FORD KUGA 2011 1.G Workshop Manual

6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
E114914
Description
Item
Haldex clutch fluid
1
Inlet filter
2
Electric feed pump
3
Filters4
Pressure accumulator
5Description
Item
Control valve
6
Dished washer
7
Ring piston
8
Clutch plate pack
9
Return pressure accumulator
10
Return control valve
11
Full torque is available at any time on the 4th
generation Haldex clutch because the pressure is
not dependent on the difference in the speeds of
rotation. This is used for instance to activate the
Haldex clutch for better traction when moving off.
On the 4th generation Haldex clutch, the preload
function which applied 80 Nm to the plates in the
3rd generation is no longer required.
On request from the control unit and at engine
speeds above 400 rpm, the electric feed pump runs
and maintains the storage pressure at about 30
bar.
A pressure reducing valve acts as a control valve,
allowing the all-wheel drive control unit to control
the pressure with much greater precision. The
all-wheel drive control unit monitors the position and function of the control valve. The control valve
distributes the pressure, depending on the
requirements, across its three outlet openings
(storage pressure, working pressure, return).
From the storage pressure (30 bar) and depending
on the requirements, the control valve regulates a
working pressure of 0 - 17 bar, which is applied to
the ring piston. At 17 bar working pressure, the
maximum torque of 1000 Nm is transferred to the
rear wheels. The all-wheel drive control unit
ensures the best possible performance under all
driving conditions, for all road conditions and
independent of the speed.
G1076981en2008.50 Kuga8/2011
205-02-
16
Rear Drive Axle/Differential
205-02- 16
DESCRIPTION AND OPERATION
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Differential Fluid Level Check
MaterialsSpecification
Name
WSP-M2C197-A / 4U7J-
M2C197-AA
Rear Axle Oil SAE 80W-
90 F
1. Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2.
E104195
3. Material: Rear Axle Oil SAE 80W-90 F
(WSP-M2C197-A / 4U7J-M2C197-AA)
transmission fluid
•
• Correct the rear axle oil level if neccessary.
• 24ml~1mm
E104196
G1087340en2008.50 Kuga8/2011
205-02-
17
Rear Drive Axle/Differential
205-02- 17
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4.Torque: 43Nm
E104195
G1087340en2008.50 Kuga8/2011
205-02- 18
Rear Drive Axle/Differential
205-02- 18
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Active On-Demand Coupling Fluid Level Check
MaterialsSpecification
Name
8U7J-8708687-AA
Transmission Oil AWD
Activation
5. Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
6. NOTE: This component does not have a drain
plug because the fluid does not need to be
drained or changed. 7.
E102723
8.
Material: Transmission Oil AWD
(8U7J-8708687-AA) transmission fluid
•
• Correct the oil level if neccessary.
• 24ml~1mm
5mm5mm
E102724
G1087341en2008.50 Kuga8/2011
205-02-
19
Rear Drive Axle/Differential
205-02- 19
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9.Torque: 43Nm
E102723
G1087341en2008.50 Kuga8/2011
205-02- 20
Rear Drive Axle/Differential
205-02- 20
GENERAL PROCEDURES
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Differential Case
General EquipmentCable Ties
Removal
All vehicles
1. Refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).
Vehicles with 2.0L diesel engine
2.
1
2x6x3
1
2x6x3
E101687
3.
E101709
Vehicles with 2.5L engine
4. Refer to: Driveshaft (205-01 Driveshaft,
Removal and Installation).
5.
E114256
6.
x2x2
E114255
G1061458en2008.50 Kuga8/2011
205-02- 21
Rear Drive Axle/Differential
205-02- 21
REMOVAL AND INSTALLATION
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All vehicles
7.
E101710
Vehicles with 2.0L diesel engine
8.General Equipment: Cable Ties
30 mm
30 mm
x2
30 mm
30 mm
x2
E101711
All vehicles
9.
x2x2
E101713
Installation
All vehicles
1.
x2x2
E101714
G1061458en2008.50 Kuga8/2011
205-02- 22
Rear Drive Axle/Differential
205-02- 22
REMOVAL AND INSTALLATION
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Vehicles with 2.0L diesel engine
2.
x2x2
E101712
All vehicles
3.Torque: 80Nm
E101710
Vehicles with 2.0L diesel engine
4.Torque: 80Nm
E101709
5. CAUTION: Make sure that the
installation marks are aligned.
1. Torque: 35Nm
2. Torque: 35Nm
3. Torque: 35Nm
3
x2
1
2
2x3
13
x2
1
2
2x3
1
E101688
G1061458en2008.50 Kuga8/2011
205-02- 23
Rear Drive Axle/Differential
205-02- 23
REMOVAL AND INSTALLATION
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Vehicles with 2.5L engine
6.
x2x2
E114255
7.Torque: 80Nm
E114256
8.Refer to: Driveshaft (205-01 Driveshaft,
Removal and Installation).
All vehicles
9. Refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).
10. Refer to: Differential Fluid Level Check (205-02
Rear Drive Axle/Differential, General
Procedures).
G1061458en2008.50 Kuga8/2011
205-02- 24
Rear Drive Axle/Differential
205-02- 24
REMOVAL AND INSTALLATION
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Active On-Demand Coupling Module
MaterialsSpecification
Name
8U7J-8708687-AA
Transmission Oil AWD
Removal
All vehicles
1. Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
Vehicles with 2.0L diesel engine
3.
x2x2
E102531
4.
1
2x6x3
1
2x6x3
E101687
5.
x4
x2
x4
x2
E102544
G1076971en2008.50 Kuga8/2011
205-02- 25
Rear Drive Axle/Differential
205-02- 25
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL