FORD KUGA 2011 1.G Workshop Manual

Transfer Case Fluid Level Check
MaterialsSpecification
Name
8U7J-19G518-BA
Rear Axle Oil SAE 75W-
90
Inspection
1. Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2.
E139436
3. Material: Rear Axle Oil SAE 75W-90
(8U7J-19G518-BA) transmission fluid
•
• Correct the rear axle oil level if neccessary.
• 20ml~1mm
0mm0mm
E114595
4. NOTE:
Make sure that a new component is
installed.
Torque: 34
Nm
E139434
G1164988en2008.50 Kuga8/2011
307-07- 9
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 9
GENERAL PROCEDURES
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transfer Case Connecting Sleeve
Special Tool(s) / General Equipment308-784
Installer, Halfshaft Seal
E115803
Special Tool(s) / General Equipment308-785
Installer, Halfshaft Seal
E115804
Copper Hammer
Flat-bladed screwdriver
Hot Air Gun
Puller
Punch
Removal
G1164990en2008.50 Kuga8/2011
307-07-10
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 10
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

1.Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2. Refer to: Transfer Case (307-07 Transfer Case
- Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, Removal).
3. General Equipment: Puller
2.
2
1
2
1
E115596
4. General Equipment: Flat-bladed screwdriver
E115627
5.General Equipment: Punch
E115597
Installation
1.General Equipment: Hot Air Gun
175
150175
150
E115598
2.
General Equipment: Copper Hammer
E115599
G1164990en2008.50 Kuga8/2011
307-07- 11
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 11
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

3.Special Tool(s): 308-785
308-785
60
308-785
60
E115600
4.
E115601
5.Special Tool(s): 308-784
308-784308-784
E114369
6.Refer to: Transfer Case (307-07 Transfer Case
- Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, Installation).
7. 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).
G1164990en2008.50 Kuga8/2011
307-07- 12
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 12
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transfer Case Connecting Sleeve Seals — Vehicles With: 5-SpeedAutomatic Transaxle - AW55 AWD
Removal
1.Refer to: Transfer Case Connecting Sleeve
(307-07 Transfer Case - Vehicles With:
5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle -
6DCT450, Removal and Installation).
Installation
1. To install, reverse the removal procedure.
G1164991en2008.50 Kuga8/2011
307-07- 13
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 13
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transfer Case Rear Seal
Removal
1.Refer to: Transfer Case Rear Seal (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 Rear Seal (307-07
Transfer Case - Vehicles With: 5-Speed
Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450, Removal
and Installation).
G1164992en2008.50 Kuga8/2011
307-07- 14
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 14
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR 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
TO MODEL INDEX
BACK TO CHAPTER INDEX
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
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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
TO MODEL INDEX
BACK TO CHAPTER INDEX
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
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL