Ford Galaxy / Ford S-MAX. Manual - part 497

CHECK the splines of the transmission input shaft for damage or insufficient
or no grease and signs of corrosion. CLEAN and lubricate the splines on the
clutch disc with the specified lubricant as required. CLEAN the splines of the
transmission input shaft. If the transmission input shaft is damaged,
REPLACE the components as required. TEST the system for normal
operation.

C7: CHECK THE SPLINES ON THE CLUTCH DISC FOR SIGNS OF DAMAGE OR
SIGNIFICANT FRICTION

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 damage or signs of significant
friction.

Are there signs of damage or significant friction on the splines of the clutch
disc?
Yes

RENEW the clutch set. Lubricate the splines of the clutch disc with the
specified lubricant as required. TEST the system for normal operation.

CHECK the splines of the transmission input shaft for damage or insufficient
or no grease and/or signs of corrosion. CLEAN and lubricate the splines on
the clutch disc with the specified lubricant as required. CLEAN the splines of
the transmission input shaft. If the transmission input shaft is damaged,
REPLACE the components as required. TEST the system for normal
operation.

PINPOINT TEST D : CLUTCH PEDAL PULSATING

TEST

CONDITIONS

DETAILS/RESULTS/ACTIONS

D1: CHECK THE BELLEVILLE SPRING FINGERS FOR UNIFORMITY

Remove the transmission. 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).

CHECK the diaphragm spring fingers for uniformity.

Are the diaphragm spring fingers all at the same height?
Yes

Check the frequency modulator and RENEW if necessary (if present)

RENEW the clutch set.

PINPOINT TEST E : EXCESSIVE NOISE

TEST CONDITIONS

DETAILS/RESULTS/ACTIONS

E1: CHECK THE TRANSMISSION AT IDLING A)

Ignition switch in position III.

Start the engine.

Depress the clutch pedal fully.

Is the noise apparent when the clutch is operated?
Yes

GO to E3

There is a problem with the transaxle. REFER to
Symptom Chart(s).

E2: CHECK THE TRANSMISSION AT IDLING B)

Are the noises coming from the pedal box?
Yes

Go to "Service – Clutch Pedal".

GO to E3

E3: TEST CLUTCH RELEASE BEARING

Check the release bearing for wear and corrosion.

Are there signs of wear or rust?
Yes

INSTALL a new clutch release bearing.

CHECK the crankshaft for excessive end float.Are
there still noises?

GO to E5

E4: ENGINE SELECTION – DIESEL ENGINES

Does the engine have a 1.8L diesel engine or a 2.0L
diesel engine?
Yes

Vehicles with a 1.8L diesel engine

GO to E5

. Vehicles

with a 2.0L diesel engine

GO to E13

GO to E22

E5: CHECK THE ROTATION OF THE SECONDARY MASS OF THE DUAL MASS FLYWHEEL

CAUTIONS:

Do not rework or machine the dual mass

flywheel if it is distorted.

Do not clean the dual mass flywheel with any

kind of liquid. Use only a dry cloth to clean the
flywheel.

Do not clean the gap between the primary and

secondary mass. Only clean the bolt connection
surface and the clutch surface.
NOTE: Discoloration is not a reason in itself to
replace the dual mass flywheel.

Remove the clutch disc and clutch pressure plate.

Can the secondary mass be turned freely by more than
15 teeth?
Yes

INSTALL A NEW dual mass flywheel.

GO to E8

E6: CHECK THE SPRING RESISTANCE

Twist the secondary mass in both directions.

Can spring resistance be felt in both directions?
Yes

CONTINUE

INSTALL A NEW dual mass flywheel.

E7: ROTATION OF THE DUAL-MASS FLYWHEEL

Secure the primary side. Twist the secondary side
in a clockwise direction until spring resistance is

felt and release. Mark the rest position on the
primary and secondary sides. Then twist the
secondary side in a counter-clockwise direction until
spring resistance is felt and release. Mark the new
rest position on the primary side. Count the number
of teeth between the marks for both directions on
the toothed ring.

Are more than 5 teeth counted?
Yes

INSTALL A NEW dual mass flywheel.

GO to E8

E8: CHECK THE DUAL-MASS FLYWHEEL

Perform a visual inspection of the dual mass
flywheel.

Is the dual mass flywheel free of damage?
Yes

GO to E9

INSTALL A NEW dual mass flywheel.

E9: CHECK THE TOOTHED RING OF THE DUAL-MASS FLYWHEEL

Perform a visual inspection of the toothed ring of
the dual mass flywheel.

Perform a visual inspection of the toothed ring of the
dual mass flywheel.
Yes

GO to E10

INSTALL A NEW dual mass flywheel.

E10: CHECK THE WELD SEAM OF THE DUAL-MASS FLYWHEEL

Visually inspect the weld seam of the dual mass
flywheel to check for loss of grease.

Is a clear loss of grease visible at the weld seam of the
dual mass flywheel?
Yes

INSTALL A NEW dual mass flywheel.

GO to E11

E11: GUIDE PINS OF THE DUAL-MASS FLYWHEEL

Check the installation of the guide pins of the dual-
mass flywheel.

Are the guide pins for the dual mass flywheel present,
and do they all have the same length?
Yes

GO to E12

INSTALL A NEW dual mass flywheel.

E12: DISCOLORATION OF THE DUAL MASS FLYWHEEL DUE TO OVERHEATING

Check the dual mass flywheel for discoloration due
to overheating.

Is any discoloration evident in the marked area?
Yes

INSTALL A NEW dual mass flywheel.

The dual mass flywheel is OK.

E13: CHECK THE ROTATION OF THE SECONDARY MASS OF THE DUAL MASS
FLYWHEEL

CAUTIONS:

Do not rework or machine the dual mass

flywheel if it is distorted.

Do not clean the dual mass flywheel with any

kind of liquid. Use only a dry cloth to clean the

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