all FORD KUGA 2011 1.G Workshop Manual

Drive Pinion Seal
Special Tool(s)303-293
Remover, Crankshaft Seal
21143
Special Tool(s)308-643
Installer, Input Shaft Seal
E65343
Removal
1.Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2. Refer to: Active On-Demand Coupling Module
(205-02 Rear Drive Axle/Differential, Removal
and Installation).
3. Special Tool(s): 303-293
303-293
303-293
303-293
303-293
E102546
Installation
1. CAUTION: Take extra care not to
damage the seal.
Special Tool(s): 308-643
308-643308-643
E102547
2.Refer to: Active On-Demand Coupling Module
(205-02 Rear Drive Axle/Differential, Removal
and Installation).
G1357281en2008.50 Kuga8/2011
205-02- 41
Rear Drive Axle/Differential
205-02- 41
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

20.Special Tool(s): 205-072, 303-249
Torque: 150
Nm
205-072
303-249
205-072
303-249
E102500
21. CAUTION: Make sure that the
installation marks are aligned.
1. Torque: 35Nm
2. Torque: 35Nm
3. Torque: 35Nm
3
x2
1
2
2
x3
13
x2
1
2
2
x3
1
E114197
22.
E114296
23.
20 mm1
2
20 mm1
2
E114377
G1268328en2008.50 Kuga8/2011
205-02- 47
Rear Drive Axle/Differential
205-02- 47
DISASSEMBLY AND ASSEMBLY
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24. CAUTION: Make sure that theinstallation marks are aligned.
1. Torque: 35Nm
2. Torque: 35Nm
3. Torque: 35Nm
3
x2
2
1
2
1
x3
3
x2
2
1
2
1
x3
E101042
25.Torque: 25Nm
x2
x2
x2
x2
x2
x2
E114188
G1268328en2008.50 Kuga8/2011
205-02- 48
Rear Drive Axle/Differential
205-02- 48
DISASSEMBLY AND ASSEMBLY
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

26.Torque:
• Stage 1: 35
Nm
• Stage 2: Loosen 360°
• Stage 3: 85Nm
E114375
27.
E98543
x7
28. N O T E : Make sure that a new component is
installed.
1.
2. Material: Transmission Oil AWD
(8U7J-8708687-AA) transmission fluid
2
1
2
1
E124780
29.
E128367
30.Torque: 6Nm
x2x2
E124749
31.Material: Transmission Oil AWD
(8U7J-8708687-AA) transmission fluid
E124750
G1268328en2008.50 Kuga8/2011
205-02- 49
Rear Drive Axle/Differential
205-02- 49
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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.
E99269
4.
E101039
5. WARNING: Make sure that no load is placed on the brake hose.
E100801
G1076961en2008.50 Kuga8/2011
205-04- 6
Front Drive Halfshafts
205-04- 6
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

6.
E67589
7.
E132305
8.If equipped.
E125279
9. CAUTION: Make sure that the ball joint
ball does not rotate.
E99197
10.Special Tool(s): 211-020
E99198
211-020
11 .
E97635
G1076961en2008.50 Kuga8/2011
205-04- 7
Front Drive Halfshafts
205-04- 7
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL