ASSEMBLY FORD KUGA 2011 1.G Owners Manual

8.Torque: 25Nm
E100040
x4
9.
E98184
10.
E98183
11 .Remove the cable ties securing the radiator and
condenser assembly.
G1062292en2008.50 Kuga8/2011
303-03- 9
Engine Cooling
303-03- 9
GENERAL PROCEDURES
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Throttle Body(23 198 0)
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Remove the right-hand side headlamp
assembly.
2.
E74132
3. NOTE: The gasket is to be reused unless
damaged.
Torque: 10
Nm
E74133
x4
Installation
1. To install, reverse the removal procedure.
2. NOTE: Make sure that the pedals remain in the
rest position.
Turn the ignition key to position II and wait for
one minute to initialize the throttle body. 3.
E101067
G1079056en2008.50 Kuga8/2011
303-04A-
23
Fuel Charging and Controls
— 2.5L Duratec (147kW/200PS) -
VI5
303-04A- 23
REMOVAL AND INSTALLATION
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307-01-29
Automatic transmission, selector lever in position "D". ...................................................
307-01-29
Sport mode, selector lever in position "S" .......................................................................
307-01-29
Changing gear in select-shift mode........................................................................\
........
307-01-30
Selector lever from 'N' to 'R' position ........................................................................\
......
307-01-30
Self-test and Diagnosis ........................................................................\
...........................
307-01-30
Temperature controlled torque converter lockup ............................................................
307-01-30
Slip locking ........................................................................\
..............................................
307-01-30
Hill climbing ........................................................................\
.............................................
307-01-31
Downhill driving ........................................................................\
.......................................
307-01-31
Hill-hold function ........................................................................\
.....................................
307-01-31
Altitude correction ........................................................................\
...................................
307-01-31
Selector lever lock ........................................................................\
..................................
307-01-31
Shifting from P into another transmission range .............................................................
307-01-31
Shifting from N into another transmission range .............................................................
307-01-31
Power flow through the transmission ........................................................................\
......
307-01-31
Clutches and brakes ........................................................................\
...............................
307-01-33
Position P (park) ........................................................................\
.....................................
307-01-34
Position N (neutral) ........................................................................\
.................................
307-01-35
Position D, 1st gear........................................................................\
................................
307-01-36
Position D, 2nd gear ........................................................................\
...............................
307-01-37
Position D, 3rd gear ........................................................................\
................................
307-01-38
Position D, 4th gear ........................................................................\
................................
307-01-39
Position D, 5th gear ........................................................................\
................................
307-01-40
Position R (reverse) ........................................................................\
................................
307-01-41
Service instructions ........................................................................\
.................................
307-01-41
Towing procedure ........................................................................\
...................................
307-01-42
Reset adaptation data ........................................................................\
.............................
307-01-42
Limp home mode ........................................................................\
....................................
307-01-42
Component Description ........................................................................\
..............................
Tasks of the electronic components ........................................................................\
........
307-01-44
Input signals ........................................................................\
............................................
307-01-45
Output signals ........................................................................\
.........................................
Control valve assembly ........................................................................\
...........................
Shift solenoids S1 - S5 ........................................................................\
...........................
PWM-

solenoid valve – TCC (SLU) ........................................................................\
........
PWM solenoid valve – shift pressure (SLS) ...................................................................
PWM solenoid valve for main line pressure (SLT) ..........................................................
307-01-52
Installation position ........................................................................\
.................................
Operation ........................................................................\
................................................
Selector lever with integrated select-shift switch module ...............................................
Oil pump ........................................................................\
..................................................
Torque converter with TCC ........................................................................\
.....................
The TSS sensor ........................................................................\
......................................
The OSS sensor ........................................................................\
.....................................
The TFT sensor ........................................................................\
......................................
The TR sensor ........................................................................\
........................................
GENERAL PROCEDURES
T ransmission Fluid Level Check ........................................................................\
.................
307-01-63
T ransmission Fluid Drain and Refill ........................................................................\
............
REMOVAL AND INSTALLATION 307-01-67
Halfshaft Seal LH ........................................................................\
........................................
307-01-68
Halfshaft Seal RH........................................................................\
.......................................
307-01-69
Main Control Valve Body ........................................................................\
............................
307-01-2
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 2
.
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307-01-42
307-01-49
307-01-52 307-01-47
307-01-45
307-01-50
307-01-51
307-01-53
307-01-55
307-01-54
307-01-56
307-01-57
307-01-58
307-01-61 307-01-60
PAGE 2 OF 3 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transmission Description – Overview
Components of the AW55 automatic
transaxle
E112298
Description
Item
Torque converter
1
Differential
2
The OSS (output shaft speed) sensor
3Description
Item
Planetary gear set.
4
The TSS (turbine shaft speed) sensor
5
Control valve assembly
6
TCM (transmission control module)
7
General overview
G1163604en2008.50 Kuga8/2011
307-01- 6
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 6
DESCRIPTION AND OPERATION
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23
4
5
6
7
1

E77584
NOTE:Due to static charging, measurements
inside the transaxle using a multimeter are
prohibited.
Stored DTCs in the engine management system
may affect transmission control. As a result, faults
in the transmission control system and engine
management system must be rectified in
accordance with the symptom-based diagnosis in
FordEtis IDS.
Applications of IDS Standard include:
• Resetting the counter for fluid change intervals.
• Programming the selector lever position 'N'.
• Resetting the values learned by the TCM.
Resetting the counter for fluid change
intervals.
This function must be performed if the transmission
fluid has been changed or a new automatic
transaxle has been installed with the previous TCM.
This function resets the values stored for the
pollution level of the transmission fluid.
Programming the 'N' position of the TR
sensor
This function must be executed if
• the TCM with integrated TR sensor is renewed,
• a new automatic transaxle is installed with the previous TCM.
• the selector lever cable or the selector mechanism assembly is renewed
• TR have been set due to a fault in the selector lever assembly or in the DTC (diagnostic trouble
code) sensor.
The TCM learns and stores the voltage value in
the 'N' position when this function is executed.
Resetting the values learned by the TCM
This function must be executed if
• a new automatic transaxle is installed with the previous TCM.
• a component of the automatic transaxle has been renewed.
G1163604en2008.50 Kuga8/2011
307-01- 19
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 19
DESCRIPTION AND OPERATION
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To exactly determine the activation points of the
gear shifts and torque converter lockup on the
basis of the type of driving mode chosen, the TCM
receives the following information:
• Selected transmission range (TR sensor)
• Selected driving mode (normal/sport/select-shift)
• Transmission input shaft speed (TSS sensor)
• Transmission output shaft speed (OSS sensor)
• Transmission fluid temperature (TFT sensor)
• The engine speed and the torque as well as thethrottle plate opening - from the PCM via the
CAN databus
• Actuation of accelerator – from the PCM via the CAN databus
• The coolant temperature – from the PCM via the CAN databus
• Road speed – from the ABS module via the CAN databus
• Actuation of brake pedal – from the PCM via the CAN databus
Gearshift control
Adaptation
The TCM monitors every shift operation in all
driving conditions to make even and smooth gear
shifts possible. This is done by the control module,
which either lowers or increases the hydraulic line
pressure during gearshifts.
The changed pressure values are stored in the
control module memory after the engine is switched
off and retrieved during engine starting. This
improves the shift comfort and extends the service
life.
Full adaptability occurs when the following criteria
are met:
• Throttle plate opening is constant.
• Transmission fluid temperature between 65 °Cand 110 °C.
Shifting from 'P' to another transmission
range
To be able to move the selector lever from 'P' into
another transmission range, the ignition must be
switched on and the brake pedal pressed (stoplamp
switch on). The TCM detects the position of the
brake pedal via the CAN data bus and the engaged
transmission range from the TR sensor. Based on this information, the TCM transmits a
signal to the select-shift switch module. This
activates the brake shift interlock actuator in the
selector lever assembly.
When the brake shift interlock actuator is activated,
the locking pin is retracted so that another
transmission range can be selected.
The brake shift interlock actuator is deactivated
when the ignition is switched off. It is mechanically
locked when the gear selector lever is in 'P'.
Automatic transmission, selector lever in
position "D".
The TCM adapts the shift points to match the
driving conditions. Normally the TCM is in adaptive
mode and gear changes take place adapted to the
driving conditions. If special driving conditions are
detected, the TCM switches to predefined
characteristics.
When driving with normal acceleration, the TCM
uses a preset shift program which is optimized for
economical driving.
This shift program is suitable for "normal" driving
and delivers early upward changes and torque
converter lockup. Furthermore, the transmission
fluid pressure is adapted to make smooth
engagement of the gears possible.
Sport mode, selector lever in position "S"
The transmission switches from automatic
operation into sport mode. In this mode the TCM
switches to another set of characteristic curves.
These characteristic curves for control of the gear
changes are adapted to sporting calculations (e.g.
gear change at higher engine speed).
In the sport mode shift program the shift points are
set so that good performance is offered. Changing
down occurs at lower engine speeds.
Manual gear changes (select-shift mode) can be
made in sport mode by moving the selector lever
in the (+) or (-) direction.
Changing gear in select-shift mode
If you move the selector lever to 'S', the automatic
transaxle remains hydraulically in 'D' position. If
you move the gear selector lever forwards (-), the
G1163605en2008.50 Kuga8/2011
307-01-
29
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 29
DESCRIPTION AND OPERATION
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The TCM detects uphill driving by comparing the
engine load transmitted by the PCM with the engine
speed. If the engine load increases and the engine
speed falls, then the TCM causes the transaxle to
shift to a lower transmission range in order to
increase the traction force.
Downhill driving
The TCM detects downhill driving by comparing
the engine load and engine speed values
transmitted by the PCM with the OSS sensor
signal. In order to prevent overloading of the
vehicle brakes, the TCM causes the transaxle to
shift to a lower transmission range.
Hill-hold function
If the vehicle is stopped on an uphill incline, the
TCM detects this through the faster drop in engine
speed compared with the drop in engine speed
when stopping on the flat. In this situation, the
hydraulics are actuated by the TCM in such a way
that the vehicle is prevented from rolling back. This
function is not used on steep inclines.
If the vehicle is parked on an uphill incline (ignition
switched off), the hill-hold function is not active
when pulling away.
Altitude correction
Lower air density results in reduced engine
performance. In order to compensate for this
operating situation, the TCM changes the shift
points.
Selector lever lock
To prevent the selector lever being accidentally
moved from the P or N position, the vehicle also
has an electrically operated selector lever lock.
This blocks the locking pin in the locking segment
and thus locks the selector lever in the P or N
position.
Shifting from P into another transmission
range
To be able to move the selector lever from P into
another transmission range, the ignition must be
switched on and the brake pedal must be
depressed (stop light switch on). The TCM detects
the position of the brake pedal via the CAN data
bus and the engaged transmission range from the
TR sensor.
The signal is then transferred from the TCM to the
select-shift switch module in order to activate the
solenoid valve in the selector mechanism
assembly.
In position P, the solenoid valve is activated and
the locking pin is pulled in so that the lock button
on the selector lever can be pressed as usual to
engage another transmission range.
In the selector mechanism assembly there is a Hall
sensor which is affected by a permanent magnet
on the gate of the selector mechanism assembly.
If the selector lever is moved from the P position,
both the Hall sensor and the selector lever lock
solenoid are simultaneously deactivated, to prevent
the selector from being kept in the N position.
If the ignition is set to "I" or "0" the solenoid valve
is deactivated. When the selector lever is in the P
position, it is mechanically locked because it has
no voltage.
Shifting from N into another transmission
range
The conditions are the same as for shifting from P
into another transmission range.
However, the lock button on the selector lever must
be pressed to be able to select R or P.
Power flow through the transmission
Clutches and brakes
G1163605en2008.50 Kuga8/2011
307-01-31
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 31
DESCRIPTION AND OPERATION
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Output signals
Hard wired
• Item 8: PCM– Start inhibitor. Supplies the PCM with a signalthat indicates whether the engine can be
started or not.
• Item 9: Selector lever module (select-shift module)
– Controls the solenoid switch in the selectorlever unit.
• Position 10: PWM solenoid valve – shift pressure (SLS)
– Matches the line pressure to a shift pressureand is activated for certain gears.
• Position 11: PWM solenoid valve – main line pressure (SLT)
– Adjusts the linear line pressure for gearchanges without jolts.
• Position 12: PWM- solenoid valve – TCC (SLU) – Matches the line pressure to a torqueconverter lock-up pressure. Is also used for
certain gearshifts.
• Items 13 - 17: Shift solenoids S1 – S5 – The TCM checks which gear is engaged asthe solenoids become active in different
patterns.
Via the LIN data bus
• Item 7: Selector lever module (select-shift module)
– The TCM transmits a signal to the selectorlever module which activates the LED (light
emitting diode) in the selector mechanism
assembly according to the selector lever
position. Via the CAN data bus
• Item 2: GEM
– The selector lever module transmits a signalvia the TCM, which indicates that the selector
lever is locked in position P. The GEM uses
this information to control the ignition switch
key inhibit function.
– The TCM transmits a signal via the GEM to activate the back-up lamps.
• Item 3: Instrument Cluster – Current selector lever position. Used toindicate the selector lever position in the
instrument cluster.
– Check the warning lamps via the GEM. In the event of a fault, the general warning lamp
lights.
– Text messages in the instrument cluster via the GEM. The driver receives various
malfunction messages from the TCM.
– The TCM transmits signals on the CAN data bus to the PCM so that the MIL lights up in
the event of emissions-related faults.
• Item 4: PCM – Transmission fluid temperature, used tocompensate for increased loads at low fluid
temperatures.
– Gear selected, used by the engine so that it can compensate for different loads.
– Torque converter lockup, used by the engine so that it can compensate for different loads.
– Next gear planned by the TCM, used by the engine to compensate for different loads.
– Requirement for a reduced engine torque during gear shifts, the engine reduces the
engine torque during gear shifts.
– Torque limiting requirement, the engine limits the engine torque according to the gear
engaged.
• Item 5: ABS module – Current gear, used to transmit a signal, notfor shift control.
– Vehicle speed, used as reserve.
Control valve assembly
G1163605en2008.50 Kuga8/2011
307-01- 45
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 45
DESCRIPTION AND OPERATION
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Function of the shift solenoid valves in the gears and when shifting gears
S5
S4
S3
S2
S1
Gear
–
–
–
–
–
Park
0
–
0
–
–
R (V<=7)
–
–
–
–
0
R (V>7)
–
–
–
–
–
N
–
–
0
0
0
1
–
–
0
–
–
1<=>2
–
–
0
–
–
2
0
0
0
–
–
2<=>3
–
0
0
–
–
3
0
0
–
–
–
3<=>4
–
0
–
–
–
4
–
0
–
0
–
4<=>5
–
0
–
0
–
5
• V= Road speed in km/h
• 0= Actuated
• –= Not actuated
• x<=>x = Gear change "up/down"
Shift solenoids S1 - S5
E112324
1
2
4
5
3
Description
Item
Shift solenoid S1
1
Shift solenoid S4
2
Shift solenoid S3
3
Description
Item
Shift solenoid S5
4
Shift solenoid S2
5
Shift solenoids S1, S2, S3, S4 and S5 are located
in the control valve assembly on the front of the
transmission.
Function
The shift solenoid valves are actuated by the TCM
TCM. The shift solenoid valves S1 and S4 are fully
open when de-energized. The shift solenoid valves
S2, S3, and S5 are fully closed when de-energized.
They control gearshifting, while the TCM decides
which gear should be engaged by activating the
shift solenoid valves in different combinations.
Consequences of signal failure
G1163605en2008.50 Kuga8/2011
307-01- 47
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 47
DESCRIPTION AND OPERATION
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Description
Item
Hydraulic pressure
1
Average current (A)
2
The valve directly actuates the multi-plate brake
(B1) in 2nd - 4th gear as well as the clutch (C2) in
5th and reverse gear. The PWM control achieves
smooth engagement of the gears.
The hydraulic function of the valve is linear. The
hydraulic valve is controlled by means of the
varying current resulting from the current duty
cycle. The system pressure is low with a high duty
cycle, i.e. with high current intensity (approx. 1 A),
and vice versa.
Consequences of signal failure
E125991
2
1
Description
Item
PWM solenoid valve – shift pressure (SLS)
1
TCM connector 'C'
2
The shift pressure increases to the maximum value
in the event of interruptions, which leads to hard
gearshifts when shifting to another gear. The valve
is then fully open. If the PWM solenoid valve for shift pressure (SLS)
fails, the MIL is activated and the vehicle can be
driven in emergency mode 3.
PWM solenoid valve for main line pressure
(SLT)
E112327
Installation position
The PWM solenoid valve – main line pressure
(SLT) is located in the control valve assembly on
the front of the transmission.
Function
G1163605en2008.50 Kuga8/2011
307-01-
51
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 51
DESCRIPTION AND OPERATION
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