FORD KUGA 2011 1.G Workshop Manual

E101688
Vehicles with automatic transmission
4. CAUTION: Make sure that theinstallation marks are aligned.
E114197
All vehicles
5.
20 mm
E114036
6. CAUTION: Make sure that theinstallation marks are aligned.
E101042
Vehicles with manual transmission
3. CAUTION: Make sure that theinstallation marks are aligned.
1. Torque: 35Nm
1. Torque: 35Nm
2. Torque: 35Nm
3. Torque: 35Nm
3
x2
2
1
2
1
x3
G1076972en2008.50 Kuga8/2011
205-02- 36
Rear Drive Axle/Differential
205-02- 36
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2. Torque: 35Nm
3. Torque: 35Nm
3
x2
1
2
2
1
1. Torque: 35Nm
2. Torque: 35Nm
3. Torque: 35Nm
3
x2
1
2
2
x3
1
1
2

7.Torque: 25Nm
x2
x2
x2
x2
x2
x2
E114188
8.Torque:
• Stage 1: 35
Nm
• Stage 2: Loosen 360°
• Stage 3: 85Nm
E114034
9.Refer to: Differential Fluid Level Check (205-02
Rear Drive Axle/Differential, General
Procedures).
10.
E98543
x7
11 . Lower the vehicle.
G1076972en2008.50 Kuga8/2011
205-02- 37
Rear Drive Axle/Differential
205-02- 37
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Differential Support Insulator
Special Tool(s)204-598
Hydraulic Cylinder 10t
E75373
204-598-03
Adapter for 204-598
E103784
Special Tool(s)308-762
Remover/Installer, Bush RDU
E102678
Materials
Specification
Name
WSS-M2C200-D2 /
7U7J-M2C200-BA
Transmission Oil 75W
FE
Removal
1.
Refer to: Differential Case (205-02 Rear Drive
Axle/Differential, Removal and Installation).
2. Special Tool(s): 204-598, 204-598-03, 308-762
308-762
204-598
204-598-03
308-762
204-598
204-598-03
E102574
Installation
1.Special Tool(s): 204-598, 204-598-03, 308-762
Material: Transmission Oil 75W FE
(WSS-M2C200-D2 / 7U7J-M2C200-BA)
transmission fluid
308-762
204-598
204-598-03
308-762
204-598
204-598-03
E102575
2. Refer to: Differential Case (205-02 Rear Drive
Axle/Differential, Removal and Installation).
G1076973en2008.50 Kuga8/2011
205-02- 38
Rear Drive Axle/Differential
205-02- 38
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Rear Halfshaft Seal
Special Tool(s) / General Equipment303-395
Installer, Crankshaft Seal
21171
Special Tool(s) / General EquipmentTire Lever
Removal
1. Refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).
2. General Equipment: Tire Lever
E102535
3.General Equipment: Tire Lever
E102536
Installation
1.Special Tool(s): 303-395
303-395303-395
E102537
G1080736en2008.50 Kuga8/2011
205-02- 39
Rear Drive Axle/Differential
205-02- 39
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2.Special Tool(s): 303-395
303-395303-395
E102538
3.Refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).
4. Refer to: Differential Fluid Level Check (205-02
Rear Drive Axle/Differential, General
Procedures).
G1080736en2008.50 Kuga8/2011
205-02- 40
Rear Drive Axle/Differential
205-02- 40
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Drive Pinion Seal
Special Tool(s)303-293
Remover, Crankshaft Seal
21143
Special Tool(s)308-643
Installer, Input Shaft Seal
E65343
Removal
1.Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2. Refer to: Active On-Demand Coupling Module
(205-02 Rear Drive Axle/Differential, Removal
and Installation).
3. Special Tool(s): 303-293
303-293
303-293
303-293
303-293
E102546
Installation
1. CAUTION: Take extra care not to
damage the seal.
Special Tool(s): 308-643
308-643308-643
E102547
2.Refer to: Active On-Demand Coupling Module
(205-02 Rear Drive Axle/Differential, Removal
and Installation).
G1357281en2008.50 Kuga8/2011
205-02- 41
Rear Drive Axle/Differential
205-02- 41
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Active On-Demand Coupling — Vehicles With: 5-Speed AutomaticTransaxle - AW55 AWD/6-Speed Automatic Transaxle -
6DCT450
Special Tool(s) / General Equipment
205-072
Universal Flange Holding
Wrench
15030A
Special Tool(s) / General Equipment303-249
Remover, Crankshaft Timing
Pulley
21132
Puller
Materials
Specification
Name
8U7J-8708687-AA
Transmission Oil AWD
Disassembly
G1268328en2008.50 Kuga8/2011
205-02- 42
Rear Drive Axle/Differential
205-02- 42
DISASSEMBLY AND ASSEMBLY
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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).
3.
E114257
4. WARNING: Be prepared to collect escaping fluid.
E124748
5.
E124778
6. WARNING: Be prepared to collectescaping fluid.
x2x2
E124749
7.
E128365
G1268328en2008.50 Kuga8/2011
205-02- 43
Rear Drive Axle/Differential
205-02- 43
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8.
E98543
x7
9.
E114375
10.
x2
x2
x2
x2
x2
x2
E114188
11 .
1
2x6
x3
1
2x6
x3
E101018
G1268328en2008.50 Kuga8/2011
205-02-44
Rear Drive Axle/Differential
205-02- 44
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12.
20 mm1
2
20 mm1
2
E114376
13.
E114295
14.
1
2x6
x3
1
2x6
x3
E114196
15.Special Tool(s): 205-072, 303-249
205-072
303-249
205-072
303-249
E102495
G1268328en2008.50 Kuga8/2011
205-02- 45
Rear Drive Axle/Differential
205-02- 45
DISASSEMBLY AND ASSEMBLY
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL