ECT FORD KUGA 2011 1.G Workshop Manual

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
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307-05-
11
Automatic Transmission/Transaxle External
Controls
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450
307-05-11
.

6.
E114521
7.
E114522
Installation
CAUTION: Gearshift cables must not be
kinked or bent.
1. Install all components in reverse order.
2. 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).
G1163687en2008.50 Kuga8/2011
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
307-05-
12
Automatic Transmission/Transaxle External
Controls
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450
307-05-12
.

SECTION 307-07 Transfer Case— Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle - 6DCT450
VEHICLE APPLICATION: 2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
307-07-2
Specifications ........................................................................\
..............................................
DESCRIPTION AND OPERATION 307-07-3
Transfer Case (Component Location) ........................................................................\
........
307-07-8
Transfer Case (System Operation and Component Description) .......................................
307-07-8
System Operation ........................................................................\
.......................................
GENERAL PROCEDURES 307-07-9
Transfer Case Fluid Level Check ........................................................................\
...............
REMOVAL AND INSTALLATION 307-07-10
Transfer Case Connecting Sleeve ........................................................................\
..............
307-07-13
Transfer Case Connecting Sleeve Seals — Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD........................................................................\
............................................. 307-07-14
Transfer Case Rear Seal ........................................................................\
............................
307-07-15
Transfer Case Seal LH........................................................................\
...............................
307-07-17
Transfer Case Seal RH ........................................................................\
...............................
REMOVAL 307-07-18
Transfer Case ........................................................................\
.............................................
INSTALLATION 307-07-19
Transfer Case ........................................................................\
.............................................
307-07-1
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 1
.
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transfer box
1
23
E115223
Description
Item
Transfer box
1
Heat deflector
2
Bracket, transfer box to engine
3
G1164985en2008.50 Kuga8/2011
307-07- 4
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 4
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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

Transfer Case Fluid Level Check
MaterialsSpecification
Name
8U7J-19G518-BA
Rear Axle Oil SAE 75W-
90
Inspection
1. Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2.
E139436
3. Material: Rear Axle Oil SAE 75W-90
(8U7J-19G518-BA) transmission fluid
•
• Correct the rear axle oil level if neccessary.
• 20ml~1mm
0mm0mm
E114595
4. NOTE:
Make sure that a new component is
installed.
Torque: 34
Nm
E139434
G1164988en2008.50 Kuga8/2011
307-07- 9
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 9
GENERAL PROCEDURES
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Transfer Case Connecting Sleeve
Special Tool(s) / General Equipment308-784
Installer, Halfshaft Seal
E115803
Special Tool(s) / General Equipment308-785
Installer, Halfshaft Seal
E115804
Copper Hammer
Flat-bladed screwdriver
Hot Air Gun
Puller
Punch
Removal
G1164990en2008.50 Kuga8/2011
307-07-10
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 10
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transfer Case Connecting Sleeve Seals — Vehicles With: 5-SpeedAutomatic Transaxle - AW55 AWD
Removal
1.Refer to: Transfer Case Connecting Sleeve
(307-07 Transfer Case - Vehicles With:
5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle -
6DCT450, Removal and Installation).
Installation
1. To install, reverse the removal procedure.
G1164991en2008.50 Kuga8/2011
307-07- 13
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 13
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transfer Case Seal LH
Special Tool(s)204-351
Installer, Pivot Bushing
E45281
Special Tool(s)303-293
Remover, Crankshaft Seal
21143
308-788
Protector, Transfer Case Seal
E115807
Removal
G1164993en2008.50 Kuga8/2011
307-07-15
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 15
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL