Ford Galaxy / Ford S-MAX. Manual — part 530

Description

Transmission housing taper roller bearing

Needle bearing

6th gear wheel

6th gear synchronizer ring

Snap ring

5th/6th gear synchronizer

Synchronizer ring (5th gear)

Stop disc unit

Needle bearing

5th gear wheel

Snap ring

Oil storage ring (until 10/2005)

Clutch housing taper roller bearing

Output shaft 5th/6th/reverse gear

Reverse gear wheel

Needle bearing

Reverse gear synchronizer ring

Reverse gear synchronizer

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Bearing retaining bolt (left-hand thread)

Oil funnel and oil storage ring

Until 10/2005 an oil storage ring was installed on the clutch side in each of the two output
shafts.

Description

Oil funnel until 10/2005

Oil storage ring until 10/2005

Oil funnel from 11/2005

When installing a new oil funnel, from 11/2005 onwards, an oil storage ring is no longer
permitted, as this could lead to a loss of transmission fluid pressure in the output shaft and
therefore to a loss of lubrication.

Synchroniser assembly

Description

Sliding block assembly

Synchroniser hub

Sliding collar

The (MMT6) synchroniser assemblies have been reworked for the 6-speed manual
transmission.

The detent balls, springs and sliding blocks form one unit.

This arrangement makes it easier to service the synchroniser assembly.

Differential

Because the Vehicle Speed Sensor (VSS) is discontinued, so is the sender wheel.

The ABS wheel speed sensors send the current wheel speed to the powertrain control
module (PCM).

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The differential has taper roller bearings.

This bearing arrangement requires the shaft to be preloaded. Please refer to the service
literature for further information on how to measure the pre-load.

Description

Transmission housing taper roller bearing

Differential

Clutch housing taper roller bearing

Crown wheel bolts

Crown wheel

Power transmission in the individual gears

The following diagrams show a schematic representation of the power flow.

Power is transmitted via the non-positive gear pair to the output pinion of the output shaft
(s) and thus to the differential ring gear.

NOTE: The three shafts are shown away from their real positions for clarity.

Power transmission route in 1st gear

The 1st gear wheel is positively connected to the 1st to 4th gear output shaft by the
1st/2nd gear synchroniser assembly.

Power transmission route in second gear

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The 2nd gear wheel is positively connected to the 1st to 4th gear output shaft by the
1st/2nd gear synchroniser assembly.

Power transmission route in 3rd gear

The 3rd gear wheel is positively connected to the 1st to 4th gear output shaft by the
3rd/4th gear synchroniser assembly.

Power transmission route in 4th gear

The 4th gear wheel is positively connected to the 1st to 4th gear output shaft by the
3rd/4th gear synchroniser assembly.

Power transmission route in 5th gear

The 5th gear wheel is positively connected to the 5th/6th/reverse gear output shaft by the
5th/6th gear synchroniser assembly.

Power transmission route in 6th gear