK\f\bnd\fINSTALL\fnew\fbolts\f\bs\fnecess\bry.\f\f
REFER\fto:\fSteering\fGe\br\f(211-
02\fPower\fSteering,\f
Remov\bl\f\bnd\fInst\bll\btion).\f
*
Loose\fsteering\f
column\fret\bining\f
bolts.\f
*CHECK\f\bnd\fINSTALL\fnew\fbolts\f\bs\fnecess\bry.\f\f
REFER\fto:\fSteering\fColumn\f(211-04\fSteering\f
Column,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
Loose\fsteering\f
column\fto\fsteering\f
ge\br\fpinion\fret\bining\f
bolt.\f
*CHECK\f\bnd\fINSTALL\f\b\fnew\fbolt\f\bs\fnecess\bry.\f\f
REFER\fto:\fSteering\fColumn\f(211-04\fSteering\f
Column,\fRemov\bl\f\bnd\fInst\bll\btion).\f
*
Excessive\fsteering\f
ge\br\fb\bckl\bsh.\f
*CARRY\fOUT\fthe\fSteering\fLink\bge\fComponent\f
Test.\fREFER\fto\fSteering\fLink\bge\fComponent\fTest.\f
*
Steering\f\bssist\f
does\fnot\fv\bry\f
with\fvehicle\f
\bssistPowertr\bin\fcontrol\f
module\f(PCM).\f
*REFER\fto\fWDS.\f
*
Electro-hydr\bulic\f
power\fsteering\f
(EHPS)\fcontrol\f
module.\f
*REFER\fto\fWDS.\f
*
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Page 359 of 4402

$FORD S-MAX 2006 Service Repair Manual Tie\fRod\b1. 1.\b Noises\fsuch\f\bs\fknocks,\fwhich\fm\by\f\bppe\br\fto\forigin\bte\ffrom\fthe\fsteering\flink\bge,\f m \by\f\blso\fbe\fgener\bted\fby\ffront\fsuspension\fcomponents.\f\f REFER\fto:\f$

Page 360 of 4402

$FORD S-MAX 2006 Service Repair Manual 7.7.\b If\fthere\fis\ffree\fpl\by\f\bt\fthe\ftie-rod\finner\fb\bll\fjoint,\finst\bll\f\b\fnew\ftie-rod.\f\f R EFER\fto:\fTie\fRod\f(211-03\fSteering\fLink\bge,\fRemov\bl\f\bnd\fInst\bll\btion).\f 8. 8$

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auxiliary battery deactivate airbag navigation system tire type fuses checking oil