fluid FORD KUGA 2011 1.G Repair Manual

7.Torque: 25Nm
x2
x2
x2
x2
x2
x2
E114188
8.Torque:
• Stage 1: 35
Nm
• Stage 2: Loosen 360°
• Stage 3: 85Nm
E114034
9.Refer to: Differential Fluid Level Check (205-02
Rear Drive Axle/Differential, General
Procedures).
10.
E98543
x7
11 . Lower the vehicle.
G1076972en2008.50 Kuga8/2011
205-02- 37
Rear Drive Axle/Differential
205-02- 37
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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

2.Special Tool(s): 303-395
303-395303-395
E102538
3.Refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).
4. Refer to: Differential Fluid Level Check (205-02
Rear Drive Axle/Differential, General
Procedures).
G1080736en2008.50 Kuga8/2011
205-02- 40
Rear Drive Axle/Differential
205-02- 40
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

1.Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
3.
E114257
4. WARNING: Be prepared to collect escaping fluid.
E124748
5.
E124778
6. WARNING: Be prepared to collectescaping fluid.
x2x2
E124749
7.
E128365
G1268328en2008.50 Kuga8/2011
205-02- 43
Rear Drive Axle/Differential
205-02- 43
DISASSEMBLY AND ASSEMBLY
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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

32.Torque: 6Nm
E124748
33.
E114257
34.Refer to: Active On-Demand Coupling Fluid
Level Check (205-02 Rear Drive
Axle/Differential, General Procedures).
35. Lower the vehicle.
G1268328en2008.50 Kuga8/2011
205-02- 50
Rear Drive Axle/Differential
205-02- 50
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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
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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

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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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL