Ford Galaxy / Ford S-MAX. Manual — part 495

Fluid Leakage Concerns

Check that the leaking fluid is actually transmission fluid and not hydraulic fluid (from the
hydraulically operated clutch) or engine oil.
Check the transmission fluid level. If necessary, drain off any excess fluid.
Locate the oil leak with the aid of a fluorescent test fluid and an ultraviolet inspection
lamp.
Clean the transaxle and the adjacent areas carefully before road testing.

Symptom Chart – General Concerns

Are there extremely harsh vibrations from the powertrain? Vibrations disappear
when the accelerator pedal is released briefly.

1a Driving situation:

0

0

Road test the vehicle. Drive the vehicle in simulated "stop and go" mode (1st
gear). Check for transmission rattle during gentle acceleration and deceleration.
Diagnosis:
Are there noises from the powertrain in driving situations between idling speed
and a maximum of 2000 rev/min which occur at a specific, vehicle-dependent
vehicle/engine speed?

2

Driving situation:

0

0

Raise the vehicle. Check all engine/transmission and exhaust mountings with the
engine not running, while starting the engine and when it is idling.
Diagnosis:
Does the engine/transmission shake severely or make rattling noises during
starting? Longer time before engine reaches idle speed. Renew any damaged
components (engine/transmission or exhaust mountings) and redo the test.

3

Driving situation:

0

0

Check the front axle driveshafts and the manual transmission. Lock the wheels
and apply the parking brake. Start the engine, engage 1st gear and slowly
release the clutch pedal while the engine idles.
Diagnosis:
Engine speed does not drop, power not transferred, vehicle does not move.

4

Driving situation:

0

0

Start engine, put shift lever in neutral and slowly release the clutch. Switch off
the engine.
Diagnosis:
Hard metallic noise as the engine stops, coming from the manual transmission
during the last engine revolution before the engine finally stops, is NOT caused by
the dual mass flywheel. On vehicles with a diesel engine and without an intake
manifold flap solenoid valve, the concern (harsh, metallic noise) cannot be
resolved by installing a new dual mass flywheel. In diesel engines with an intake
manifold flap solenoid valve, check the operation of the solenoid valve.
If a clattering noise is detected as the engine is switched off with the clutch pedal
depressed, check the transmission housing for grease residues (more than 2
grams) from the dual mass flywheel (remove the starter motor and check the bell
housing).

Symptom

Possible Sources

Action

High-effort gear
shifting in one
or more gears

Synchronizer ring or

synchronization
damaged

*

INSTALL a new synchronizer hub with synchronizer

ring set and INSTALL a new gear wheel belonging to
the synchronizer unit as necessary.

Because of various changes and the difficulty in

estimating the level of wear, a complete new
installation (as described above) is recommended.

*

-

Clutch does not

operate correctly.

*

CHECK the clutch function and the brake fluid level.

*

Internal gearshift

*

Remove the internal gearshift mechanism and check

*

mechanism

the components. - RENEW.

Clashing or
scratching
noise during
gear shifting

Synchronizer hub or

synchronizer ring
damaged

*

INSTALL a new synchronizer hub with synchronizer

ring set and INSTALL a new gear wheel belonging to
the synchronizer unit as necessary.

Because of various changes and the difficulty in

estimating the level of wear, a complete new
installation (as described above) is recommended.

*

-

Clutch does not

operate correctly.

*

CHECK the clutch function and the brake fluid level.

*

Gear
engagement
not functioning
correctly

External gearshift

mechanism
damaged

*

CHECK the external gearshift mechanism for

damage. If no concern is determined, REMOVE the
transmission.REFER to:

Transmission - 1.8L Duratorq-TDCi (Lynx)
Diesel

(308-03A Manual Transmission/Transaxle

- Vehicles With: 5-Speed Manual Transaxle -
MTX75, Removal),

Transmission - 2.0L Duratec-HE (107kW/145PS)
- MI4/2.0L Duratec-HE Flex Fuel
(107kW/145PS) - MI4

(308-03A Manual

Transmission/Transaxle - Vehicles With: 5-
Speed Manual Transaxle - MTX75, Removal),

Transmission - 1.8L Duratorq-TDCi (Lynx)
Diesel

(308-03B Manual Transmission/Transaxle

- Vehicles With: 6-Speed Manual Transaxle -
MMT6, Removal),

Transmission - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, 2.0L Duratorq-TDCi
(DW) Diesel

(308-03B Manual

Transmission/Transaxle - Vehicles With: 6-
Speed Manual Transaxle - MMT6, Removal),

Transmission - 2.5L Duratec (162kW/220PS) -
VI5

(308-03C Manual Transmission/Transaxle -

Vehicles With: 6-Speed Manual Transaxle -
M66, Removal).

*

Gear jumps out
of engagement
while driving

Missing snap rings;

synchronization
components
damaged or worn
clutch splines

*

INSTALL a new gear set, synchronizer unit and

selector fork as necessary. CHECK the transmission
for damage, particularly to the sliding sleeve.

*

Incorrect sliding

sleeve; worn clutch
splines

*

INSTALL a new gear set, synchronizer unit and

selector fork as necessary. CHECK the transmission
for damage, particularly to the sliding sleeve.

*

Selector forks

*

RENEW gear wheels, sliding sleeves and selector

forks as necessary. CHECK the transmission for
damage, particularly to the sliding sleeve.

*

Gearshift lever
feels loose

Gearshift lever

fixing.

*

Check the external gearshift mechanism; replace if

necessary. Check gear lever mounting, external
gearshift mechanism and shift cables; tighten if
necessary. REFER to:

External Controls

(308-06A Manual

Transmission/Transaxle External Controls -
Vehicles With: 5-Speed Manual Transaxle -
MTX75, Description and Operation),

External Controls

(308-06B Manual

Transmission/Transaxle External Controls -
Vehicles With: 6-Speed Manual Transaxle -
MMT6, Description and Operation).

*

Symptom Chart - Transaxle noises

Internal gearshift

mechanism

*

Check the internal shift mechanism for play at the

transmission.

*

Symptom

Possible Sources

Action

Gear wheels banging
when shifting

Clutch worn

*

Check clutch
REFER to: (308-01A Clutch - Vehicles With:

5-Speed Manual Transaxle - MTX75)

Clutch

(Diagnosis and Testing),

Clutch

(Diagnosis and Testing),

Clutch

(Diagnosis and Testing).

*
*

Air in the clutch

system; fluid loss

*

Check the clutch system for leaks. Check the

clutch master cylinder bleed screw for
blockage. Remove any blockage from the
clutch master cylinder bleed screw and bleed
the clutch system as necessary.
REFER to:

Manual Transaxle and Clutch

(308-

00 Manual Transmission/Transaxle and Clutch
- General Information, Diagnosis and Testing).

*

Slight buzzing, rattling
or metallic scraping
noise from the
transmission at 2500 to
3500 rpm when on
overrun or driving
without load
(particularly in 2nd and
3rd gear)

Rotational

vibration from the
engine not
sufficiently
damped by the
clutch.

*

These noises do not affect the operation and

durability of the transaxle.

*

Engine speed-

dependent
transmission noise

*

CHECK transmission input shaft bearings.

REMOVE the transmission REFER to:

Transmission - 1.8L Duratorq-TDCi (Lynx)
Diesel

(308-03A Manual

Transmission/Transaxle - Vehicles With:
5-Speed Manual Transaxle - MTX75,
Removal),

Transmission - 2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4

(308-03A

Manual Transmission/Transaxle - Vehicles
With: 5-Speed Manual Transaxle -
MTX75, Removal),

Transmission - 1.8L Duratorq-TDCi (Lynx)
Diesel

(308-03B Manual

Transmission/Transaxle - Vehicles With:
6-Speed Manual Transaxle - MMT6,
Removal),

Transmission - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW, 2.0L Duratorq-
TDCi (DW) Diesel

(308-03B Manual

Transmission/Transaxle - Vehicles With:
6-Speed Manual Transaxle - MMT6,
Removal),

Transmission - 2.5L Duratec
(162kW/220PS) - VI5

(308-03C Manual

Transmission/Transaxle - Vehicles With:
6-Speed Manual Transaxle - M66,
Removal).

*

Vehicle speed-

dependent
transmission noise

*

CHECK driveshaft tripod joints. REFER to:

(205-04 Front Drive Halfshafts)

Front Halfshaft LH

(Removal and

*

Installation),

Front Halfshaft RH

(Removal and

Installation).

Steering angle-

dependent
transmission noise

*

CHECK differential splines for damage. Turn

the differential bevel gears against one
another. For this purpose, REMOVE the
differential.
REFER to:

Front Halfshaft LH

(205-04 Front

Drive Halfshafts, Removal and Installation) /

Front Halfshaft RH

(205-04 Front Drive

Halfshafts, Removal and Installation).

*

The engine and

transaxle
assembly is in
contact with the
body.

*

Look for points of contact and REPAIR as

necessary.

*

Collar screws –

engine/gearbox

*

TIGHTEN the transmission bolts.REFER to:

Transmission - 1.8L Duratorq-TDCi (Lynx)
Diesel

(308-03A Manual

Transmission/Transaxle - Vehicles With:
5-Speed Manual Transaxle - MTX75,
Installation),

Transmission - 2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4

(308-03A

Manual Transmission/Transaxle - Vehicles
With: 5-Speed Manual Transaxle -
MTX75, Installation),

Transmission - 1.8L Duratorq-TDCi (Lynx)
Diesel

(308-03B Manual

Transmission/Transaxle - Vehicles With:
6-Speed Manual Transaxle - MMT6,
Installation),

Transmission - 2.0L Duratorq-TDCi
(85kW/115PS) - DW/2.0L Duratorq-TDCi
(100kW/136PS) - DW/2.0L Duratorq-TDCi
(103kW/140PS) - DW

(308-03B Manual

Transmission/Transaxle - Vehicles With:
6-Speed Manual Transaxle - MMT6,
Installation),

Transmission - 2.5L Duratec
(162kW/220PS) - VI5

(308-03C Manual

Transmission/Transaxle - Vehicles With:
6-Speed Manual Transaxle - M66,
Installation).

*

Transaxle fluid

level low.

*

Check the transmission fluid level.

*

Transaxle

bearings and gear
wheels (usually on
high-mileage
vehicles).

*

REMOVE the transaxle. CHECK the bearings

and gear wheels and INSTALL new
components as necessary.REFER to:

Transmission - 1.8L Duratorq-TDCi (Lynx)
Diesel

(308-03A Manual

Transmission/Transaxle - Vehicles With:
5-Speed Manual Transaxle - MTX75,
Removal),

Transmission - 2.0L Duratec-HE
(107kW/145PS) - MI4/2.0L Duratec-HE
Flex Fuel (107kW/145PS) - MI4

(308-03A

Manual Transmission/Transaxle - Vehicles
With: 5-Speed Manual Transaxle -

*