Ford Galaxy / Ford S-MAX. Manual — part 550

with two friction surfaces and the synchronizer cone also with two friction surfaces. The
outer synchronizer cone is virtually unchanged. It is fitted into the synchronizer hub with its
recesses in such a way that it can only turn by half a tooth in both directions.

An important aspect for the action of the two friction surfaces is the torque proof
connection between the gear wheel and the intermediate ring. At the same time, the two
synchronizer rings are also connected together in a torque proof manner via pawls. The
synchronizer therefore operates like a multiple wet clutch.

Power flow

When a gear is to be selected, the synchronizing sleeve in question located on the relevant
shaft is moved by its selector fork along the synchronizing hub towards the trailing wheel of
the desired gear. The synchronizing sleeve and synchronizing hub engage and lock the
trailing wheel to the hub and the relevant countershaft.

The power flow is transferred from the clutch to the input shaft. The power flow travels
from the input shaft to a countershaft via a pair of drives consisting of a gear and a trailing
wheel. The trailing wheel is locked to the hub by means of the synchronizing unit, which
allows the power flow to be transferred. The power flow is transferred from the
countershaft via the final drive pinion to the final drive (ring gear) mounted on the
differential.

1st gear

Description

Input shaft

1st-2nd and 5th-6th gear output shaft

Ring gear

Toothed wheel - 1st gear

Synchronizer hub - 1st/2nd gear

Output pinion - 1st-2nd and 5th-6th gear output shaft

Gear wheel - 1st gear

2nd gear

Description

Input shaft

Item

A

B

4

15

19

20

21

Item

A

Part Number

-

-

-

-

-

-

-

Part Number

-

-

1st-2nd and 5th-6th gear output shaft

Ring gear

Gear wheel - 2nd gear

Toothed wheel - 2nd gear

Synchronizer hub - 1st/2nd gear

Output pinion - 1st-2nd and 5th-6th gear output shaft

3rd gear

Description

Input shaft

3rd-4th gear output shaft

Ring gear

Synchronizer hub - 3rd/4th gear

Gear wheel - 3rd gear

Output pinion - 3rd-4th gear output shaft

Toothed wheel - 3rd gear

4th gear

Description

Input shaft

3rd-4th gear output shaft

Ring gear

Gear wheel - 4th gear

Synchronizer hub - 3rd/4th gear

Toothed wheel - 4th gear

Output pinion - 3rd-4th gear output shaft

5th gear

B

4

5

14

19

20

Item

A

C

4

12

16

17

18

Item

A

C

4

10

12

13

17

-

-

-

-

-

-

Part Number

-

-

-

-

-

-

-

Part Number

-

-

-

-

-

-

-

Description

Input shaft

1st-2nd and 5th-6th gear output shaft

Ring gear

Toothed wheel - 5th gear

Synchronizer hub - 5th/6th gear

Gear wheel - 5th gear

Output pinion - 1st-2nd and 5th-6th gear output shaft

6th gear

Description

Input shaft

1st-2nd and 5th-6th gear output shaft

Ring gear

Toothed wheel - 6th gear

Gear wheel - 6th gear

Synchronizer hub - 5th/6th gear

Output pinion - 1st-2nd and 5th-6th gear output shaft

Reverse gear

Description

Item

A

B

4

6

9

11

20

Item

A

B

4

7

8

9

20

Item

Part Number

-

-

-

-

-

-

-

Part Number

-

-

-

-

-

-

-

Part Number

-

Input shaft

1st-2nd and 5th-6th gear output shaft

Reverse gear output shaft

Output pinion - reverse gear output shaft

Gear wheel - reverse gear

Synchronizer hub - reverse gear

Ring gear

Toothed wheel - 1st gear

Gear wheel - 1st gear

Internal control

Description

Shift unit

5th/6th gear governor

Carrier plate with gearshift gate

Switch for reverse gear signal

Shift guide

Lower shift finger

Guide plate

Upper shift finger

Spring

Shift arm with damping weight

Spring

Selector lever

Carrier plate with gearshift gate

Vent cap

The gearshift mechanism is secured to the transaxle housing by four bolts and may only be
replaced as a complete unit in the event of a fault.

A

B

D

1

2

3

4

15

21

Item

1

2

3

4

5

6

7

8

9

10

11

12

13

14

-

-

-

-

-

-

-

-

Part Number

-

-

-

-

-

-

-

-

-

-

-

-

-

-