Ford Galaxy / Ford S-MAX. Manual — part 544

Special Tool
(s):

308

16. Remove the following items:

Special Tool(s):

206-003

17.

CAUTION: Extreme cleanliness must be exercised

when handling these components.

Tighten the transmission housing bolts, working diagonally.

Torque:

32 Nm

18. Clean the end face of the differential assembly and mark it

at one place.

Special Tool(s):

205-044-01

,

205-070

19.

Repeat this and the following three steps three times
and determine the average values.
To measure the bearing pre-load turn the differential
20 times while pressing down at the same time, so
that the bearings settle.

Special Tool(s):

308-192

20.

Attach the dial gauge to the special tool and align with
the mark.

Special Tool(s):

205-044-01

,

205-070

Pre-load the dial gauge to 1 mm and zero it.

21. Turn the transmission through 180 degrees with the clutch

side downwards.

22.

1. To measure the bearing pre-load turn the differential

20 times while pressing down at the same time, so
that the bearings settle.

Special Tool(s):

308-192

2. Turn the differential until the measuring pin is on the

marked spot.

3. Measure the differential end float: Make a note of the

measurement, e.g. 0.34 mm. Example: 0.34 mm
+0.36 mm +0.38 mm, divided by 3 = 0.36 mm.

23.

Determine the thickness of the differential adjusting
shim:
Installed measuring shim thickness: 1.10 mm.
Determined differential end float 0.36 mm
Differential bearing pre-load 0.20 mm
Required adjusting shim thickness: 1.10 mm + 0.36
mm +0.20 mm = 1.66 mm.
Determined adjusting shim thickness: 1.66 mm.

24.

25. Remove the following items:

1. Differential bearing outer race

Special Tool(s):

205-176

2. Measuring shim

Vehicles built up to 10/2005 inclusive

Vehicles built from 11/2005

26.

1. Heat the clutch housing with a hot air gun to approx.

90 °C.

General Equipment:

Hot air gun

2. Install the measured adjusting shim.
3. Insert the differential bearing outer race by hand and

after the clutch housing has cooled, install using the
special tool.

Special Tool(s):

205-296

27.

1. Heat the clutch housing with a hot air gun to approx.

90 °C.

General Equipment:

Hot air gun

2. Install a new output shaft oil thrower.
3. Install the measured adjusting shim.
4. Insert the output shaft bearing outer race by hand

and after the clutch housing has cooled, install using
the special tool.

Special Tool(s):

205-296

28.

1. Heat the clutch housing with a hot air gun to approx.

90 °C.

General Equipment:

Hot air gun

2. Install a new output shaft oil thrower.
3. Install the measured adjusting shim.
4. Insert the output shaft bearing outer race by hand

and after the clutch housing has cooled, install using
the special tool.

Special Tool(s):

205-296

29.

1. Heat the clutch housing with a hot air gun to approx.

90 °C.

General Equipment:

Hot air gun

2. Install a new output shaft oil thrower.
3. Install the measured adjusting shim.
4. Insert the output shaft bearing outer race by hand

and after the clutch housing has cooled, install using

All vehicles

the special tool.

Special Tool(s):

308-095

30.

1. Heat the clutch housing with a hot air gun to approx.

90 °C.

General Equipment:

Hot air gun

2. Install a new output shaft oil thrower.
3. Install the measured adjusting shim.
4. Insert the output shaft bearing outer race by hand

and after the clutch housing has cooled, install using
the special tool.

Special Tool(s):

308-095

31.

1. Heat the clutch housing with a hot air gun to approx.

90 °C.

General Equipment:

Hot air gun

2. Insert the input shaft parallel roller bearing by hand

and after the clutch housing has cooled, install using
the special tool.

Special Tool(s):

205-081

32. Pay attention to the installation position of the input shaft

ball bearing retainer. The retainer of the input shaft ball
bearing must be held in place by the 1st - 4th gear selector
shaft.

33.

CAUTION: Take special care to avoid damaging the

bearing.