Drive shaft FORD KUGA 2011 1.G User Guide

SECTION 205-02 Rear Drive Axle/Differential
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
205-02-2
Rear Drive Axle and Differential (Component Location) .....................................................
205-02-6
Rear Drive Axle and Differential (System Operation and Component Description) ...........
205-02-6
System Operation ........................................................................\
.......................................
205-02-6
General Information ........................................................................\
................................
205-02-6
Driving situations ........................................................................\
....................................
205-02-6
Haldex clutch ........................................................................\
..........................................
205-02-7
General overview ........................................................................\
....................................
205-02-7
Operation ........................................................................\
................................................
205-02-7
Design of the 3rd generation Haldex clutch ....................................................................
205-02-9
Design of the multi-plate clutch ........................................................................\
...............
205-02-10
All-wheel drive control unit ........................................................................\
......................
205-02-10
Electric feed pump ........................................................................\
..................................
205-02-10
Pressure control - 3rd generation Haldex clutch .............................................................
205-02-11
Base pressure ........................................................................\
.........................................
205-02-12
Increased base pressure (preload) ........................................................................\
.........
205-02-13
Pressure build-up ........................................................................\
....................................
205-02-14
Design of the 4th generation Haldex clutch ...................................................................
205-02-14
General overview ........................................................................\
....................................
205-02-15
Pressure control - 4th generation Haldex clutch .............................................................
GENERAL PROCEDURES 205-02-17
Differential Fluid Level Check ........................................................................\
.....................
205-02-19
Active On-Demand Coupling Fluid Level Check ................................................................
REMOVAL AND INSTALLATION 205-02-21
Differential Case ........................................................................\
.........................................
205-02-25
Active On-Demand Coupling Module ........................................................................\
.........
205-02-32
Differential Input Shaft Seal ........................................................................\
........................
205-02-38
Differential Support Insulator ........................................................................\
......................
205-02-39
Rear Halfshaft Seal ........................................................................\
.....................................
205-02-41
Drive Pinion Seal ........................................................................\
........................................
DISASSEMBLY AND ASSEMBLY
205-02-42
Active On-Demand Coupling — Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450 ...............................................................
205-02-1
Rear Drive Axle/Differential
205-02- 1
.
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Rear Drive Axle and Differential – Component Location
Powertrain
6
6
1
2
3
3
4
5
6
6
E102416
Description
Item
Transmission assembly
1
Transfer box,
2
Halfshaft - front axle
3Description
Item
Drive shaft
4
Rear axle
5
Halfshaft - rear axle
6
G1076980en2008.50 Kuga8/2011
205-02- 2
Rear Drive Axle/Differential
205-02- 2
DESCRIPTION AND OPERATION
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Rear Drive Axle and Differential – System Operation andComponent Description
System Operation
General Information
The powertrain with all-wheel drive consists of the
following main components:
• engine
• transaxle with front axle differential
• transfer box
• halfshafts and driveshafts
• Haldex clutch
• rear axle differential
The Haldex clutch guarantees continuous variable
torque transmission to the rear axle under all
driving conditions. The Haldex clutch reacts
immediately and equally quickly with slow or fast
wheel slip.
A difference in angle of rotation of 90° between the
input and output shafts is required to build up
maximum pressure at the multi-plate clutch or to
transmit maximum torque.
The advantage of vehicles with all-wheel drive is
that they distribute the drive between all four
wheels. They therefore have a higher tractive
power. They feature improved cornering behaviour,
as the grip at all four wheels can be better utilised.
Thus, the wheels contribute to a greater degree
towards cornering stability.
The engine torque is transmitted from the transfer
box to the rear axle via a driveshaft. The driveshaft
is flange-mounted to the input side of the Haldex
clutch.
Driving situations
Pulling away and accelerating
• When pulling away and accelerating, as muchall-wheel drive as necessary must be available
immediately in the short-term. During
acceleration, the electronic system detects slip
at the front axle. This slip is counter-controlled
and thus the propulsive force optimally
distributed to the two axes.
Cornering • A sporty driving style, in particular dynamic
cornering, demands stable cornering behaviour.
The all-wheel system distributes the propulsive
force to all four wheels and by so doing boosts
the high cornering forces so that the vehicle
makes optimum contact with the road surface.
Snow and black ice
• Snow and black ice require particularly high grip. Under these conditions, the Haldex clutch
always distributes the propulsive force to the
axle with the better traction. The all-wheel
system reacts intelligently and quickly to all
driving situations.
Trailer operation
• When driving with a trailer, the trailer weight (support load) is transmitted to the rear axle via
the towbar. This reduces the load on the front
wheels, which means they can slip. The
electronic system detects this difference and
distributes most of the propulsive force to the
rear axle.
Haldex clutch
E100642
G1076981en2008.50 Kuga8/2011
205-02- 6
Rear Drive Axle/Differential
205-02- 6
DESCRIPTION AND OPERATION
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General overview
Haldex clutches of the 3rd and 4th generations are
used in the Ford Kuga.
The development of the third generation Haldex
clutch represents a big step forward in modern
all-wheel technology. The Haldex clutch is
electro-hydraulically controlled. Additional
information is taken into consideration during
control tasks via the all-wheel drive control unit.
Slip alone is no longer decisive for the distribution
of the propulsive forces; the vehicle's driving
dynamics are also taken into consideration. The
control unit accesses the driving-related data via
the data bus. With this data, the control unit has
all the essential information about speed, cornering,
coasting or traction operation, and can optimally
react to every driving situation.
Compared with the previous generation, the 4th
generation Haldex clutches operate with higher
pressure and achieve shorter response times when
distributing the drive forces.
Advantages of the Haldex clutch:
• Permanent all-wheel drive withelectronically-controlled multi-plate clutch
• Fast response
• No straining when parking and manoeuvring
• Compatible with different tyres (e.g. emergency spare wheel)
• Fully combinable with driving dynamic control systems
The driveshaft is connected to the input shaft of
the Haldex clutch. Within the Haldex clutch, the
input shaft is separated from the output shaft to
the rear axle differential by means of a multi-plate
clutch. Torque is only transmitted to the rear axle
differential when the plate assembly of the Haldex
clutch is closed.
The multi-plate clutch is electro-hydraulically
controlled via the all-wheel drive control unit. For
ecological driving, the torque to the rear axle is reduced to a minimum up to a throttle position of
approx. 50%. A prerequisite for this is that there is
no difference in speed in the Haldex clutch between
the input and output shafts.
Operation
E100645
16
3
25
4
Description
Item
Output shaft
1
Working piston
2
Plates
3
Ring piston pump
4
Control Valve
5
Input shaft
6
Within the Haldex clutch is a plate assembly and
a so-called ring piston pump with a pump plunger
and a working piston.
Fluid supply is started if there is a speed difference
between the input and output shafts.
This fluid pressure is transmitted to the working
piston and in this way the plate assembly is
compressed.
Design of the 3rd generation Haldex
clutch
G1076981en2008.50 Kuga8/2011
205-02- 7
Rear Drive Axle/Differential
205-02- 7
DESCRIPTION AND OPERATION
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E100664
1
3
4
11
11
10
9
8
76
5
2
Description
Item
Multiplate clutch
1
Ring piston pump
2
All-wheel drive control unit
3
Pressure relief valve (high pressure)
4
Input shaft
5Description
Item
Electric feed pump
6
Fluid filter
7
Pressure accumulator
8
Pressure relief valve (low pressure)
9
Preload valve
10
High-pressure valves
11
G1076981en2008.50 Kuga8/2011
205-02- 8
Rear Drive Axle/Differential
205-02- 8
DESCRIPTION AND OPERATION
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The Haldex clutch is based on the principle of a
simple wet clutch that distributes the torque variably
between the front and rear axles.
Three components are linked within the Haldex
clutch:• A mechanical component, comprising input and
output shafts, the plate assembly (clutch) as
well as the cam plate and the roller bearing.
• A hydraulic component, essentially comprising pressure valves, a pressure accumulator, the
control valve, the ring pistons and a fluid filter.
• The electronic control comprises the electric fluid pump and the all-wheel drive control unit
with integrated pressure/temperature sensor
and an actuator motor for the control valve.
Design of the multi-plate clutch
7
4
3
2
8
1
6
10911
13
A
B12
5
E100662
Description
Item
Pump plunger assembly
A
Working piston assembly
B
Output shaft
1
Inner plates
2
Outer plates
3
Disc drum
4
Contact plate
5Description
Item
Input shaft
6
Cam disc
7
Springs
8
Pump plunger roller
9
Pump plunger roller
10
Pump plunger
11
Working piston roller
12
Working piston
13
G1076981en2008.50 Kuga8/2011
205-02- 9
Rear Drive Axle/Differential
205-02- 9
DESCRIPTION AND OPERATION
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E100540
Description
Item
Barometric Pressure
A
Base pressure
BDescription
Item
Increased base pressure (preload)
C
Operating pressure
Drive
The hydraulic fluid is drawn from the sump of the
hydraulic system and directed through a filter. The
feed pump pressurises the system and pumps
hydraulic fluid into the pump plungers. This base
pressure of 4 bar presses the rollers for the pump
plungers against the cam disc. At the same time,
hydraulic fluid flows into the working piston. This
eliminates the play in the clutch plates. The Haldex
clutch can respond quickly and distribute the torque
within fractions of a second. The spring force in
the pressure accumulator determines the base pressure of 4 bar and compensates pressure
fluctuations. A compensating spring works in the
opposite direction and prevents the plate discs
becoming blocked by the force of the working
piston. This restricts the transferable torque to
approx. 7 Nm. This value can, however, deviate
slightly due to temperature and/or the difference
in speed between the input and output shafts.
Increased base pressure (preload)
G1076981en2008.50 Kuga8/2011
205-02-
12
Rear Drive Axle/Differential
205-02- 12
DESCRIPTION AND OPERATION
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E100541
Description
Item
Barometric Pressure
A
Base pressure
BDescription
Item
Increased base pressure (preload)
C
Operating pressure
Drive
To ensure very fast torque transmission, a higher
voltage is applied to the electric feed pump and
the control valve fully closed before the shaft-driven
pump is brought into operation. As a result, the
maximum pressure is raised above the base
pressure, and a torque of up to 80 Nm applied to
the multi-plate clutch. This achieves significantly
faster pressure build-up than with older systems (second generation). To protect the pump from
overloading, the pressure is restricted to approx.
10 bar by the pressure relief valve. The hydraulic
fluid flows back into the sump via the pressure
accumulator.
Pressure build-up
G1076981en2008.50 Kuga8/2011
205-02-
13
Rear Drive Axle/Differential
205-02- 13
DESCRIPTION AND OPERATION
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E100542
Description
Item
Barometric Pressure
A
Base pressure
BDescription
Item
Increased base pressure (preload)
C
Operating pressure
Drive
The pump plungers generate the operating
pressure that is controlled by the control valve as
a function of the difference in speed between the
input and output shafts. The control valve works
progressively from fully open to fully closed. The
fluid pressure can be approx. 67 bar when the
control valve is fully open. The maximum pressure is mechanically controlled by means of the
pressure relief valve.
Design of the 4th generation Haldex
clutch
General overview
G1076981en2008.50 Kuga8/2011
205-02-
14
Rear Drive Axle/Differential
205-02- 14
DESCRIPTION AND OPERATION
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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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