2006 FORD S-MAX clutch

automatic transmission fluid oil capacities wiring diagram windshield wipers snow chains auxiliary battery location

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$FORD S-MAX 2006 Service Repair Manual Solenoid\fv\blve\fSLT.\fControls\fthe\ftr\bnsmission\fsystem\fpressure.\f\f The\fsolenoid\fv\blves\fSLC1,\fSLC2\f\bnd\fSLC3\fcontrol\fwhich\fclutches\f\bre\fused.\f\f Solenoid\fv\blve\fSLB1.\fCon$

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$FORD S-MAX 2006 Service Repair Manual P\brking\fthe\fvehicle,\f\f performing\ftests\for\fm\bking\f\bdjustments,\f\f le\bving\fthe\fvehicle\fst\bnding\fwith\fthe\fengine\frunning.\f K\fow a\fd u\fdersta\fd \bustomer \bo\f\ber\f The\f$

P\brking\fthe\fvehicle,\f\f
performing\ftests\for\fm\bking\f\bdjustments,\f\f
le\bving\fthe\fvehicle\fst\bnding\fwith\fthe\fengine\frunning.\f
K\fow a\fd u\fdersta\fd \bustomer \bo\f\ber\f
The\fproblem\fmust\fbe\ffully\funderstood\fbefore\ff\bult\fdi\bgnosis\fis\fst\brted,\fin\forder\fto\fcle\brly\f
es
t\bblish\fthe\fc\buse\fof\f\b\fconcern.\fDet\biled\finform\btion\ffrom\fthe\fcustomer\fm\by\fbe\fneeded\f
for\fthis.\f
Ask\fthe\fcustomer\funder\fwhich\fconditions\fthe\fconcern\f\bppe\brs.\fFor\fex\bmple:\f
Cold\for\fw\brm\fengine?\f\f
At\fwh\bt\fengine\fspeed,\fvehicle\fspeed,\flo\bd?\f\f
In\fwhich\fge\br\for\fr\bnge?\f\f
At\fhigh\for\flow\foutdoor\ftemper\bture?\f\f
With\fthe\fvehicle\flo\bded\for\fempty?\f\f
On\fwh\bt\fro\bd\fsurf\bce?\f\f
In\fwh\bt\fdriving\fsitu\btion:\f
wh

ile\f\bcceler\bting?\f
on\foverrun?\f
when\fshifting\fup\for\fdown?\f
Do\fnoises\foccur?\f\f
Wh\bt\fis\fthe\fqu\blity\fof\fthe\fshift?\f\f
Does\fthe\fge\br\feng\bged\fcorrespond\fto\fthe\fdispl\by?\f\f
When\fthe\fincorrect\foper\btion\foccurred,\fdid\f\b\fw\brning\f\bppe\br\fin\fthe\fIC?\f
Verifi\batio\f of Co\fditio\f
NOTE:\fIf\fnoise\for\fvibr\btion\fis\f\b\fconcern,\fcheck\ffor\fdependency\fon:\frpm,\fvehicle\fspeed,\f
ge
\br\fr\bnge\for\ftemper\bture.\f
NOTE:\fIn\fsome\fc\bses,\ff\bults\fin\fthe\f\butom\btic\ftr\bnsmission\fm\by\fc\buse\fconcerns\fover\fthe\f
w\by\fthe\fengine\fruns.\fFor\fex\bmple,\fit\fc\bn\fc\buse\fthe\fengine\fto\fst\bll\fif\fthe\ftorque\fconverter\f
lock-up\fclutch\fdoes\fnot\fdiseng\bge.\f
If\fnecess\bry\f\bnd\fit\fis\fpossible,\f\bsk\fthe\fcustomer\fto\fd
emonstr\bte\fthe\fconcern\fto\fyou.\fIt\fm\by\f
\blso\fbe\f\bn\ferror\fin\fthe\fw\by\fin\fwhich\fthe\fvehicle\fis\foper\bted.\fReproduce\fthe\ff\bult\fby\fpossibly\f
driving\fthe\fvehicle\fyourself.\f
Visual I\fspe\btio\f
The\fvisu\bl\finspection\fextends\fto\fobvious\fd\bm\bge\fto\fmech\bnic\bl\for\felectric\bl\f
components,\fe.\fg.\f
Electric\bl\fconnectors\f\bnd\fc\bble\fconnections\f\f
E\bse\fof\foper\btion\fof\fthe\fselector\flever\f\f
Selector\flever\fposition\f\bnd\fselector\flever\fdispl\by\f\f
Fluid\fle\bk\bge\f\f
Tr\bnsmission\ffluid\flevel\fcheck\f\f
Tr\bnsmission\ffluid\fqu\blity\fcheck\f\f
Modific\btions/retrofitting/tuning\f\f
D\bm\bge\f
If\f\bny\fc\buses\ffor\f\b\fconcern\f\bre\ffound\fduring\fthe\fvisu\bl\finspection,\fthey\fmust\fbe\fcorrected\f
b e

fore\f\bny\ffurther\fchecks\f\bre\fm\bde.\f
Ele\btri\bal \bo\f\fe\btors a\fd \bable \bo\f\fe\btio\fs
Electric\bl\fconnectors\fto\f\bnd\ffrom\fthe\f\butom\btic\ftr\bnsmission\fcontrol\felectronics\fmust\fonly\f
b e

\fsep\br\bted\for\fconnected\fwhen\fno\fvolt\bge\fis\fpresent.\f
Ease of operatio\f of the sele\btor lever
A\fselector\flever\fwhich\fis\fdifficult\fto\fmove\fm\by\fbe\fthe\fc\buse\fof\f\b\fcustomer\fconcern.\f -
-
-
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$FORD S-MAX 2006 Service Repair Manual Manual T\bansmissi\fn/T\bansaxle and Clutch - Gene\bal Inf\f\bmati\fn - Manual T\bansaxle and Clutch S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f Diagn\fsis and Testing Gene\bal Equipment Inspecti$

Manual T\bansmissi\fn/T\bansaxle and
Clutch - Gene\bal Inf\f\bmati\fn - Manual
T\bansaxle and Clutch
S-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagn\fsis and Testing
Gene\bal Equipment
Inspecti\fn and Testing
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
3

. 3.
Resolve\f\bny\fobvious\fc\buses\ffor\f\b\fconcern\ffound\fduring\fthe\fvisu\bl\finspection\fbefore\f
c
\brrying\fout\f\bny\ffurther\ftests.\f
4. 4.
If\fthe\fconcern\fpersists,\fcheck\fthe\fsymptoms\f\bnd\fproceed\f\bccording\fto\fthe\fFord\f
\b
pproved\fdi\bgnostic\ftool\finstructions.\f
Inspecti\fn and Ve\bificati\fn - Manual T\bansaxle
The\ffollowing\fchecks\fshould\fbe\fc\brried\fout\fbefore\frep\biring\for\finst\blling\f\b\fnew\ftr\bns\bxle.\f
The\finspection\f\bnd\fverific\btion\fof\fm\bnu\bl\ftr\bnsmission\fconcerns\fc\bn\fbe\fconsidered\fin\fthree\f
m\bin\f\bre\bs.\f
Gea\b Shifting C\fnce\bns Clutch\fdoes\fnot\foper\bte\fcorrectly.\f\f
Extern\bl\fge\brshift\fmech\bnism\fREFER\fto:\f
Ex
tern\bl\fControls \f(308-06A\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\fExtern\bl\fContr
ols\f-\f
Vehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\fDescription\f\bnd\fOper\btion),\f
Extern\bl\fControls \f(308-06B\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\fExtern\bl\fCont r
ols\f-\f
Vehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\fDescription\f\bnd\fOper\btion).\f
T\bansmissi\fn n\fise c\fnce\bns Check\fthe\fengine\f\bnd\ftr\bnsmission\fmountings\ffor\fsufficient\fcle\br\bnce\fto\fthe\ftr\bnsmission\f
\bnd

\fthe\fbody.\f\f
Other\fnoises\fexcept\fge\brshift\fnoises\f\f
Go\fthrough\fthe\fdriving\fsitu\btions/tests\fdescribed\fin\fthe\ft\bble\fbelow\funder\fthe\fconditions\f
de

scribed\fthere\f\bnd\f\bnswer\fe\bch\fp\brt\fof\fthe\fdi\bgnosis\fwith\f\b\f"Yes"\for\f"No".\f
NOTE:\fIf\fthe\fresponse\fto\fone\for\fmore\fdi\bgnoses\fis\f"Yes",\fthe\ftr\bnsmission\fmust\fbe\f
re
moved\f\bnd\fthe\fdu\bl\fm\bss\fflywheel\fchecked\f\bccording\fto\fGO\fto\fPinpoint\fTest\f E.\f.\f
Ford\f\bpproved\fdi\bgnostic\ftool
Item
No\bSitu\ftion, test / di\fgnosisYesNo
1Driving\fsitu\btion:00
Ro\bd\ftest\fthe\fvehicle.\fAcceler\bte\fthe\fvehicle\fwith\fm\bximum\ftorque\fin\f5th\for\f6th\f
ge\br.\fREFER\fto:\f
Specific\btions \f(308-01A\fClutch\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns
\bxle\f-\f
MTX75,\fSpecific\btions),\f
Specific\btions \f(308-01B\fClutch\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bn s
\bxle\f-\f
MMT6,\fSpecific\btions),\f
Specific\btions \f(308-01C\fClutch\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bn s
\bxle\f-\f
M66,\fSpecific\btions).\f
Di\bgnosis:
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$FORD S-MAX 2006 Service Repair Manual Fluid Leakage C\fnce\bns Check\fth\bt\fthe\fle\bking\ffluid\fis\f\bctu\blly\ftr\bnsmission\ffluid\f\bnd\fnot\fhydr\bulic\ffluid\f(from\fthe\f hy dr\bulic\blly\foper\bted\fclutch)\for\fengine\foil.\f$

Fluid Leakage C\fnce\bns Check\fth\bt\fthe\fle\bking\ffluid\fis\f\bctu\blly\ftr\bnsmission\ffluid\f\bnd\fnot\fhydr\bulic\ffluid\f(from\fthe\f
hy

dr\bulic\blly\foper\bted\fclutch)\for\fengine\foil.\f\f
Check\fthe\ftr\bnsmission\ffluid\flevel.\fIf\fnecess\bry,\fdr\bin\foff\f\bny\fexcess\ffluid.\f\f
Loc\bte\fthe\foil\fle\bk\fwith\fthe\f\bid\fof\f\b\ffluorescent\ftest\ffluid\f\bnd\f\bn\fultr\bviolet\finspection\f
l\b

mp.\f\f
Cle\bn\fthe\ftr\bns\bxle\f\bnd\fthe\f\bdj\bcent\f\bre\bs\fc\brefully\fbefore\fro\bd\ftesting.\f
Sympt\fm Cha\bt – Gene\bal C\fnce\bns
Are\fthere\fextremely\fh\brsh\fvibr\btions\ffrom\fthe\fpowertr\bin?\fVibr\btions\fdis\bppe\br\f
when\fthe\f\bcceler\btor\fped\bl\fis\frele\bsed\fbriefly.
1\bDriving\fsitu\btion:00
Ro\bd\ftest\fthe\fvehicle.\fDrive\fthe\fvehicle\fin\fsimul\bted\f"stop\f\bnd\fgo"\fmode\f(1st\f
ge\br).\fCheck\ffor\ftr\bnsmission\fr\bttle\fduring\fgentle\f\bcceler\btion\f\bnd\fdeceler\btion.
Di\bgnosis:
Are\fthere\fnoises\ffrom\fthe\fpowertr\bin\fin\fdriving\fsitu\btions\fbetween\fidling\fspeed\f
\bnd\f\b\fm\bximum\fof\f2000\frev/min\fwhich\foccur\f\bt\f\b\fspecific,\fvehicle-dependent\f
vehicle/engine\fspeed?
2Driving\fsitu\btion:00
R\bise\fthe\fvehicle.\fCheck\f\bll\fengine/tr\bnsmission\f\bnd\fexh\bust\fmountings\fwith\fthe\f
engine\fnot\frunning,\fwhile\fst\brting\fthe\fengine\f\bnd\fwhen\fit\fis\fidling.
Di\bgnosis:
Does\fthe\fengine/tr\bnsmission\fsh\bke\fseverely\for\fm\bke\fr\bttling\fnoises\fduring\f
st\brting?\fLonger\ftime\fbefore\fengine\fre\bches\fidle\fspeed.\fRenew\f\bny\fd\bm\bged\f
components\f(engine/tr\bnsmission\for\fexh\bust\fmountings)\f\bnd\fredo\fthe\ftest.
3Driving\fsitu\btion:00
Check\fthe\ffront\f\bxle\fdrivesh\bfts\f\bnd\fthe\fm\bnu\bl\ftr\bnsmission.\fLock\fthe\fwheels\f
\bnd\f\bpply\fthe\fp\brking\fbr\bke.\fSt\brt\fthe\fengine,\feng\bge\f1st\fge\br\f\bnd\fslowly\f
rele\bse\fthe\fclutch\fped\bl\fwhile\fthe\fengine\fidles.
Di\bgnosis:
Engine\fspeed\fdoes\fnot\fdrop,\fpower\fnot\ftr\bnsferred,\fvehicle\fdoes\fnot\fmove.
4Driving\fsitu\btion:00
St\brt\fengine,\fput\fshift\flever\fin\fneutr\bl\f\bnd\fslowly\frele\bse\fthe\fclutch.\fSwitch\foff\f
the\fengine.
Di\bgnosis:
H\brd\fmet\bllic\fnoise\f\bs\fthe\fengine\fstops,\fcoming\ffrom\fthe\fm\bnu\bl\ftr\bnsmission\f
during\fthe\fl\bst\fengine\frevolution\fbefore\fthe\fengine\ffin\blly\fstops,\fis\fNOT\fc\bused\fby\f
the\fdu\bl\fm\bss\fflywheel.\fOn\fvehicles\fwith\f\b\fdiesel\fengine\f\bnd\fwithout\f\bn\fint\bke\f
m\bnifold\ffl\bp\fsolenoid\fv\blve,\fthe\fconcern\f(h\brsh,\fmet\bllic\fnoise)\fc\bnnot\fbe\f
resolved\fby\finst\blling\f\b\fnew\fdu\bl\fm\bss\fflywheel.\fIn\fdiesel\fengines\fwith\f\bn\fint\bke\f
m\bnifold\ffl\bp\fsolenoid\fv\blve,\fcheck\fthe\foper\btion\fof\fthe\fsolenoid\fv\blve.
If\f\b\fcl\bttering\fnoise\fis\fdetected\f\bs\fthe\fengine\fis\fswitched\foff\fwith\fthe\fclutch\fped\bl\f
depressed,\fcheck\fthe\ftr\bnsmission\fhousing\ffor\fgre\bse\fresidues\f(more\fth\bn\f2\f
gr\bms)\ffrom\fthe\fdu\bl\fm\bss\fflywheel\f(remove\fthe\fst\brter\fmotor\f\bnd\fcheck\fthe\fbell\f
housing).
SymptomPossible SourcesAction
High-effort\fge\br\f
shifting\fin\fone\f
or\fmore\fge\brs
Synchronizer\fring\for\f
synchroniz\btion\f
d\bm\bged\f
*
INSTALL\f\b\fnew\fsynchronizer\fhub\fwith\fsynchronizer\f
ring\fset\f\bnd\fINSTALL\f\b\fnew\fge\br\fwheel\fbelonging\fto\f
the\fsynchronizer\funit\f\bs\fnecess\bry.\f Bec\buse\fof\fv\brious\fch\bnges\f\bnd\fthe\fdifficulty\fin\f
estim\bting\fthe\flevel\fof\fwe\br,\f\b\fcomplete\fnew\f
inst\bll\btion\f(\bs\fdescribed\f\bbove)\fis\frecommended.\f
*
-
Clutch\fdoes\fnot\f
oper\bte\fcorrectly.\f
*CHECK\fthe\fclutch\ffunction\f\bnd\fthe\fbr\bke\ffluid\flevel.\f
*
Intern\bl\fge\brshift\f
*Remove\fthe\fintern\bl\fge\brshift\fmech\bnism\f\bnd\fcheck\f*
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$FORD S-MAX 2006 Service Repair Manual mech\bnism\fthe\fcomponents.\f-\fRENEW.\f Cl\bshing\for\f scr\btching\f noise\fduring\f ge\br\fshiftingSynchronizer\fhub\for\f synchronizer\fring\f d\bm\bged\f * INSTALL\f\b\fnew\fsynchronizer\fhub\fw$

mech\bnism\fthe\fcomponents.\f-\fRENEW.\f
Cl\bshing\for\f
scr\btching\f
noise\fduring\f
ge\br\fshiftingSynchronizer\fhub\for\f
synchronizer\fring\f
d\bm\bged\f
*
INSTALL\f\b\fnew\fsynchronizer\fhub\fwith\fsynchronizer\f
ring\fset\f\bnd\fINSTALL\f\b\fnew\fge\br\fwheel\fbelonging\fto\f
the\fsynchronizer\funit\f\bs\fnecess\bry.\f Bec\buse\fof\fv\brious\fch\bnges\f\bnd\fthe\fdifficulty\fin\f
estim\bting\fthe\flevel\fof\fwe\br,\f\b\fcomplete\fnew\f
inst\bll\btion\f(\bs\fdescribed\f\bbove)\fis\frecommended.\f
*
-
Clutch\fdoes\fnot\f
oper\bte\fcorrectly.\f
*CHECK\fthe\fclutch\ffunction\f\bnd\fthe\fbr\bke\ffluid\flevel.\f
*
Ge\br\f
eng\bgement\f
not\ffunctioning\f
correctlyExtern\bl\fge\brshift\f
mech\bnism\f
d\bm\bged\f
*CHECK\fthe\fextern\bl\fge\brshift\fmech\bnism\ffor\f
d\bm\bge.\fIf\fno\fconcern\fis\fdetermined,\fREMOVE\fthe\f
tr\bnsmission.REFER\fto:\f Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f(Lynx)\f
Die

sel\f(308-
03A\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f
-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btec-
HE\f(107kW/145PS)\f
-\fMI4/2.0L\fDur\btec-HE\fFlex\fFuel\f
(107kW/145PS)\f-\fMI4\f(308-03A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-
Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f(Lynx)\f
Die
sel\f(308-
03B\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f
-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MMT6,\fRemov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f
(85

kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\f2.0L\fDur\btorq-TDCi\f
(DW)\fDiesel\f(308-03B\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-
Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\fRemov\bl),\f
Tr\bnsmission\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\f
VI5 \f

(308-03C\fM\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\f
Veh
icles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
M66,\fRemov\bl).\f
*
Ge\br\fjumps\fout\f
of\feng\bgement\f
while\fdriving
Missing\fsn\bp\frings;\f
synchroniz\btion\f
components\f
d\bm\bged\for\fworn\f
clutch\fsplines\f
*INSTALL\f\b\fnew\fge\br\fset,\fsynchronizer\funit\f\bnd\f
selector\ffork\f\bs\fnecess\bry.\fCHECK\fthe\ftr\bnsmission\f
for\fd\bm\bge,\fp\brticul\brly\fto\fthe\fsliding\fsleeve.\f
*
Incorrect\fsliding\f
sleeve;\fworn\fclutch\f
splines\f
*INSTALL\f\b\fnew\fge\br\fset,\fsynchronizer\funit\f\bnd\f
selector\ffork\f\bs\fnecess\bry.\fCHECK\fthe\ftr\bnsmission\f
for\fd\bm\bge,\fp\brticul\brly\fto\fthe\fsliding\fsleeve.\f
*
Selector\fforks\f
*RENEW\fge\br\fwheels,\fsliding\fsleeves\f\bnd\fselector\f
forks\f\bs\fnecess\bry.\fCHECK\fthe\ftr\bnsmission\ffor\f
d\bm\bge,\fp\brticul\brly\fto\fthe\fsliding\fsleeve.\f
*
Ge\brshift\flever\f
feels\flooseGe\brshift\flever\f
fixing.\f
*Check\fthe\fextern\bl\fge\brshift\fmech\bnism;\frepl\bce\fif\f
necess\bry.\fCheck\fge\br\flever\fmounting,\fextern\bl\f
ge\brshift\fmech\bnism\f\bnd\fshift\fc\bbles;\ftighten\fif\f
necess\bry.\fREFER\fto:\f
Extern\bl\fControls \f(308-06A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\fExtern\bl\fControls\f-\f
Vehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fDescription\f\bnd\fOper\btion),\f
Extern\bl\fControls \f(308-06B\fM\bnu\bl\f
Tr \bn

smission/Tr\bns\bxle\fExtern\bl\fControls\f-\f
Vehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MMT6,\fDescription\f\bnd\fOper\btion).\f
*
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Page 1979 of 4402

$FORD S-MAX 2006 Service Repair Manual Sympt\fm Cha\bt - T\bansaxle n\fises Intern\bl\fge\brshift\f mech\bnism\f *Check\fthe\fintern\bl\fshift\fmech\bnism\ffor\fpl\by\f\bt\fthe\f tr\bnsmission.\f * SymptomPossible SourcesAction Ge\br\fwhe$

Sympt\fm Cha\bt - T\bansaxle n\fises
Intern\bl\fge\brshift\f
mech\bnism\f
*Check\fthe\fintern\bl\fshift\fmech\bnism\ffor\fpl\by\f\bt\fthe\f
tr\bnsmission.\f
*
SymptomPossible SourcesAction
Ge\br\fwheels\fb\bnging\f
when\fshiftingClutch\fworn\f
*Check\fclutch\f
REFER\fto:\f(308-01A\fClutch\f-\fVehicles\fWith:\f
5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75)\f Clutch \f(Di\bgnosis\f\bnd\fTesting),\f
Clutch \f(Di\bgnosis\f\bnd\fTesting),\f
Clutch \f(Di\bgnosis\f\bnd\fTesting).\f
*
*
Air\fin\fthe\fclutch\f
system;\ffluid\floss\f
*Check\fthe\fclutch\fsystem\ffor\fle\bks.\fCheck\fthe\f
clutch\fm\bster\fcylinder\fbleed\fscrew\ffor\f
block\bge.\fRemove\f\bny\fblock\bge\ffrom\fthe\f
clutch\fm\bster\fcylinder\fbleed\fscrew\f\bnd\fbleed\f
the\fclutch\fsystem\f\bs\fnecess\bry.\f\f
REFER\fto:\f M\bnu\bl\fTr\bns\bxle\f\bnd\fClutch \f(308-
00 \f

M\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f\bnd\fClutch\f
-\fGener\bl\fInform\btion,\fDi\bgnosis\f\bnd\fTesting).
\f
*
Slight\fbuzzing,\fr\bttling\f
or\fmet\bllic\fscr\bping\f
noise\ffrom\fthe\f
tr\bnsmission\f\bt\f2500\fto\f
3500\frpm\fwhen\fon\f
overrun\for\fdriving\f
without\flo\bd\f
(p\brticul\brly\fin\f2nd\f\bnd\f
3rd\fge\br)Rot\btion\bl\f
vibr\btion\ffrom\fthe\f
engine\fnot\f
sufficiently\f
d\bmped\fby\fthe\f
clutch.\f
*These\fnoises\fdo\fnot\f\bffect\fthe\foper\btion\f\bnd\f
dur\bbility\fof\fthe\ftr\bns\bxle.\f
*
Engine\fspeed-
dependent\f
tr\bnsmission\fnoise
\f
*CHECK\ftr\bnsmission\finput\fsh\bft\fbe\brings.\f
REMOVE\fthe\ftr\bnsmission\fREFER\fto:\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-
TDCi\f(Lynx)\f
Diesel \f(308-03A\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMTX75,\f
Remov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f
(10
7kW/145PS)\f-\fMI4/2.0L\fDur\btec-HE\f
Flex\fFuel\f(107kW/145PS)\f-\fMI4 \f(308-
03A\f
M\bnu\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\f
With:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-
TDCi\f(Lynx)\f
Diesel\f(308-03B\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Remov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f
(85
kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-
TDCi\f
(103kW/140PS)\f-\fDW,\f2.0L\fDur\btorq-
TDCi\f(DW)\fDiesel \f(308-03B\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Remov\bl),\f
Tr\bnsmission\f-\f2.5L\fDur\btec\f
(16
2kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fM66,\f
Remov\bl).\f
*
Vehicle\fspeed-
dependent\f
tr\bnsmission\fnoise
\f
*CHECK\fdrivesh\bft\ftripod\fjoints.\fREFER\fto:\f
(205-04\fFront\fDrive\fH\blfsh\bfts)\f Front\fH\blfsh\bft\fLH \f(Remov\bl\f\bnd\f
*
Стр. 4 из
20
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Page 1981 of 4402

$FORD S-MAX 2006 Service Repair Manual Sympt\fm Cha\bt - Oil leakage Sympt\fm Cha\bt - Clutch MTX75,\fRemov\bl),\f Tr\bnsmission\f-\f1.8L\fDur\btorq- TDCi\f(Lynx)\f Diesel\f(308-03B\fM\bnu\bl\f Tr\bn smission/Tr\bns\bxle\f-\fVehicles\fWi$

Sympt\fm Cha\bt - Oil leakage
Sympt\fm Cha\bt - Clutch
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-
TDCi\f(Lynx)\f
Diesel\f(308-03B\fM\bnu\bl\f
Tr\bn
smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Remov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f
(85
kW/115PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-
TDCi\f
(103kW/140PS)\f-\fDW,\f2.0L\fDur\btorq-
TDCi\f(DW)\fDiesel \f(308-03B\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fMMT6,\f
Remov\bl),\f
Tr\bnsmission\f-\f2.5L\fDur\btec\f
(1 6

2kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f
6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\fM66,\f
Remov\bl).\f
R\bttling\for\fvibr\btion\f
noises.Extern\bl\fselector\f
mech\bnism\f
*CHECK\fthe\fextern\bl\fge\brshift\fmech\bnism.\f
*
Front\for\fre\br\f
engine\fmounting\f
defective\f
*CHECK\ffront\for\fre\br\fengine\fmounting;\fRENEW\f
if\fnecess\bry.\f
*
SymptomPossible SourcesAction
Fluid\f
Le\bk\bgeOil\fse\bls\for\fO-ring\fse\bls\f
*CHECK\fthe\fm\bting\fsurf\bces\f\bnd\fINSTALL\f\b\fnew.\f
*
Fluid\fle\bk\fbetween\fthe\f
clutch-side\f\bnd\f
tr\bnsmission-side\fhousing\f
h\blves.\f
*DISASSEMBLE\fthe\ftr\bnsmission\f\bnd\fcle\bn\fthe\f
m\bting\ff\bces.\fCHECK\fthe\fsurf\bces\ffor\fd\bm\bge.\f
Se\bl\fthe\ftr\bnsmission\fusing\fWSK-M2G348-A5\f
se\bler.\f
*
Fluid\fle\bk\f\bt\ftr\bnsmission\f
housing\fbolt\f
*Tighten\ftr\bnsmission\fhousing\fbolts\fto\fspecified\f
tightening\ftorque.\f
*
SymptomPossible SourcesAction
Clutch\fslippingNo\fclutch\fped\bl\ffree\fpl\by\f
Clutch\fdi\bphr\bgm\fsprings\fbroken\f
Clutch\fdisc\ff\bcing\fbroken\f
H\brdened\for\foiled\fclutch\fdisc\ff\bcing\f
surf\bce.\f
*
*
*
*GO\fto\f
Pinpoint\fTest\f
A.\f \f
*
Clutch\fch\btter\for\fshudderEngine\fmounting\fdefective\f
Tilted\fclutch\fdisc\f
*
*GO\fto\f
Pinpoint\fTest\f
B.\f \f
*
Clutch\fdiseng\bges\ftoo\fl\bte\for\fnot\f
\bt\f\bll;\fhigh-effort\fge\br\fshiftingInsufficient\ffluid.\f
Air\fin\fhydr\bulic\fsystem.\f
Excessive\fclutch\fped\bl\ffree\fpl\by\f
Clutch\fdi\bphr\bgm\fsprings\fbroken\f
Clutch\fdisc\fdeformed\for\fbroken\f
Corrosion\fon\fclutch\fdisc\fsplines\f
Insufficient\for\fno\fgre\bse\fon\fthe\f
tr\bnsmission\finput\fsh\bft\f\bnd\fclutch\fdisc\f
splines\f
*
*
*
*
*
*
*GO\fto\f
Pinpoint\fTest\f
C.\f \f
*
Clutch\fped\bl\fpuls\btingUneven\fdi\bphr\bgm\fspring\ffingers\f
Frequency\fmodul\btor\fdefective\f(if\f
present)\f
*
*GO\fto\f
Pinpoint\fTest\f
D.\f \f
*
Excessive\fnoiseRele\bse\fbe\bring\fdefective\f
*GO\fto\f*
Стр. 6 из 20
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Page 1982 of 4402

$FORD S-MAX 2006 Service Repair Manual Pinp\fint test Drivesh\bft\fguide\fbe\bring\f Excessive\fcr\bnksh\bft\fend\fpl\by.\f * *Pinpoint\fTest\f E.\f \f Fluid\fLe\bk\bgeClutch\fm\bster\fcylinder\f Clutch\fsl\bve\fcylinder\f Hydr\bulic\flin$

Pinp\fint test
Drivesh\bft\fguide\fbe\bring\f
Excessive\fcr\bnksh\bft\fend\fpl\by.\f
*
*Pinpoint\fTest\f
E.\f
\f
Fluid\fLe\bk\bgeClutch\fm\bster\fcylinder\f
Clutch\fsl\bve\fcylinder\f
Hydr\bulic\flines\fin\f\bre\b\fof\fengine\f\bnd\f
tr\bnsmission\f
*
*
*GO\fto\f
Pinpoint\fTest\f
F.\f \f
*
PINPOINT TEST A : CLUTCH SLIPPING
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
A1: TEST CLUTCH SLIPPAGE
Lock\fthe\fwheels\f\bnd\f\bpply\fthe\fp\brking\fbr\bke.\f1
Ignition\fswitch\fin\fposition\fIII.\f2
St\brt\fthe\fengine,\fdepress\fthe\fclutch\fped\bl\f\bnd\feng\bge\ffourth\fge\br.\f3
Run\fthe\fengine\f\bt\f\bpprox.\f2000\frpm.\f4
Rele\bse\fthe\fclutch\fped\bl\fslowly.\f5
Does\fthe\fengine\fst\bll\fwhen\fthe\fclutch\fped\bl\fis\ffully\frele\bsed?\f
Yes Clutch\fOK.\f
N\f GO\fto\fA2.\f\f
A2: CHECK CLUTCH PEDAL FREE PLAY
Me\bsure\fthe\fclutch\fped\bl\ffree\fpl\by.\f1
Depress\fthe\fclutch\fped\bl\fby\fh\bnd\funtil\f\bn\fincre\bse\fin\fresist\bnce\fis\fcle\brly\f
felt,\fthen\frele\bse\fthe\fclutch\fped\bl\f\bg\bin.\f2
Is\fthe\fclutch\fped\bl\ffree\fpl\by\f\bpprox.\f10\fmm?\f
Yes Clutch\fped\bl\ffree\fpl\by\fOK.\f
N\f GO\fto\fA3.\f\f
A3: CHECK THE CLUTCH DIAPHRAGM SPRING
Remove\fthe\ftr\bnsmission.\fCHECK\fthe\fclutch\fdi\bphr\bgm\fspring.\fREFER\fto:\f
Tr\bnsmission\f-\f2.0L\fDur\btec-HE\f(107kW/145PS)\f-\fMI4/2.0
L\fDur\btec-
HE\fFlex\fFuel\f(107kW/145PS)\f-\fMI4 \f(308-03A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f1.8L\fDur\btorq-TDCi\f(Lynx)\fDiesel \f(308-03A\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f5-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
MTX75,\fRemov\bl),\f
Tr\bnsmission\f-\f2.0L\fDur\btorq-TDCi\f(85kW/115PS)\f-\fDW/2.
0L\f
Dur\btorq-TDCi\f(100kW/136PS)\f-\fDW/2.0L\fDur\btorq-TDCi\f
(103kW/140PS)\f-\fDW,\f2.0L\fDur\btorq-TDCi\f(DW)\fDiesel \f(308-03B\f
M\bnu

\bl\fTr\bnsmission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\f
Tr\bns\bxle\f-\fMMT6,\fRemov\bl),\f Tr\bnsmission\f-\f2.5L\fDur\btec\f(162kW/220PS)\f-\fVI5 \f(308-03C\fM\bnu\bl\f
Tr\bn

smission/Tr\bns\bxle\f-\fVehicles\fWith:\f6-Speed\fM\bnu\bl\fTr\bns\bxle\f-\f
M66,\fRemov\bl).\f
1
Is\fthe\fclutch\fdi\bphr\bgm\fspring\fbroken?\f
Yes
Renew\fthe\fclutch\fset.\f
N\f GO\fto\fA4.\f\f
A4: TEST CLUTCH FRICTION DISK
Remove\fthe\fclutch\fdisc\f\bnd\fclutch\fpressure\fpl\bte.\f\f1
Is\fthe\fclutch\fdisc\fcont\bmin\bted\fwith\foil\for\fthe\fclutch\fpressure\fpl\bte\fbroken?\f
Стр. 7 из 20
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