Ford Galaxy / Ford S-MAX. Manual — part 543

Materials

General Equipment

NOTE: The transmission must cool to room temperature before performing measurements.

All vehicles

307-300-03
Adapter for 307-300-02

307-430
Gauge, Transmission End Play

308-095
Installer, Input Shaft Bearing

308-112
Installer, Output Drive Flange Seal

308-192
Remover, Halfshaft

308-603
Gauge, Differential/Transfer Gear Bearing Shim

Name

Specification

Flange Sealant - Anaerobic LR WSK-M2G348-A5 / 2U7J-M2G348-AA

Hot air gun

1.

1. Heat the transmission housing to approx. 90 °

a hot air gun.

General Equipment:

Hot air gun

2. Insert the output shaft bearing outer race by hand

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

Special Tool(s):

205-217

2.

1. Heat the transmission housing to approx. 90 °

a hot air gun.

General Equipment:

Hot air gun

2. Insert the output shaft bearing outer race by hand

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

Special Tool(s):

205-217

3.

1. Heat the transmission housing to approx. 90 °

a hot air gun.

General Equipment:

Hot air gun

2. Insert the differential bearing outer race by hand and

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

Special Tool(s):

205-296

4.

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

90°C.

General Equipment:

Hot air gun

2. Install a 1.10 mm measuring 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

5. Special Tool(s):

206-003

6.

CAUTIONS:

Take special

care to avoid
damaging the
bearing.

Extreme

cleanliness must
be exercised when
handling these
components.

Install the
output shafts
in the
transmission

housing
together.

Special Tool
(s):

308

Place the
bearing outer
races in
position on the
output shaft
tapered roller
bearing.

7.

Repeat this and the following four steps three times
and determine the average values.
Pull out the measuring rings to approx. 10 mm.
Hold the bearing outer races, turn the output shaft 20
times while pressing down at the same time, so that
the bearings settle.

Special Tool(s):

308-603

8.

NOTE: The mounting faces must be clean and free from
foreign bodies.

Install the special tools.

Special Tool(s):

205-070

,

307-430

9.

Make certain that the clutch housing does not become
skewed.
Make certain that the special tools are inserted
correctly in the clutch housing bearing outer race
seats.
Attach the clutch housing.

Special Tool(s):

205-070

,

206-003

,

307-430

Torque:

32 Nm

10.

Make certain that the clutch housing does not become
skewed.
Detach the special tools.

Special Tool(s):

205-070

,

206-003

,

307-430

11.

While taking the measurements, only press lightly on
the special tool, to avoid incorrect readings.
Record the measurement results.

Special Tool(s):

307-300-02

,

307-300-03

,

308

12.

Measure the required thickness of the 1st - 4th gear
output shaft adjustment shim:
Add the measured values, divide by three and then
add the value for the bearing pre-load.
1st - 4th gear output shaft bearing pre-load: 0.17
mm.
Example: 1.56 mm +1.57 mm +1.55 mm, divided by
3 = 1.56 mm. 1.56 mm +0.17 mm = 1.73 mm.
Determined adjusting shim thickness: 1.73 mm.

13.

Measure the required thickness of the 5th/6th
gear/reverse gear output shaft adjustment shim:
Add the measured values, divide by three and then
add the value for the bearing pre-load.
Bearing pre-load - output shaft - 5th/6th/reverse
gear: 0.15 mm.
Example: 1.51 mm + 1.52 mm + 1.50 mm, divided
by 3 = 1.51 mm. 1.51 mm + 0.15 mm = 1.66 mm.
Determined adjusting shim thickness: 1.66 mm.

14. Remove the special tools.

Special Tool(s):

205-070

,

307-430

15. Remove the following

items:

1. Special Tool

(s):

308

2. Output shaft

bearing outer
races

3. Output shafts