Ford Galaxy / Ford S-MAX. Manual — part 529

Reverse gear synchronizer clutch

Reverse gear wheel

Output pinion – 5th/6th/reverse gear output shaft

Clutch housing

Construction features on the differential side

All gears have helical teeth and are permanently engaged.

5th, 6th and reverse gear have simple synchronisation. 1st to 4th gears are double
synchronised.

Construction features on the input shaft side.

Description

Output shaft 5th/6th/reverse gear

Input shaft

Output shaft 1st/4th gear

3rd/4th gear synchronizer clutch selector fork

1st/2nd gear synchronizer clutch selector fork

Clutch housing

1st gear

2nd gear

5th gear

Reverse gear synchronizer clutch selector fork

3rd gear

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5th/6th gear synchronizer clutch selector fork

4th/6th gear gearwheel

All driving gear wheels of the transmission are located on the input shaft.

The input shaft is a solid shaft and runs on one ball bearing and one roller bearing.

Because of this mounting the input shafts runs without preload and therefore needs no
adjusting shims.

The input shaft seal nearest the clutch is pressed into the clutch housing.

Input shaft

Description

Clutch housing roller bearing

1st gear

2nd gear

5th gear

3rd gear

Input shaft ball bearing holder

Bearing retaining bolt

4th/6th gear wheel

Input shaft

The gear wheels for 1st and 2nd gear are an integral part of the input shaft. The gearwheels
for 3rd and 5th gears and the gearwheel for 4th/6th gear are pressed on.

Because of the high force used to press on the components, the gear wheels cannot be
pressed off in service. A faulty input shaft can only be replaced as a complete unit.

Defective bearings can be pressed off and changed.

Output shaft 1st/4th gear

The 1st/4th gear output shaft runs on tapered 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.

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The output pinion of the 1st/4th gear output shaft is an integral part of the shaft.

The synchroniser assemblies of the 1st/2nd and the 3rd/4th gears are located on the output
shaft.

The 1st to 4th gear output shaft is a hollow shaft; the oil is supplied to the internal oilways
via oil funnels.

Internal oilways provide lubrication to the needle roller bearings and the synchroniser
assemblies.

Description

Transmission housing taper roller bearing

4th gear wheel

Needle bearing

Inner synchroniser ring

4th gear synchronizer cone

Outer synchronizer ring (4th gear)

Snap ring

3rd/4th gear synchronizer

Outer synchronizer ring (3rd gear)

3rd gear synchronizer cone

Inner synchroniser ring

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3rd gear wheel

Needle bearing

Stop disc unit

2nd gear wheel

Needle bearing

Inner synchroniser ring

2nd gear synchronizer cone

Outer synchronizer ring (2nd gear)

Snap ring

1st/2nd gear synchronizer

Outer synchronizer ring (1st gear)

1st gear synchronizer cone

Inner synchroniser ring

1st gear wheel

Needle bearing

Output shaft 1st/4th gear

Oil storage ring (until 10/2005)

Clutch housing taper roller bearing

Bearing retaining bolt (left-hand thread)

Output shaft 5th/6th/reverse gear

The 5th/6th/reverse gear output shaft runs on tapered 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.

The output pinion is an integral part of the shaft.

The 5th/6th and reverse gear synchronizer assemblies are located on the shaft.

The 5th/6th/reverse gear output shaft is a hollow shaft; the oil is supplied to the internal
oilways via oil funnels.

Internal oil passages provide lubrication to the needle roller bearings and the synchronizer
assemblies.

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