200 FORD KUGA 2011 1.G Workshop Manual

Transfer Case Seal LH
Special Tool(s)204-351
Installer, Pivot Bushing
E45281
Special Tool(s)303-293
Remover, Crankshaft Seal
21143
308-788
Protector, Transfer Case Seal
E115807
Removal
G1164993en2008.50 Kuga8/2011
307-07-15
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 15
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

1.Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
Refer to: Transfer Case (307-07 Transfer Case
- Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, Removal).
2. Special Tool(s): 303-293
303-293303-293
E115696
Installation
1. Install the Special Tool(s): 308-788
1.
3. Special Tool(s): 204-351
2308-788
1
204-351/1
3
204-351/2
3
2308-788
1
204-351/1
3
204-351/2
3
E115697
2. Remove the Special Tool(s): 308-788
3. Refer to: Transfer Case (307-07 Transfer Case
- Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, Installation).
Refer to: Transfer Case Fluid Level Check
(307-07 Transfer Case - Vehicles With:
5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle -
6DCT450, General Procedures).
G1164993en2008.50 Kuga8/2011
307-07- 16
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 16
REMOVAL AND INSTALLATION
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Transfer Case Seal RH
Removal
1.Refer to: Transfer Case Seal RH (307-07
Transfer Case - Vehicles With: 5-Speed
Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450, Removal
and Installation).
Installation
1. Refer to: Transfer Case Seal RH (307-07
Transfer Case - Vehicles With: 5-Speed
Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450, Removal
and Installation).
G1164994en2008.50 Kuga8/2011
307-07- 17
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 17
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transfer Case
Removal
1.Refer to: Transfer Case (307-07 Transfer Case
- Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, Removal).
G1164996en2008.50 Kuga8/2011
307-07- 18
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 18
REMOVAL
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transfer Case
Installation
1.Refer to: Transfer Case (307-07 Transfer Case
- Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, Installation).
G1164998en2008.50 Kuga8/2011
307-07- 19
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 19
INSTALLATION
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SECTION 309-00 Exhaust System— 2.5L Duratec (147kW/200PS) - VI5
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
309-00-2
Exhaust System (Component Location) ........................................................................\
.....
REMOVAL AND INSTALLATION 309-00-3
Exhaust Flexible Pipe ........................................................................\
.................................
309-00-6
Catalytic Converter ........................................................................\
.....................................
309-00-1
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
1
.
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Exhaust System – Component Location
E106894
1
2
3
4
5
6
7
8
Description
Item
Exhaust flexible pipe gasket
1
HO2S (heated oxygen sensor)
2
Exhaust flexible pipe
3
Front gasket, catalytic converter
4Description
Item
Exhaust catalytic convertor
5
Rear gasket, catalytic converter
6
Rear Muffler
7
Catalyst monitor sensor
8
G1079149en2008.50 Kuga8/2011
309-00- 2
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
2
DESCRIPTION AND OPERATION
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Exhaust Flexible Pipe
General EquipmentCable TiesMaterials
Specification
Name
SA-M1C9107-A / YS5J-
M1C9107-AA
Grease KS-PS
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1.
E65070
2. CAUTION: Make sure that the inside of the pipe ends are clean and free of oil
residue.
1. Torque: 10Nm
2. Torque: 4Nm
3. Torque: 10Nm
2
1
3
E68504
3.Torque: 20Nm
E112607
1
2
34
4.
E67948
2
1
5. CAUTIONS:
Jointing compound must not be used
forward of the catalytic converter.
G1079152en2008.50 Kuga8/2011
309-00- 3
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
3
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Make sure that the exhaust flexible pipe
is not forcibly bent.
2. Torque: 47
Nm
3. Torque: 28Nm
E112609
x3
1
2
3
6. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
7.
E65299
8. General Equipment: Cable Ties
TIE0014991
9.
E66050
10.Torque: 30Nm
E112254
G1079152en2008.50 Kuga8/2011
309-00- 4
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
4
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

11. CAUTION: Make sure that the exhaustflexible pipe is not forcibly bent.
Torque: 48Nm
E112253
x2
12.Material: Grease KS-PS (SA-M1C9107-A /
YS5J-M1C9107-AA) grease
Torque: 48
Nm
E112608
Installation
1. To install, reverse the removal.
G1079152en2008.50 Kuga8/2011
309-00- 5
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
5
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL