AIR CON FORD KUGA 2011 1.G Workshop Manual

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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1
2
3
4
E115887
Description
Item
Fluid filter
1
All-wheel drive control unit
2Description
Item
Electric feed pump
3
Pressure accumulator
4
The electric feed pump is an axial piston pump
which is more robustly designed than the gerotor
pump in the 3rd generation Haldex. The higher
feed pressure means that the ring piston pump at
the clutch plate assembly, the pressure relief
valves, preload valve and the high pressure valves
are no longer necessary.
The pressure accumulator on the 4th generation
Haldex is larger and is designed for the higher
pressure. The 4th generation Haldex has a larger fluid filter
which contains a non-return valve.
The all-wheel drive control unit no longer contains
a pressure sensor in the 4th generation Haldex.
Pressure control - 4th generation Haldex
clutch
G1076981en2008.50 Kuga8/2011
205-02-
15
Rear Drive Axle/Differential
205-02- 15
DESCRIPTION AND OPERATION
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6
7
8
9
10
11
1
2
3
4
5
6
7
8
9
10
11
E114914
Description
Item
Haldex clutch fluid
1
Inlet filter
2
Electric feed pump
3
Filters4
Pressure accumulator
5Description
Item
Control valve
6
Dished washer
7
Ring piston
8
Clutch plate pack
9
Return pressure accumulator
10
Return control valve
11
Full torque is available at any time on the 4th
generation Haldex clutch because the pressure is
not dependent on the difference in the speeds of
rotation. This is used for instance to activate the
Haldex clutch for better traction when moving off.
On the 4th generation Haldex clutch, the preload
function which applied 80 Nm to the plates in the
3rd generation is no longer required.
On request from the control unit and at engine
speeds above 400 rpm, the electric feed pump runs
and maintains the storage pressure at about 30
bar.
A pressure reducing valve acts as a control valve,
allowing the all-wheel drive control unit to control
the pressure with much greater precision. The
all-wheel drive control unit monitors the position and function of the control valve. The control valve
distributes the pressure, depending on the
requirements, across its three outlet openings
(storage pressure, working pressure, return).
From the storage pressure (30 bar) and depending
on the requirements, the control valve regulates a
working pressure of 0 - 17 bar, which is applied to
the ring piston. At 17 bar working pressure, the
maximum torque of 1000 Nm is transferred to the
rear wheels. The all-wheel drive control unit
ensures the best possible performance under all
driving conditions, for all road conditions and
independent of the speed.
G1076981en2008.50 Kuga8/2011
205-02-
16
Rear Drive Axle/Differential
205-02- 16
DESCRIPTION AND OPERATION
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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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Lubricants, Fluids, Sealers and Adhesives
Specifications
WSS-M1C 259-A1
Outer Constant Velocity Joint
Grease
Specifications
WSS-M1C 259-A1
Inner Constant Velocity Joint Grease
Capacity
Driveshaft Joint Grease Fill Capacity
Description
Outer (Grams)
Inner (Grams)
180
160
2.0 L Duratorq
2.5 L Duratec
Torque Specifications
lb-in
lb-ft
Nm
Item
-
35
48
2.0 L Duratorq - Intermediate shaft center bearing
bracket to engine block bolts - 2WD (M10x 30)
35
48
2.0 L Duratorq - Intermediate shaft center bearing
bracket to engine block bolts - 4WD (M10x 30)
-
44
60
2.0 L Duratorq - Intermediate shaft center bearing
bracket to engine block bolt - 4WD (M10x 40)
-
35
48
2.5 L Duratec - Intermediate shaft center bearing
bracket to engine block bolts - 4WD (M10x 30)
-
44
60
2.5 L Duratec - Intermediate shaft center bearing
bracket to engine block bolt - 4WD (M10x 40)
G1081400en2008.50 Kuga8/2011
205-04- 2
Front Drive Halfshafts
205-04- 2
SPECIFICATIONS
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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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Vehicles with automatic transaxle
19.General Equipment: Tire Lever
E132267
All vehicles
20. 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
2
204-605
90
204-159
3
4
1
2
204-605
E132272
G1076961en2008.50 Kuga8/2011
205-04- 10
Front Drive Halfshafts
205-04- 10
REMOVAL AND INSTALLATION
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204-602204-602
E132271
2. NOTE:Make sure that a new component is
installed.
E132269
3. 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°.
1. Special Tool(s): 204-605
4. Special Tool(s): 204-159
5. Remove the Special Tool(s): 205-775
G1076961en2008.50 Kuga8/2011
205-04- 12
Front Drive Halfshafts
205-04- 12
REMOVAL AND INSTALLATION
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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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204-602204-602
E132271
2. 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
G1076962en2008.50 Kuga8/2011
205-04- 22
Front Drive Halfshafts
205-04- 22
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL