2006 FORD S-MAX drive

Front Dr\bve H\flfsh\ffts - Inner Const\fnt
Veloc\bty (CV) Jo\bnt BootS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\fl \fnd Inst\fll\ft\bon
Spec\b\fl Tool(s)
M\ft

er\b\fls
Gener\fl Equ\bpment
Remov\fl
204-169\f
Cl\bmping\fTool,\fBoot\fRet\bining\fCl\bmp\f
308-046\f
Inst\bller,\fTr\bnsmission\fExtension\fHousing\fBushing/Se\bl
\f
NameSpec\bf\bcat\bo\f
Gre\bse\fFD-RWSS-M1C259-A1\f/\f3M5J-M1C259-AA
Puller 1. Refer\fto:\fFront\fH\blfsh\bft\fLH \f(205-04\fFront\fDrive\f
H\blf

sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Front\fH\blfsh\bft\fRH \f(205-04\fFront\fDrive\f
H\blf

sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Disc\brd\fthe\fgre\bse.\f
3. \f
4. General \bqui\fment: Puller\f
\f
\f
\f\f
\f\f
\f\f
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Inst\fll\ft\bon 5. \f
1.

\f
2. S\fecial Tool(s): 204-169\f
To r

que: 21\fNm
\f
3. S\fecial Tool(s): 308-046\f
4. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
i
n

st\blled.\f
5. \f\f
Fill\fthe\fCV\fjoint\fwith\fgre\bse.\f
Mat

erial: Gre\bse\fFD-R\f(WSS-M1C259-A1\f/\f
3M 5

J-M1C259-AA) \f

Insert\f\b\fsm\bll\fscrewdriver\funder\fthe\fboot\f
\f\f
\f\f
\f\f
\f\f
\f\f
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se\bt\fto\f\bllow\fthe\f\bir\fto\fesc\bpe.\f

Push\fon\fthe\ftripode\fhousing\fto\fstop,\fthen\f
pu

ll\fit\fb\bck\f25\fmm\f(x\f=\f95\fmm).\f

Remove\fthe\fscrewdriver.\f
6. S

\fecial Tool(s): 204-169\f
Tor

que: 21\fNm
\f
7. Refer\fto:\f Front\fH\blfsh\bft\fLH \f(205-04\fFront\fDrive\f
H\bl f

sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Front\fH\blfsh\bft\fRH \f(205-04\fFront\fDrive\f
H\blf

sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
\f\f
\f\f
Стр. 3 из
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Front Dr\bve H\flfsh\ffts - Outer Const\fnt
Veloc\bty (CV) Jo\bnt BootS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\fl \fnd Inst\fll\ft\bon
Spec\b\fl Tool(s)
Remov\fl
In

st\fll\ft\bon
204-169\f
Cl\bmping\fTool,\fBoot\fRet\bining\fCl\bmp
\f
1. Remove\fthe\finner\fCV\fjoint\fboot.\f Refer\fto:\f Inner\fConst\bnt\fVelocity\f(CV)\fJoint\fBoot \f
(20

5-04\fFront\fDrive\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. \f
1. \f\f
Fill\fthe\fCV\fjoint\fwith\fgre\bse.\f

Insert\f\b\fsm\bll\fscrewdriver\funder\fthe\fboot\f
se

\bt\fto\f\bllow\fthe\f\bir\fto\fesc\bpe.\f
2. Special\bTool(\f):\b 204-169\f
Tor

que:\b 21\fNm
\f
3. Inst\bll\fthe\finner\fCV\fjoint\fboot.\f Refer\fto:\f Inner\fConst\bnt\fVelocity\f(CV)\fJoint\fBoot \f
(2 0

5-04\fFront\fDrive\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
\f
\f\f
\f\f
\f\f
Стр. 1 из 1
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Brake S\bstem \f General Information \f
Brake S\bstemS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description and Operation
The\fbr\bking\fsystem\fis\fof\f\b\fdi\bgon\blly\fsplit,\fdu\bl\fcircuit\fdesign\ffe\bturing\ffront\f\bnd\fre\br\fdisc\f
br

\bkes.\f\f
The\fhydr\bulic\fsystem\fh\bs\fsep\br\bte\fcircuits\ffor\fe\bch\fp\bir\fof\fdi\bgon\blly\fopposed\fwheels\f(left\f
front,\fright\fre\br\f\bnd\fright\ffront,\fleft\fre\br).\fThe\ffront\fbr\bke\fc\bliper\fis\fof\f\b\fsingle\fsliding\f
piston\fdesign\fwhich\fm\bkes\fsure\fth\bt\fequ\bl\feffort\fis\f\bpplied\fthrough\fboth\fbr\bke\fp\bds.\f\f
The\fp\brking\fbr\bke\fcontrol\foper\btes\fthe\fre\br\fbr\bkes\fthrough\f\b\fc\bble\fsystem.\fThere\fis\f\blso\f
\bn\felectronic\fp\brking\fbr\bke\f(EPB)\fsystem\f\bv\bil\bble.\f\f
The\fbr\bke\fm\bster\fcylinder\fis\fof\f\b\ft\bndem\fdesign\f\bnd\fis\flinked\fto\f\b\fbr\bke\fbooster\fwhich\f
reduces\fthe\fbr\bke\fped\bl\feffort.\fThe\ft\bndem\fdesign\fwill\fm\bke\fsure\fth\bt\fin\fthe\fevent\fof\fone\f
br\bke\fcircuit\ff\biling\fthe\fother\fwill\frem\bin\ffully\foper\btion\bl.\f\f
The\fbr\bke\fbooster\fv\bcuum\fon\fvehicles\fwith\fdiesel\fengine\fis\fprovide\fby\f\b\fc\bmsh\bft\fdriven\f
v\bcuum\fpump.\f\f
The\f\bnti-lock\fbr\bke\fsystem\f(ABS)\fis\fcontrolled\fby\fthe\fhydr\bulic\fcontrol\funit\f(HCU),\f
incorpor\bted\fwithin\fthe\fhydr\bulic\fsystem,\f\bnd\fonly\foper\btes\fwhen\fthe\fwheel\fspeed\fsensors\f
detect\fthe\fonset\fof\fwheel\flock\fup.\f\f
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Brake S\bstem \f General Information \f
Brake S\bstemS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagnosis and Testing
Principles of Operation
Th

e\fbr\bke\fsystem\foper\btes\fby\ftr\bnsferring\feffort\f\bpplied\fto\fthe\fbr\bke\fped\bl\fby\fthe\fdriver\fto\f
the\fbr\bkes\f\bt\fe\bch\fwheel.\f
The\fbr\bking\feffort\fis\fdistributed\fto\fe\bch\fwheel,\fusing\f\bn\fhydr\bulic\fsystem.\fThe\fsystem\fis\f
\bssisted\fusing\f\b\fv\bcuum\fbr\bke\fbooster\fth\bt\freduces\fped\bl\feffort\f\bnd\fincre\bses\fhydr\bulic\f
pressure.\fThe\fp\brking\fbr\bke\foper\btes\fon\fthe\fre\br\fwheels\f\bnd\fis\f\bpplied\fusing\f\b\fh\bnd\f
oper\bted\fcontrol.\f
Inspection and Verification
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

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

isual Inspection Chart
3. 3.
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.
If\fthe\fconcern\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\f
S
ymptom\fCh\brt.\f
Road Test
C\brry\fout\f\b\fro\bd\ftest\fto\fcomp\bre\f\bctu\bl\fvehicle\fbr\bking\fperform\bnce\fwith\fthe\fperform\bnce\f
st\bnd\brds\fexpected\fby\fthe\fdriver.\fThe\f\bbility\fof\fthe\ftest\fdriver\fto\fm\bke\fv\blid\fcomp\brison\f
\bnd\fdetect\fperform\bnce\fdeficiencies\fwill\fdepend\fon\fexperience.\f
The\fdriver\fshould\fh\bve\f\b\fthorough\fknowledge\fof\fbr\bke\fsystem\foper\btion\f\bnd\f\bccepted\f
gener\bl\fperform\bnce\fguidelines\fto\fm\bke\fgood\fcomp\brisons\f\bnd\fdetect\fperform\bnce\f
concerns.\f
An\fexperienced\fbr\bke\ftechnici\bn\fwill\f\blw\bys\fest\bblish\f\b\froute\fth\bt\fwill\fbe\fused\ffor\f\bll\fbr\bke\f
di\bgnosis\fro\bd\ftests.\fThe\fro\bds\fselected\fwill\fbe\fre\bson\bbly\fsmooth\f\bnd\flevel.\fGr\bvel\for\f
bumpy\fro\bds\f\bre\fnot\fsuit\bble\fbec\buse\fthe\fsurf\bce\fdoes\fnot\f\bllow\fthe\ftires\fto\fgrip\fthe\fro\bd\f
equ\blly.\fCrowned\fro\bds\fshould\fbe\f\bvoided\fbec\buse\fof\fthe\fl\brge\f\bmount\fof\fweight\fshifted\fto\f
the\flow\fset\fof\fwheels\fon\fthis\ftype\fof\fro\bd.\fOnce\fthe\froute\fis\fest\bblished\f\bnd\fconsistently\f
used,\fthe\fro\bd\fsurf\bce\fv\bri\bble\fc\bn\fbe\felimin\bted\ffrom\fthe\ftest\fresults.\f
Before\f\b\fro\bd\ftest,\fobt\bin\f\b\fcomplete\fdescription\fof\fthe\fcustomer\fconcerns\for\fsuspected\f
condition.\fFrom\fthe\fdescription,\fthe\ftechnici\bn's\fexperience\fwill\f\bllow\fthe\ftechnici\bn\fto\f
m\btch\fpossible\fc\buses\fwith\fsymptoms.\fCert\bin\fcomponents\fwill\fbe\ft\bgged\f\bs\fpossible\f
suspects\fwhile\fother\fwill\fbe\felimin\bted\fby\fthe\fevidence.\fMore\fimport\bntly,\fthe\fcustomer\f
description\fc\bn\freve\bl\funs\bfe\fconditions\fwhich\fshould\fbe\fchecked\for\fcorrected\fbefore\fthe\f
ro\bd\ftest.\fThe\fdescription\fwill\f\blso\fhelp\fform\fthe\fb\bsic\f\bppro\bch\fto\fthe\fro\bd\ftest\fby\f
n\brrowing\fthe\fconcern\fto\fspecific\fcomponents,\fvehicle\fspeed\for\fconditions.\f
Mechanica\b

Tire\fpressure\f\f

Wheels\f\bnd\ftires\f\f

Fluid\fle\bk\ffrom\fbr\bke\fline(s)\f\f

Fluid\flevel\f\f

Fluid\fcont\bmin\btion\f
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conditions.\f
*\fS\bfety,\fthe\fvehicle\fc\bn\fbe\fslowed\fdown\fwith\fthe\fEPB\fif\fthe\fhydr\bulics\fof\fthe\fbr\bke\fsystem\f
f\bil\fwhile\fdriving.\fThe\fsystem\fis\f\butom\btic\blly\fcoordin\bted\fwith\fthe\fABS\fsystem\fto\fprevent\f
the\fbr\bked\fwheels\ffrom\flocking.\f
The\fsystem\fcomprises\fthe\ffollowing\fcomponents:\f
*\fEPB\fmodule:\fThis\fis\floc\bted\fin\fthe\fre\br\fstow\bge\f\bre\b,\fbehind\fthe\fleft-h\bnd\fre\br\fqu\brter\f
trim\fp\bnel.\fThe\fmodule\fis\fthe\fsystem\fcontrol\funit\f\bnd\foper\btes\fthe\fre\br\fbr\bke\fc\blipers\f\bs\f
required\fusing\finform\btion\ffrom\fthe\fEPB\fswitch,\fthe\fignition\fkey\f\bnd\fv\brious\fsystem\fd\bt\b\f
from\fthe\fhigh-speed\fCAN\fBus.\f
*\fEPB\fSwitch:\fThis\fis\f\b\fpush-pull\ftype\fswitch\f\bnd\fis\floc\bted\fin\fthe\ffloor\fconsole.\fTo\frele\bse\f
the\fEPB,\fpush\fthe\fEPB\fswitch\fdown.\fTo\feng\bge\fthe\fEPB,\fpull\fthe\fEPB\fswitch\fup.\f
*\fEPB\fActu\btors:\fThese\f\bre\f\btt\bched\fto\fthe\fleft\f\bnd\fright-h\bnd\fre\br\fbr\bke\fc\bliper\fhousings.\f
They\fuse\f\bn\felectric\fmotor\fto\foper\bte\fthe\fc\blipers\fby\fturning\f\b\fthre\bded\fspindle\fwithin\f\b\f
pressure\fnut\fth\bt\fpresses\f\bg\binst\fthe\fbr\bke\fc\bliper\fpiston.\f
Modes\fof\fOper\btion:\f
St\btic\fMode\f(vehicle\fst\btion\bry):\fFull\f\bpplic\btion\f\bnd\frele\bse\fof\fthe\fre\br\fbr\bkes\fis\fpossible.\f
The\fp\brking\fbr\bke\fwill\fonly\frele\bse\fif\fthe\fbr\bke\fped\bl\for\fclutch\fped\bl\fis\fdepressed\f\bt\fthe\f
s\bme\ftime\f\bs\frele\bsing\fthe\fEPB\fswitch,\for\fwhen\fthe\fvehicle\fis\fdriven\f\bw\by.\f
Key\fOut\fApply:\fThe\fp\brking\fbr\bke\fis\f\butom\btic\blly\f\bpplied\f(\buto\fcl\bmp)\fwhen\fthe\fignition\f
key\fis\fremoved\ffrom\fthe\fignition\fswitch.\f
Dyn\bmic\fMode\f(vehicle\fin\fmotion):\fThe\fp\brking\fbr\bke\fis\fgr\bdu\blly\f\bctiv\bted\fwhen\fthe\fEPB\f
switch\fis\f\bpplied\f\bnd\frele\bsed\fwhen\fthe\fEPB\fswitch\fis\frele\bsed.\f
Drive\fAw\by\fAssist:\fThis\fsystem\fen\bbles\fthe\fdriver\fto\fdrive\f\bw\by\fon\f\bn\fincline\fwithout\fthe\f
vehicle\frolling\fb\bck\funintention\blly.\fAfter\fstopping\fthe\fvehicle\fon\f\bn\fincline\for\f\b\fdescent\f
\bnd\fthe\fp\brking\fbr\bke\fis\f\bpplied,\fit\fwill\fbe\frele\bsed\fwhen\foper\bting\fthe\f\bcceler\btor\fped\bl\f
without\f\bny\ffurther\fdriver\fintervention.\f
Disc\fTemper\bture\fMode:\fIf\f\bfter\fbringing\fthe\fvehicle\fto\f\b\fh\blt\fthe\fre\br\fbr\bke\fdiscs\f
temper\bture\fexceeds\f300°C,\fthe\fp\brking\fbr\bke\fwill\fbe\f\bctiv\bted\f\bnd\fwill\fnot\frele\bse\funtil\f
the\fbr\bke\fdiscs\fh\bve\fsufficiently\fcooled.\f
St\bll\fApply:\fIf\fthe\fengine\fis\fst\blled\fthe\fp\brking\fbr\bke\fis\f\butom\btic\blly\f\bpplied.\f
Service\fmode\f\bctiv\btion\f\bnd\fde\bctiv\btion\f
On\fvehicles\fwith\fElectronic\fP\brking\fBr\bke\f(EPB)\fit\fis\frequired\fto\f\bctiv\bte\fthe\fservice\fmode\f
before\f\bny\fwork\fis\fst\brted.\fAlso\fthe\fde\bctiv\btion\fof\fthe\fservice\fmode\fis\frequired\f\bfter\fthe\f
rep\bir.\fThe\fService\fmode\fc\bn\fbe\f\bctiv\bted\feither\fusing\fthe\fvehicle\fsystem\for\fusing\fthe\fFord\f
di\bgnostic\fsystem.\fFor\f\bddition\bl\finform\btion,\frefer\fto\f206-05\fP\brking\fBr\bke\f\bnd\fActu\btion,\f
Gener\bl\fProcedures.\f
A\fsep\br\bte\fprocedure\fis\f\bv\bil\bble\fif\fthe\fvehicle\fis\fwithout\fpower.\fFor\f\bddition\bl\finform\btion,\f
refer\fto\f206-05\fP\brking\fBr\bke\f\bnd\fActu\btion,\fGener\bl\fProcedures.\f
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Parking\bBrake\band\b\fctuation\b-\bParking\b
BrakeS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagnosis\band\bTesting\b
Refer\bto\bWiring\bDiagrams\bSection\b206-05,\bfor\bschematic\band\bconnector\b
in

formation.\b\b
General\bEquipment\b
Principles\bof\bOperation\b
In

spection\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
Worldwide\fDi\bgnostic\fSystem\f(WDS)
Mechanica\bE\bectrica\b

P\brking\fbr\bke\fswitch\f\f

Clutch\fped\bl\fswitch\f\f

C\bliper\f\f

Br\bke\fdisc\f\f

Br\bke\fp\bd\f
P\brking\fbr\bke\fswitch\f\f

Clutch\fped\bl\fswitch\f\f

Fuse(s)\f\f

Electric\bl\fconnector(s)\f\f

Circuit(s)\f
\fymptomPossib\be \fourcesAction
Poor\fdrive\f\bw\by\frele\bseReversing\fl\bmp\f
switch\fstuck\fon.\f
*Check\fthe\foper\btion\fof\fthe\freversing\f
l\bmps.\f\f
REFER\fto:\f Reversing\fL\bmps\f(417-01\f
Ext

erior\fLighting,\fDi\bgnosis\f\bnd\f
Testing).\f
*
Clutch\fch\bnged\f
\bnd\fnot\fre-le\brned.\f
*C\brry\fout\fsever\bl\fdrive\f\bw\bys\fwith\f
m\bnu\bl\foper\btion\fof\fthe\fEPB\fswitch.\f
*
Drive\f\bw\by\frele\bse\fnot\f
possibleClutch\fped\bl\f
position\fswitch\fnot\f
depressed\ffully.\f
*Check\fthe\fcorrect\fclutch\fped\bl\f
position\fswitch\fis\ffitted.\fAdvise\fthe\f
customer\fth\bt\fthe\fclutch\fmust\fbe\ffully\f
depressed\fto\f\bctiv\bte\fdrive\f\bw\by\f
rele\bse.\f
*
Acceler\btor\fped\bl\f
not\fdepressed\f
sufficiently.\f
*Advise\fthe\fcustomer\fth\bt\fthe\f
\bcceler\btor\fped\bl\fmust\fbe\fdepressed\f
\bt\fle\bst\f10%\fto\f\bctiv\bte\fdrive\f\bw\by\f
rele\bse.\f
*
Drive\f\bw\by\frele\bse\f
option\fconfigured\f
out.\f
*Connect\fWDS\f\bnd\fcheck\fthe\f
configur\btion.\f\f
REFER\fto:\f Module\fConfigur\btion \f(418-
01 \f

Module\fConfigur\btion,\fGener\bl\f
Procedures).\f
*
Autom\btic\f'key\fout'\fEPB\f
\bctiv\btion\fnot\fpossibleAutom\btic\f'key\fout'\f
EPB\f\bctiv\btion\f
*
Connect\fWDS\f\bnd\fcheck\fthe\f
configur\btion.\f\f
*
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