FORD KUGA 2011 1.G Workshop Manual

Selector Lever Assembly — Vehicles With: 5-Speed AutomaticTransaxle - AW55 AWD
Removal
CAUTION: Gearshift cables must not be
kinked or bent.
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Floor Console Extension - Vehicles
With: Center Armrest (501-12 Instrument
Panel and Console, Removal and Installation).
2.
E114518
3.
E114519
4.
x4x4
E101415
5. Torque: 9Nm
50 mm
x4
50 mm
x4
E114520
G1163687en2008.50 Kuga8/2011
REMOVAL AND INSTALLATION
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307-05-
11
Automatic Transmission/Transaxle External
Controls
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450
307-05-11
.

6.
E114521
7.
E114522
Installation
CAUTION: Gearshift cables must not be
kinked or bent.
1. Install all components in reverse order.
2. Refer to: Selector Lever Cable Adjustment -
Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD (307-05 Automatic
Transmission/Transaxle External Controls -
Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, General Procedures).
G1163687en2008.50 Kuga8/2011
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307-05-
12
Automatic Transmission/Transaxle External
Controls
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450
307-05-12
.

SECTION 307-07 Transfer Case— Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle - 6DCT450
VEHICLE APPLICATION: 2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
307-07-2
Specifications ........................................................................\
..............................................
DESCRIPTION AND OPERATION 307-07-3
Transfer Case (Component Location) ........................................................................\
........
307-07-8
Transfer Case (System Operation and Component Description) .......................................
307-07-8
System Operation ........................................................................\
.......................................
GENERAL PROCEDURES 307-07-9
Transfer Case Fluid Level Check ........................................................................\
...............
REMOVAL AND INSTALLATION 307-07-10
Transfer Case Connecting Sleeve ........................................................................\
..............
307-07-13
Transfer Case Connecting Sleeve Seals — Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD........................................................................\
............................................. 307-07-14
Transfer Case Rear Seal ........................................................................\
............................
307-07-15
Transfer Case Seal LH........................................................................\
...............................
307-07-17
Transfer Case Seal RH ........................................................................\
...............................
REMOVAL 307-07-18
Transfer Case ........................................................................\
.............................................
INSTALLATION 307-07-19
Transfer Case ........................................................................\
.............................................
307-07-1
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 1
.
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Capacities
Litres0.45
Transmission Fluid 8U7J-19G518-BA
G1164984en2008.50 Kuga8/2011
307-07- 2
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 2
SPECIFICATIONS
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Transfer Case – Component Location
Powertrain overview
6
6
1
2
3
3
4
5
6
6
E102416
Description
Item
Transaxle with front axle differential
1
Transfer box
2
Front wheel half shafts
3Description
Item
Drive shaft
4
Rear drive axle
5
Rear wheel half shafts
6
G1164985en2008.50 Kuga8/2011
307-07- 3
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 3
DESCRIPTION AND OPERATION
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Transfer box
1
23
E115223
Description
Item
Transfer box
1
Heat deflector
2
Bracket, transfer box to engine
3
G1164985en2008.50 Kuga8/2011
307-07- 4
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 4
DESCRIPTION AND OPERATION
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Transfer box seals
1
2
3
4
5
E115284
Description
Item
Output drive shaft flange retaining bolt
1
Output drive flange
2Description
Item
Hollow shaft seals, left
3
Hollow shaft seals, right
4
Output differential pinion gear seal
5
G1164985en2008.50 Kuga8/2011
307-07- 5
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 5
DESCRIPTION AND OPERATION
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Hollow shaft seal, left
E115285
Hollow shaft seals, right
12
3
45
E
Description
Item
Transfer box
1
Bolt
2Description
Item
Locking device
3
Adjustable bearing, transfer box
4
Oil seals
5
G1164985en2008.50 Kuga8/2011
307-07- 6
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 6
DESCRIPTION AND OPERATION
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Differential/drive - transfer box
1
2
3
4
5
2
E102901
Description
Item
Taper roller bearing - differential
1
Differential case
2Description
Item
Drive teeth - transfer box
3
Differential pinion gears
4
Spur gear
5
G1164985en2008.50 Kuga8/2011
307-07- 7
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 7
DESCRIPTION AND OPERATION
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Transfer Case – System Operation and Component Description
System Operation
1
2
3
E103728
Description
Item
Hollow shaft
1
Output shaft
2
Output drive flange
3
NOTE: From the start of series production, the
transfer box will be subject to a "Black Box Phase"
and will therefore not be repaired.
To realise the all-wheel drive, a transfer box has
been flange-mounted to the manual transaxle. The
transfer box is designed as an angular gear to
transfer the torque from the transaxle to the rear
axle. The hollow shaft of the transfer box is inserted
in a tooth on the gear case. From the hollow shaft,
torque is transferred to the driveshaft through the
output shaft/output flange via crown gear and
differential pinion gear.
G1164987en2008.50 Kuga8/2011
307-07- 8
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 8
DESCRIPTION AND OPERATION
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