Ford Galaxy / Ford S-MAX. Manual - part 496

Symptom Chart - Oil leakage

Symptom Chart - Clutch

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).

Rattling or vibration
noises.

External selector

mechanism

CHECK the external gearshift mechanism.

Front or rear

engine mounting
defective

CHECK front or rear engine mounting; RENEW

if necessary.

Symptom

Possible Sources

Action

Fluid
Leakage

Oil seals or O-ring seals

CHECK the mating surfaces and INSTALL a new.

Fluid leak between the

clutch-side and
transmission-side housing
halves.

DISASSEMBLE the transmission and clean the

mating faces. CHECK the surfaces for damage.
Seal the transmission using WSK-M2G348-A5
sealer.

Fluid leak at transmission

housing bolt

Tighten transmission housing bolts to specified

tightening torque.

Symptom

Possible Sources

Action

Clutch slipping

No clutch pedal free play
Clutch diaphragm springs broken
Clutch disc facing broken
Hardened or oiled clutch disc facing

surface.

*
*
*
*

GO to

Pinpoint Test

Clutch chatter or shudder

Engine mounting defective
Tilted clutch disc

*
*

GO to

Pinpoint Test

Clutch disengages too late or not
at all; high-effort gear shifting

Insufficient fluid.
Air in hydraulic system.
Excessive clutch pedal free play
Clutch diaphragm springs broken
Clutch disc deformed or broken
Corrosion on clutch disc splines
Insufficient or no grease on the

transmission input shaft and clutch disc
splines

*
*
*
*
*
*
*

GO to

Pinpoint Test

Clutch pedal pulsating

Uneven diaphragm spring fingers
Frequency modulator defective (if

present)

*
*

GO to

Pinpoint Test

Excessive noise

Release bearing defective

GO to

Pinpoint test

Driveshaft guide bearing
Excessive crankshaft end play.

*
*

Pinpoint Test

Fluid Leakage

Clutch master cylinder
Clutch slave cylinder
Hydraulic lines in area of engine and

transmission

*
*
*

GO to

Pinpoint Test

PINPOINT TEST A : CLUTCH SLIPPING

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

A1: TEST CLUTCH SLIPPAGE

Lock the wheels and apply the parking brake.

Ignition switch in position III.

Start the engine, depress the clutch pedal and engage fourth gear.

Run the engine at approx. 2000 rpm.

Release the clutch pedal slowly.

Does the engine stall when the clutch pedal is fully released?
Yes

Clutch OK.

GO to A2

A2: CHECK CLUTCH PEDAL FREE PLAY

Measure the clutch pedal free play.

Depress the clutch pedal by hand until an increase in resistance is clearly
felt, then release the clutch pedal again.

Is the clutch pedal free play approx. 10 mm?
Yes

Clutch pedal free play OK.

GO to A3

A3: CHECK THE CLUTCH DIAPHRAGM SPRING

Remove the transmission. CHECK the clutch diaphragm spring. REFER to:

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

(308-03A Manual

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

Is the clutch diaphragm spring broken?
Yes

Renew the clutch set.

GO to A4

A4: TEST CLUTCH FRICTION DISK

Remove the clutch disc and clutch pressure plate.

Is the clutch disc contaminated with oil or the clutch pressure plate broken?

Yes

CHECK the engine and transmission for leaks.INSTALL a new clutch disc
and pressure plate.

CHECK system operates correctly

PINPOINT TEST B : CLUTCH CHATTER OR SHUDDER

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

B1: TEST CLUTCH CHATTER OR SHUDDER

Ignition switch in position III.

Start the engine, depress the clutch and engage first gear.

Run the engine at between 1200 rpm and 1500 rpm.

Release the clutch pedal slowly.

Does the vehicle jerk when it starts off?
Yes

GO to B2

Clutch OK.

B2: TEST ENGINE/TRANSAXLE ISOLATOR, ROLL RESISTOR

Check the engine/transaxle mountings isolator and roll resistor for
damage or loose bolts.

Is the engine/transaxle isolator or roll restrictor loose or damaged?
Yes

TIGHTEN the bolts or INSTALL new bolts as necessary. CHECK system
operates correctly

GO to B3

B3: TEST CLUTCH PRESSURE PLATE

Remove clutch pressure plate.

Is the clutch pressure plate damaged?
Yes

RENEW the clutch set.

GO to B4

B4: TEST CLUTCH FRICTION DISK

CHECK the clutch disc.

Does the clutch disc show evidence of damage due to tilting?
Yes

RENEW the clutch set.

CHECK flywheel.

PINPOINT TEST C : CLUTCH DISENGAGES TOO LATE OR NOT AT ALL

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

C1: CHECK FLUID LEVEL

Check brake fluid level

Is the brake fluid level between the MAX and MIN marks on the brake fluid
reservoir?
Yes

GO to C2

Fill with brake fluid, CHECK the brake and clutch systems for leaks.

C2: CLUTCH DISENGAGES TOO LATE OR NOT AT ALL

Bleed the clutch system.

Does the clutch show improved disengaging characteristics following bleeding of

the system?
Yes

Clutch OK.

GO to C3

C3: CHECK CLUTCH PEDAL FREE PLAY

Measure the clutch pedal free play.

Depress the clutch pedal by hand until an increase in resistance is clearly
felt, then release the clutch pedal again.

Is the clutch pedal free play approx. 10 mm?
Yes

GO to C4

CHECK that the clutch pedal moves freely; remove if necessary.

C4: CHECK THE CLUTCH DIAPHRAGM SPRING

Remove the transmission and CHECK the clutch diaphragm spring.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).

Is the clutch diaphragm spring broken?
Yes

RENEW the clutch set. TEST the system for normal operation.

GO to C5

C5: TEST CLUTCH FRICTION DISK

Remove the clutch disc.

Is the clutch disc bent or broken?
Yes

RENEW the clutch set.

GO to C6

C6: CHECK THE SPLINES ON THE CLUTCH DISC FOR INSUFFICIENT LUBRICATION
AND/OR SIGNS OF CORROSION

CAUTION: Do not use solvent cleaners to clean the inside of the clutch housing or

the transmission input shaft. A lint-free damp cloth should be used for cleaning. Failure
to follow this instruction may result in incorrect clutch operation.

CHECK the splines on the clutch disc for insufficient or no grease and/or
signs of corrosion.

Is there insufficient or no grease and/or signs of corrosion on the splines of the
clutch disc?
Yes

CLEAN the splines of the clutch disc.

GO to C7

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