Ford Galaxy / Ford S-MAX. Manual — part 523

8.

NOTE: Do not oil the taper roller bearing.

Install the following items:

1.
2.
3.

9.

CAUTION: The guide pins must remain installed

in the gearbox housing.
NOTE: The mounting faces of the component must
be clean and free from foreign bodies and lubricant.

Tighten the bolts in a crisscross sequence.

Torque:

40 Nm

10. Special Tool(s):

308-194B

11. Install the Special Tool(s):

205-069

,

205-070

,

307-300

12. Input shaft measurement: Carry out the following two

steps three times and calculate the average of the
measurements. (Example: (0.22 mm + 0.23 mm + 0.21
mm) / 3 = 0.22 mm)

13. Special Tool(s):

205-175

14.

1. Pre-load the dial gauge to 1 mm and zero it.
2. Lift the input shaft with a suitable lever and note

the resulting measurement.

15. Output shaft measurement: Carry out the following three

steps three times and calculate the average of the
measurements. (Example: (0.32 mm + 0.33 mm + 0.31
mm) / 3 = 0.32 mm)

16. Special Tool(s):

205-175

17. Attach the dial gauge, pre-load it to 1 mm and zero it.

Special Tool(s):

205-069

18. Lift the output shaft with a suitable lever and note the

resulting measurement.

19. Install the Special Tool(s):

303-060

,

303-060-02

,

303

060-07

20. Differential measurement: Carry out the following two

steps three times and calculate the average of the
measurements. (Example: (0.34 mm + 0.36 mm + 0.38
mm) / 3 = 0.36 mm)

21.

1. Press down the differential during rotation.

Special Tool(s):

205-175

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

Special Tool(s):

205-069

22. Lift the differential with the special tool and note the

resulting measurement.

Special Tool(s):

303-060

,

303-060-02

23.

Calculate the required adjusting shim thickness for
the input shaft:
Installed measuring shim thickness: 1.00 mm.
Calculated average input shaft end float e. g. 0.22
mm.
End float constant: -0.07 mm.
Shim thickness required: 1.00 mm +0.22 mm
0.07 mm = 1.15 mm

24.

Calculate the required adjusting shim thickness for
the output shaft:
Installed measurement shim thickness: 1.00 mm.
Calculated average output shaft end float, e.g.:

0.32 mm.
Pre-load constant 0.13 mm.
Shim thickness required: 1.00 mm +0.32 mm
+0.13 mm = 1.45 mm.

25.

Calculate the required adjusting shim thickness for
the differential:
Installed measurement shim thickness: 1.10 mm.
Calculated average differential end float e. g. 0.36
mm.
Pre-load constant 0.33 mm.
Shim thickness required: 1.10 mm + 0.36 mm
+0.33 mm = 1.79 mm.

26. Remove the Special Tool(s):

205-069

,

205-070

,

303

303-060-02

,

303-060-07

,

307-300

,

308-194B

27.

28.

29. Special Tool(s):

205-176

30. Special Tool(s):

205-078

,

205-078-01