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Differential > < 1st-4th Gear Output Shaft

S-MAX.Galaxy 2006.5 (03.2006-)

Manual Transmission/Transaxle - Vehicles With: 6-Speed Manual Transmission (MMT6) - 5th-6th and Reverse Gear Output Shaft S-MAX/Galaxy 2006.5 (03/2006-)
Disassembly and Assembly of Subassemblies

Special Tool(s)
204-050
Installer, Front Wheel Hub Bearing Cup/Seal

205-071-01
Adapter for 205-071 (Thrust Pad)

205-295
Remover, Bearing (Main Tool)

308-046
Installer, Transmission Extension Housing Bushing/Seal

308-196
Collet for 205-295

308-197
Collet for 205-295

308-604
Installer, Output Drive Flange Seal
Materials
Name
Specification
Transmission Fluid
WSD-M2C200-C
General Equipment
Hot air gun

Disassembly

CAUTION:
CAUTION:Use protective covers.
All vehicles
  1. Clamp the output shaft in a vise.

  1. Special Tool(s): 205-071-01, 205-295, 308-197

  1. NOTE:
    NOTE:Left-hand thread
    Heat the transmission-side taper roller bearing retaining bolt to approx. 90 °C using a hot air gun and discard.
    General Equipment: Hot air gun

  1. NOTE:
    NOTE:Use a suitable washer as a thrust element.
    Special Tool(s): 205-295, 308-196

  1. Discard the snap ring.

  1. NOTE:
    NOTE:Make a note of/mark the installed positions of the components before removal.
    1. Sliding collar
    1. Blocker bar
    1. Synchroniser hub

  1. Discard the snap ring.

  1. NOTE:
    NOTE:Make a note of/mark the installed positions of the components before removal.
    1. Sliding collar
    1. Blocker bar
    1. Synchroniser hub
    1. Snap ring
Vehicles built up to 10/2005 inclusive
  1. This step is only necessary if the oil ring is damaged.
Vehicles built from 11/2005
  1. Ensure that no oil ring is installed.

Assembly

All vehicles
CAUTION:
CAUTION:Use protective covers.
  1. Clamp the output shaft in a vise.
  1. Coat all running surfaces with clean transmission fluid before assembly.
    Material: Transmission Fluid
All vehicles

  1. NOTE:
    NOTE:Make sure that the installation marks are aligned.
    1. Synchroniser hub
    1. Blocker bar
    1. Sliding collar
    1. Snap ring

  1. Special Tool(s): 308-604

  1.  
    • Fit a new snap ring.
    • The collar on the retaining ring must face upward.

  1. NOTE:
    NOTE:Make sure that the installation marks are aligned.
    1. Synchroniser hub
    1. Blocker bar
    1. Sliding collar

  1. Special Tool(s): 308-604

  1. Fit a new snap ring.

  1. NOTE:
    NOTE:Do not oil taper roller bearings.
    Install a new transmission-side taper roller bearing on the output shaft.
    Special Tool(s): 308-046

  1. CAUTION:
    CAUTION:Make sure that a new bolt is installed.
    NOTE:
    NOTE:Make sure that the component is clean and free of foreign material.
    NOTE:
    NOTE:Left-hand thread.
    Torque: 100 Nm

  1. NOTE:
    NOTE:Do not oil taper roller bearings.
    Install a new clutch-side taper roller bearing on the output shaft.
    Special Tool(s): 204-050

Differential > < 1st-4th Gear Output Shaft