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
*