ECT FORD KUGA 2011 1.G Workshop Manual

Active On-Demand Coupling Fluid Level Check
MaterialsSpecification
Name
8U7J-8708687-AA
Transmission Oil AWD
Activation
5. Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
6. NOTE: This component does not have a drain
plug because the fluid does not need to be
drained or changed. 7.
E102723
8.
Material: Transmission Oil AWD
(8U7J-8708687-AA) transmission fluid
•
• Correct the oil level if neccessary.
• 24ml~1mm
5mm5mm
E102724
G1087341en2008.50 Kuga8/2011
205-02-
19
Rear Drive Axle/Differential
205-02- 19
GENERAL PROCEDURES
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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
DISASSEMBLY AND ASSEMBLY
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16.General Equipment: Puller
E114331
17. WARNING: Be prepared to collect
escaping fluid.
x2x2
E124753
Assembly
18.Material: Transmission Oil AWD
(8U7J-8708687-AA) transmission fluid
E124752
19. Torque: 6Nm
x2x2
E124753
G1268328en2008.50 Kuga8/2011
205-02- 46
Rear Drive Axle/Differential
205-02- 46
DISASSEMBLY AND ASSEMBLY
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SECTION 205-04 Front Drive Halfshafts
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
205-04-2
Specifications ........................................................................\
..............................................
DIAGNOSIS AND TESTING 205-04-3
Front Drive Halfshafts ........................................................................\
.................................
205-04-3
Inspection and Verification ........................................................................\
..........................
REMOVAL AND INSTALLATION 205-04-5
(14 320 0)
Front Halfshaft LH ........................................................................\
..................
205-04-16
(14 321 0)
Front Halfshaft RH — LHD 4WD/RHD 4WD ..................................................
205-04-27
(14 336 0)
Inner Constant Velocity (CV) Joint Boot .........................................................
205-04-30
(14 338 0)
Outer Constant Velocity (CV) Joint Boot ........................................................
205-04-31
Halfshaft Bearing ........................................................................\
........................................
205-04-1
Front Drive Halfshafts
205-04- 1
.
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Front Drive Halfshafts
Inspection and Verification
NOTE:New front wheel drive halfshafts should not
be installed unless disassembly and inspection
reveals unusual wear.
1. Inspect front wheel driveshaft joint boots for evidence of cracks, tears or splits.
NOTE: While inspecting the front wheel driveshaft
CV joint boots, watch for indentations (dimples) in
the boot convolutions. If an indentation is observed,
it must be removed.
2. Inspect the underbody for any indication of grease splatter in the vicinity of the front wheel
driveshaft CV joint boots outboard and inboard
locations, which is an indication of front wheel
driveshaft CV joint boot and/or front wheel
driveshaft CV joint boot clamp damage. 3. Inspect for inboard CV joint stub shaft pilot
bearing housing seal leakage at the front wheel
driveshaft CV joint.
4. Make sure front axle wheel hub retainer is the correct prevailing torque type.
5. The silicone front wheel driveshaft CV joint boot will sweat during operation, causing a light film
of grease to show on the outside of the front
wheel driveshaft CV joint boot. This condition
is normal.
NOTE: Halfshafts are not balanced and do not
contribute to rotational vibration.
6. If the concerns remain after the inspection, determine the symptoms and go to the Symptom
Chart. For additional Noise, Vibration and
Harshness (NVH). REFER to Section 100-04
[Noise, Vibration and Harshness] .
Symptom Chart
Action
Possible Sources
Symptom
• INSPECT, CLEAN andLUBRICATE as necessary.
• Inadequate or contaminated
lube in outboard/inboard front
wheel driveshaft CV joint.
• Clicking, Popping or Grinding
Noises While Turning
• INSPECT and REPAIR asnecessary.
• Another component contacting
driveshaft assembly.
• INSPECT and REPAIR asnecessary. REFER to
Section 204-00 [Suspension
System - General Information]
/ 206-00 [Brake System -
General Information] /211-00
[Steering System - General
Information] .
• Wheel bearings, brakes,
suspension or steering
components.
• REPAIR or INSTALL new asnecessary. REFER to
Section 204-04 [Wheels and
Tires] .
• Out of balance front wheels or
tires.
• Vibration at Highway Speeds
• REPAIR or INSTALL new asnecessary. REFER to
Section 204-04 [Wheels and
Tires] .
• Out-of-round tires.
• REPAIR or INSTALL new asnecessary.
REFER to Halfshaft Disas-
semblv and Assembly in this
section.
• Incorrectly seated outboard
front wheel driveshaft CV joint
in front wheel hub.
G17442en2008.50 Kuga8/2011
205-04- 3
Front Drive Halfshafts
205-04- 3
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• CHECK ride height, VERIFYcorrect spring rate and CHECK
items under Halfshaft Joint
Pullout. REPAIR or INSTALL
new as necessary.
• Excessively high CV joint oper-
ating angles caused by incor-
rect ride height.
• Shudder Vibration During
Acceleration.
• INSPECT and INSTALL newas necessary.
• Excessively worn or damaged
inboard front wheel driveshaft
joint or outboard front wheel
driveshaft joint.
• INSPECT and REPAIR orINSTALL new as necessary.
• Inboard driveshaft bearing
retainer circlip missing or not
correctly seated in differential
side gear.
• Halfshaft Joint Pullout
• CHECK engine mounts fordamage or wear. REPAIR or
INSTALL new as necessary.
• Engine/transaxle assembly
mispositioned.
• CHECK underbody dimensions.REFER to REFER to
Section 501-00 [Body System
-General Information] .
• Frame rail or strut tower out of
position or damaged.
• CHECK for worn bushings orbent components (front stabil-
izer bar, front suspension lower
arm). REPAIR or INSTALL new
as necessary.
• Front suspension components
worn or damaged.
G17442en2008.50 Kuga8/2011
205-04- 4
Front Drive Halfshafts
205-04- 4
DIAGNOSIS AND TESTING
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Front Halfshaft LH(14 320 0)
Special Tool(s) / General Equipment204-159
Lever, Wheel Knuckle
14039
204-602
Installer, Halfshaft
E62067
204-605
Separator, Lower Arm Ball
Joint
E63772
204-609
Protection Cap, Ball Joint
Gaiter
E75372
205-071-01
Adapter for 205-071 (Thrust
Pad)
15026A01
205-775
Protector, Halfshaft Seal
E47098
Special Tool(s) / General Equipment211-020
Separator, Ball Joint
13006
308-782
Remover, Driveline
E115823
Puller
Tire Lever
Removal
1. NOTE:This step is only necessary when
installing a new component.
E99184
G1076961en2008.50 Kuga8/2011
205-04- 5
Front Drive Halfshafts
205-04- 5
REMOVAL AND INSTALLATION
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Vehicles with 6-speed manual transaxle
(MMT6)
17. WARNING: Be prepared to collectescaping fluid.
1. General Equipment: Tire Lever
2. Install the Special Tool(s): 205-775
1
205-7752
1
205-7752
E132274
Vehicles with 6-speed manual transmission
(M66)
18. WARNING: Be prepared to collectescaping fluid.
1. Install the Special Tool(s): 308-782
2. General Equipment: Tire Lever
3. Remove the Special Tool(s): 308-782
4. Install the Special Tool(s): 205-775
2
205-7754
308-7823
308-782
1
2
205-7754
308-7823
308-782
1
E132306
G1076961en2008.50 Kuga8/2011
205-04- 9
Front Drive Halfshafts
205-04- 9
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Front Halfshaft RH — LHD 4WD/RHD 4WD(14 321 0)
Special Tool(s) / General Equipment204-159
Lever, Wheel Knuckle
14039
204-602
Installer, Halfshaft
E62067
204-605
Separator, Lower Arm Ball
Joint
E63772
204-609
Protection Cap, Ball Joint
Gaiter
E75372
205-071-01
Adapter for 205-071 (Thrust
Pad)
15026A01
211-020
Separator, Ball Joint
13006
Puller
Removal
1. NOTE:This step is only necessary when
installing a new component.
E99184
2. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3. NOTE: This step is only necessary when
installing a new component.
E102112
G1076962en2008.50 Kuga8/2011
205-04- 16
Front Drive Halfshafts
205-04- 16
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Vehicles with 2.5L engine
18.
x2x2
E132332
All vehicles
19. WARNING: Be prepared to collectescaping fluid.
CAUTIONS:
The inner constant velocity (CV) joint
must not be bent more than 18°.
The outer constant velocity (CV) joint
must not be bent more than 45°.
Special Tool(s): 204-159, 204-605
90
204-159
3
4
1
204-605
2
90
204-159
3
4
1
204-605
2
E132335
20. N O T E : This step is only necessary when
installing a new component.
Special Tool(s): 205-071-01
General Equipment: Puller
G1076962en2008.50 Kuga8/2011
205-04- 20
Front Drive Halfshafts
205-04- 20
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL