Transmission FORD KUGA 2011 1.G Service Manual

E101688
Vehicles with automatic transmission
4. CAUTION: Make sure that theinstallation marks are aligned.
E114197
All vehicles
5.
20 mm
E114036
6. CAUTION: Make sure that theinstallation marks are aligned.
E101042
Vehicles with manual transmission
3. CAUTION: Make sure that theinstallation marks are aligned.
1. Torque: 35Nm
1. Torque: 35Nm
2. Torque: 35Nm
3. Torque: 35Nm
3
x2
2
1
2
1
x3
G1076972en2008.50 Kuga8/2011
205-02- 36
Rear Drive Axle/Differential
205-02- 36
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
2. Torque: 35Nm
3. Torque: 35Nm
3
x2
1
2
2
1
1. Torque: 35Nm
2. Torque: 35Nm
3. Torque: 35Nm
3
x2
1
2
2
x3
1
1
2

Differential Support Insulator
Special Tool(s)204-598
Hydraulic Cylinder 10t
E75373
204-598-03
Adapter for 204-598
E103784
Special Tool(s)308-762
Remover/Installer, Bush RDU
E102678
Materials
Specification
Name
WSS-M2C200-D2 /
7U7J-M2C200-BA
Transmission Oil 75W
FE
Removal
1.
Refer to: Differential Case (205-02 Rear Drive
Axle/Differential, Removal and Installation).
2. Special Tool(s): 204-598, 204-598-03, 308-762
308-762
204-598
204-598-03
308-762
204-598
204-598-03
E102574
Installation
1.Special Tool(s): 204-598, 204-598-03, 308-762
Material: Transmission Oil 75W FE
(WSS-M2C200-D2 / 7U7J-M2C200-BA)
transmission fluid
308-762
204-598
204-598-03
308-762
204-598
204-598-03
E102575
2. Refer to: Differential Case (205-02 Rear Drive
Axle/Differential, Removal and Installation).
G1076973en2008.50 Kuga8/2011
205-02- 38
Rear Drive Axle/Differential
205-02- 38
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Active On-Demand Coupling — Vehicles With: 5-Speed AutomaticTransaxle - AW55 AWD/6-Speed Automatic Transaxle -
6DCT450
Special Tool(s) / General Equipment
205-072
Universal Flange Holding
Wrench
15030A
Special Tool(s) / General Equipment303-249
Remover, Crankshaft Timing
Pulley
21132
Puller
Materials
Specification
Name
8U7J-8708687-AA
Transmission Oil AWD
Disassembly
G1268328en2008.50 Kuga8/2011
205-02- 42
Rear Drive Axle/Differential
205-02- 42
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
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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

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
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Inner Constant Velocity (CV) Joint Boot(14 336 0)
Special Tool(s) / General Equipment204-169
Clamping Tool, Boot
Retaining Clamp
14044
308-046
Installer, Transmission
Extension Housing
Bushing/Seal
16016
Flat-bladed screwdriver
Puller
Materials
Specification
Name
WSS-M1C259-A1 /
3M5J-M1C259-AA
Grease FD-R
Removal
1.
Remove the halfshaft.
Refer to: Front Halfshaft LH (205-04 Front Drive
Halfshafts, Removal and Installation).
Refer to: Front Halfshaft RH - LHD 4WD/RHD
4WD (205-04 Front Drive Halfshafts, Removal
and Installation). 2.
Discard the grease.
E105704
3.
E78743
4.General Equipment: Puller
E78744
G1076988en2008.50 Kuga8/2011
205-04- 27
Front Drive Halfshafts
205-04- 27
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Rear Halfshaft
Special Tool(s) / General Equipment308-759
Remover, Rear Driveshaft
E100143
Cable Ties
Special Tool(s) / General EquipmentTire Lever
Transmission Jack
Materials
Specification
Name
WSK-M2G349-A8 /
9U7J-M2G349-AA
Sealant LGN
Removal
1.
On both sides.
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
2. On both sides.
E101661
3.Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
4. WARNING: Make sure that no load is placed on the brake hose.
On both sides.
General Equipment: Cable Ties
E100132
5.On both sides.
Refer to: Spring(204-02 Rear Suspension,
Removal and Installation).
6. On both sides.
x4x4
E101639
7.On both sides.
E101640
G1058429en2008.50 Kuga8/2011
205-05- 2
Rear Drive Halfshafts
205-05- 2
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Installation
1.On both sides.
E101644
2.On both sides.
Torque: 1
15Nm
E101643
3. NOTE: Only tighten the bolt finger tight at this
stage.
On both sides.
E101641
4. Fabricate a spacer.
E69209
226
40
5.On both sides.
General Equipment: Transmission Jack
G1058429en2008.50 Kuga8/2011
205-05- 5
Rear Drive Halfshafts
205-05- 5
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

1
2
E93313
6.On both sides.
Torque: 130
Nm
E101642
7.Remove the following items:
1. Spacer
2. General Equipment: Transmission Jack
8. On both sides.
Torque: 5
Nm
E114252
G1058429en2008.50 Kuga8/2011
205-05- 6
Rear Drive Halfshafts
205-05- 6
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL