fluid FORD KUGA 2011 1.G Workshop Manual

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

307-01-72
Output Shaft Speed (OSS) Sensor ........................................................................\
.............
307-01-73
Torque Converter Seal ........................................................................\
................................
307-01-75
Transmission Fluid Pan ........................................................................\
..............................
307-01-77
Transmission Range (TR) Sensor ........................................................................\
..............
307-01-81
Turbine Shaft Speed (TSS) Sensor ........................................................................\
............
REMOVAL 307-01-82
Transmission ........................................................................\
..............................................
INSTALLATION 307-01-91
Transmission ........................................................................\
..............................................
307-01-3
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 3
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PAGE 3 OF 3 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Lubricants, Fluids, Sealers and Adhesives
Specification
Item
WSS-M2C924-A
Automatic transmission fluid
Capacities
Litres
7.7±0.2
Automatic transmission fluid (including cooler an cooler hoses)
Gear Ratio
Gear Ratio 4.576
1st gear
2.980
2nd gear
1.948
3rd gear
1.318
4th gear
1.000
5th gear
5.024
Reverse gear
1.018
Counter gear
2.652
Differential gear
Line Pressure Chart
Stall (psi)
Stall (kPa)
Stall (bar)
Idle (psi)
Idle (kPa)
Idle (bar)
Transmis-
sion
Range
248 - 289
1710 - 1990
17,1 - 19,9
71 - 88
490 - 610
4,9 - 6,1
R
187 - 205
1290 - 1410
12,9 - 14,1
48 - 57
330 - 390
3,3 - 3,9
D
G1163602en2008.50 Kuga8/2011
307-01- 4
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 4
SPECIFICATIONS
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Transaxle cooling
1
2
3
4
E112583
Description
Item
The transmission fluid cooler.
1
Quick-release couplings
2Description
Item
From transmission fluid cooler to
transmission
3
From transmission to transmission fluid
cooler
4
The transmission fluid cooler is mounted on the
radiator. The transmission fluid cooler and the
automatic transaxle are connected via two hose
lines, which are equipped with quick-release
couplings. The transmission fluid cooler operates according
to the heat exchanger principle. The ram air
passing through the radiator withdraws heat from
the transmission fluid.
External shift mechanism
G1163604en2008.50 Kuga8/2011
307-01-
8
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 8
DESCRIPTION AND OPERATION
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E112323
1
2
7
6
4
5
3
10
9
11
12
Description
Item
The TSS sensor
1
The OSS sensor
2
PWM (pulse width modulation)- solenoid
valve – TCC (torque converter clutch)
(SLU)
3
PWM solenoid valve – shift pressure (SLS)
4
Shift solenoid S1
5
Shift solenoid S4
6Description
Item
Shift solenoid S3
7
Shift solenoid S5
8
Shift solenoid S2
9
The TFT (transmission fluid temperature)
sensor
10
PWM solenoid valve for main line pressure
(SLT)
11
TCM with integrated TR sensor
12
Depending on the input signals, the TCM mounted
on the transaxle actuates the solenoid valves
S1-S5 in the valve body. The solenoid valves are
either in the "open" or "closed" state.
The (SLT and SLS) control valves regulate the
hydraulic pressure according to the pulse/pause
ratio of the electrical PWM signal. The controlled
hydraulic pressure enables smooth shifting or the
generation of a defined slip through actuation of
the relevant clutches and brakes. The shift timing is calculated by the TCM using the
accelerator pedal position and vehicle speed.
Under normal conditions, gear shifting and torque
converter lockup occur at low engine speeds to
reduce fuel consumption.
If the accelerator pedal is pressed down quickly,
the TCM switches automatically into kickdown
mode.
G1163604en2008.50 Kuga8/2011
307-01-
10
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 10
DESCRIPTION AND OPERATION
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• Selector lever position and selector leverposition display
• Fluid leakage
• Transmission fluid level check
• Transmission fluid quality check
• Modification/retrofitting
• Mechanical damage to the transmission
When inspecting connectors, remember that the
plugs may only be disconnected when they are not
energized.
The transaxle electronics may be destroyed by
static charge. To prevent damage, it must be
ensured that the technician complies with the
corresponding safeguards.
NOTE: Refer to the service literature for an exact
description of these safeguards.
Towing the vehicle
E66463
In general, vehicles with the AW55 transaxle can
be towed. Vehicles must never be towed
backwards.
As a result of the reduced lubrication of the
transaxle during towing, the following must be
remembered:
• The selector lever must be in the 'N' position.
• The maximum towing speed must not exceed 50 km/h.
• The maximum towing distance must not exceed 50 kilometers.
Push-starting the Vehicle
No torque is transmitted when towing or pushing
the vehicle. For this reason, vehicles with an
automatic transaxle cannot and must not be
tow-started or push-started.
Jump-starting the Vehicle
CAUTION: When jump-starting the vehicle
using a jumper lead there may be voltage
peaks. These may destroy the transaxle
electronics.
NOTE: When jump-starting the vehicle, the external
battery must remain connected for several minutes.
The voltage peaks dissipate after a few minutes.
Only then may the external battery be disconnected
without the risk of damage.
Selector Lever Emergency Release
E114512
1
2
3
4
If release of the selector lever lock by means of
the selector lever lock solenoid actuated by the
TCM fails in selector lever position 'P', it is possible
to perform an emergency release.
Procedure:
• Carefully slide a flat screwdriver into the slot (1).
• Turn the screwdriver (2).
• Press the screwdriver downwards to detach the gaiter frame from the trim panel (3).
G1163604en2008.50 Kuga8/2011
307-01- 15
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 15
DESCRIPTION AND OPERATION
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Transmission Fluid Level Check
E126079
WARNING: Beware, risk of scalding when
checking the transmission fluid.
NOTE: Refer to the service literature for the exact
procedure and specifications.
In order for the transaxle to function properly, it is
vital that the transmission fluid level is correct. If the transmission fluid level is excessively low, this
becomes noticeable by a rattling noise at the fluid
pump, etc.
Always use transmission fluid to the indicated
specification (WSS-M2C924-A).
The transmission fluid temperature is determined
using IDS.
It must be ensured that the transmission fluid
temperature is within the range specified in the
workshop literature.
The following conditions must be met in order to
carry out the transmission fluid level check
correctly:
• Ensure that the transaxle is not in limp home
mode.
• Place the vehicle on a level surface.
• Move the selector lever to the 'P' position.
• Make sure that the parking brake is fully applied.
• Run the engine at idle speed.
• Move the transmission selector lever to all positions. In doing so, wait until the transmission
engages the corresponding range.
• Move the selector lever back to the 'P' position.
• Pull out the fluid dipstick.
When the predetermined transmission fluid
temperature is reached, the fluid level shown on
the dipstick must be in the middle between 'MIN'
and 'MAX'. In this case, the fluid level is correct.
Changing the Transmission Fluid
G1163604en2008.50 Kuga8/2011
307-01- 17
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 17
DESCRIPTION AND OPERATION
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E126062
2
1
3
4
Description
Item
Fluid reservoir
1
Connection for return line from fluid cooler
2Description
Item
Connection for return line on transaxle
3
Hose
4
Under normal conditions, the transmission fluid is
filled for the service life of the transaxle and does
not need to be changed.
Under high loads (driving with a trailer or in
mountains etc.) it may be necessary to change the
transmission fluid.
To drain the transmission fluid, remove the fluid
drain plug.
Proceed as follows when topping off the
transmission fluid:
• Remove the return line from the fluid cooler to the transaxle on the transaxle. Close off the
connection on the transaxle using a plastic plug.
• Join the return line to a transparent pipe. The transparent pipe ends in the fluid reservoir in
order to collect the fluid.
• To top off the transmission fluid, insert a transparent pipe in the guide tube of the dipstick
and add approx. 2.0 liters of transmission fluid. • Move the selector lever to the 'P' position and
allow the engine to run at idle speed.
• Switch off the engine if air bubbles become visible in the transparent pipe to the fluid
reservoir.
• Top off approx. 2 liters of transmission fluid and allow the engine to run at idle speed. Switch off
the engine if air bubbles become visible in the
transparent pipe to the fluid reservoir.
• Top up the transmission fluid until the fluid level for cold fluid is indicated on the dipstick in the
middle between 'MIN' and 'MAX'.
• Then check the transmission fluid level.
Refer to the service literature for the exact
procedure and specifications.
NOTE: If the transmission fluid has been changed,
the counter for fluid change intervals must be reset
using IDS.
Diagnosis with IDS
G1163604en2008.50 Kuga8/2011
307-01- 18
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 18
DESCRIPTION AND OPERATION
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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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transmission range or gear (in select-shift mode)
is indicated to the driver in the instrument panel.
In selector lever position "S", the driver can
manually select the gears (select-shift mode). Up
(+) and down (-) shifts are made by moving the
selector lever in the appropriate direction.
Hydraulic limp home modes maintain limited
operation in the event of failure of important
electrical components.Under normal conditions, the transmission fluid is
filled for the service life of the transaxle and does
not need to be changed.
A dipstick is used to check the fluid level in the
transmission.
Functionality overview
G1163605en2008.50 Kuga8/2011
307-01-
22
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 22
DESCRIPTION AND OPERATION
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