Torque FORD KUGA 2011 1.G Workshop Manual

26.Material: Grease KS-PS (SA-M1C9107-A /
YS5J-M1C9107-AA) grease
1.
2.
NOTE: Make sure that a new component is
installed.
3. Torque: 48
Nm
x2
2
3
1
x2
2
3
1
E114732
27. Remove the following items:
1. General Equipment: Cable Ties
E98634
28. Torque: 10Nm
x2x2
E114617
29.Lower the vehicle.
30. N O T E : Install all the bolts finger tight before
final tightening.
Torque: 60
Nm
6
5
3
4
2
1
x6
6
5
3
4
2
1
x6
E124910
G1163646en2008.50 Kuga8/2011
307-01- 97
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 97
INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

31.Torque: 40Nm
E114616
32.Torque: 25
E114612
33.
E114611
34. Torque: 48Nm1.
2. Torque: 9
Nm
G1163646en2008.50 Kuga8/2011
307-01- 98
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 98
INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Nm
1
1
2
E114610
35.
Torque: 25Nm
E114609
36.
E114728
x2

37.Torque: 25Nm
E114606
38.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).
E114436
39. Torque: 48
G1163646en2008.50 Kuga8/2011
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
Nm1.
2. Torque: 25
Nm
3. Torque: 10Nm
E114615
307-01-
99
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 99
INSTALLATION
x2
x41
3
2

40.Torque: 10Nm
E101006
41.Refer to: Battery(414-01 Battery, Mounting and
Cables, Removal and Installation).
42. On both sides.
Torque: 35
Nm
E99147
x3
43.Refer to: Air Cleaner (303-12 Intake Air
Distribution and Filtering - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
44.
E114689
45. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
Refer to: Transmission Fluid Level Check
(307-01 Automatic Transmission/Transaxle -
Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD, General Procedures).
G1163646en2008.50 Kuga8/2011
307-01- 100
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 100
INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

10. CAUTION: Make sure that all openingsare sealed.
E114923
11 .Torque: 15Nm
307-02- 6
Transmission/Transaxle Cooling
— Vehicles With: 5-Speed
Automatic Transaxle - AW55 AWD/6-Speed Automatic Transaxle - 6DCT450
307-02- 6
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
E114918
12.
E114926
Installation
1.
To install, reverse the removal procedure.
2.
G1163667en2008.50 Kuga8/2011
E114925

7.
E114513
8.Lower the Vehicle.
9. Refer to: Floor Console Extension - Vehicles
With: Center Armrest (501-12 Instrument
Panel and Console, Removal and Installation).
10.
E114518
11 . Torque: 25Nm
x4x4
E100949
12.
E114519
13.Torque: 25Nm
x4x4
E114516
14.
x4x4
E101415
G1163686en2008.50 Kuga8/2011
REMOVAL AND INSTALLATION
TO MODEL INDEX
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
307-05-
8
Automatic Transmission/Transaxle External
Controls
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450
307-05-8
.

E114520
16.
E114521
17.
E114522
18.General Equipment: Knife
E114515
19.Torque: 9Nm
E114514
G1163686en2008.50 Kuga8/2011
REMOVAL AND INSTALLATION
307-05- 9
Automatic Transmission/Transaxle External
Controls
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450
307-05-9
.
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
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50 mm
15. Torque: 9Nm
x4

Installation
CAUTION: Gearshift cables must not be
kinked or bent.
1. To install, reverse the removal procedure.
2. Torque: 25
Nm1.
2. Torque: 25
Nm
3. Torque: 30Nm
4. Torque: 25Nm
4
x2
2x2
1
3
x2
4
x2
2x2
1
3
x2
E100960
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).
G1163686en2008.50 Kuga8/2011
REMOVAL AND INSTALLATION
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3.
Refer to: Selector Lever Cable Adjustment -
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
307-05-10
Automatic Transmission/Transaxle External
Controls
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450
307-05-10
.

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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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
307-05-
11
Automatic Transmission/Transaxle External
Controls
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450
307-05-11
.

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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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL