egr FORD KUGA 2011 1.G Manual PDF

307-01-29
Automatic transmission, selector lever in position "D". ...................................................
307-01-29
Sport mode, selector lever in position "S" .......................................................................
307-01-29
Changing gear in select-shift mode........................................................................\
........
307-01-30
Selector lever from 'N' to 'R' position ........................................................................\
......
307-01-30
Self-test and Diagnosis ........................................................................\
...........................
307-01-30
Temperature controlled torque converter lockup ............................................................
307-01-30
Slip locking ........................................................................\
..............................................
307-01-30
Hill climbing ........................................................................\
.............................................
307-01-31
Downhill driving ........................................................................\
.......................................
307-01-31
Hill-hold function ........................................................................\
.....................................
307-01-31
Altitude correction ........................................................................\
...................................
307-01-31
Selector lever lock ........................................................................\
..................................
307-01-31
Shifting from P into another transmission range .............................................................
307-01-31
Shifting from N into another transmission range .............................................................
307-01-31
Power flow through the transmission ........................................................................\
......
307-01-31
Clutches and brakes ........................................................................\
...............................
307-01-33
Position P (park) ........................................................................\
.....................................
307-01-34
Position N (neutral) ........................................................................\
.................................
307-01-35
Position D, 1st gear........................................................................\
................................
307-01-36
Position D, 2nd gear ........................................................................\
...............................
307-01-37
Position D, 3rd gear ........................................................................\
................................
307-01-38
Position D, 4th gear ........................................................................\
................................
307-01-39
Position D, 5th gear ........................................................................\
................................
307-01-40
Position R (reverse) ........................................................................\
................................
307-01-41
Service instructions ........................................................................\
.................................
307-01-41
Towing procedure ........................................................................\
...................................
307-01-42
Reset adaptation data ........................................................................\
.............................
307-01-42
Limp home mode ........................................................................\
....................................
307-01-42
Component Description ........................................................................\
..............................
Tasks of the electronic components ........................................................................\
........
307-01-44
Input signals ........................................................................\
............................................
307-01-45
Output signals ........................................................................\
.........................................
Control valve assembly ........................................................................\
...........................
Shift solenoids S1 - S5 ........................................................................\
...........................
PWM-

solenoid valve – TCC (SLU) ........................................................................\
........
PWM solenoid valve – shift pressure (SLS) ...................................................................
PWM solenoid valve for main line pressure (SLT) ..........................................................
307-01-52
Installation position ........................................................................\
.................................
Operation ........................................................................\
................................................
Selector lever with integrated select-shift switch module ...............................................
Oil pump ........................................................................\
..................................................
Torque converter with TCC ........................................................................\
.....................
The TSS sensor ........................................................................\
......................................
The OSS sensor ........................................................................\
.....................................
The TFT sensor ........................................................................\
......................................
The TR sensor ........................................................................\
........................................
GENERAL PROCEDURES
T ransmission Fluid Level Check ........................................................................\
.................
307-01-63
T ransmission Fluid Drain and Refill ........................................................................\
............
REMOVAL AND INSTALLATION 307-01-67
Halfshaft Seal LH ........................................................................\
........................................
307-01-68
Halfshaft Seal RH........................................................................\
.......................................
307-01-69
Main Control Valve Body ........................................................................\
............................
307-01-2
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 2
.
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307-01-42
307-01-49
307-01-52 307-01-47
307-01-45
307-01-50
307-01-51
307-01-53
307-01-55
307-01-54
307-01-56
307-01-57
307-01-58
307-01-61 307-01-60
PAGE 2 OF 3 FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

E112323
1
2
7
6
4
5
3
10
9
11
12
Description
Item
The TSS sensor
1
The OSS sensor
2
PWM (pulse width modulation)- solenoid
valve – TCC (torque converter clutch)
(SLU)
3
PWM solenoid valve – shift pressure (SLS)
4
Shift solenoid S1
5
Shift solenoid S4
6Description
Item
Shift solenoid S3
7
Shift solenoid S5
8
Shift solenoid S2
9
The TFT (transmission fluid temperature)
sensor
10
PWM solenoid valve for main line pressure
(SLT)
11
TCM with integrated TR sensor
12
Depending on the input signals, the TCM mounted
on the transaxle actuates the solenoid valves
S1-S5 in the valve body. The solenoid valves are
either in the "open" or "closed" state.
The (SLT and SLS) control valves regulate the
hydraulic pressure according to the pulse/pause
ratio of the electrical PWM signal. The controlled
hydraulic pressure enables smooth shifting or the
generation of a defined slip through actuation of
the relevant clutches and brakes. The shift timing is calculated by the TCM using the
accelerator pedal position and vehicle speed.
Under normal conditions, gear shifting and torque
converter lockup occur at low engine speeds to
reduce fuel consumption.
If the accelerator pedal is pressed down quickly,
the TCM switches automatically into kickdown
mode.
G1163604en2008.50 Kuga8/2011
307-01-
10
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 10
DESCRIPTION AND OPERATION
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Description
Item
Brake B5: Locks the rear planetary gear
carrier on the output shaft.
11Description
Item
Output shaft – transaxle
12
Input shaft – transaxle
13
Function of the clutches and brakes in the gears and during gear changes.
F2
F1
B5
B4
B3
B2
B1
C3
C2
C1
Gear
Off
Off
On
Off
Off
Off
Off
Off
Off
Off
Park
Off
Off
On
Off
On
Off
Off
Off
On
Off
R
(V<=7)
Off
Off
On
Off
Off
Off
Off
Off
Off
Off
R
(V>7)
Off
Off
On
Off
Off
Off
Off
Off
Off
Off
N
On
Off
On
Off
Off
Off
Off
Off
Off
On
1
On-Off
Off-On
On
Off
Off
Off-On
Off-On
Off
Off
On
1<=>2
Off
On
On
Off
Off
On
On
Off
Off
On
2
Off
On
On-Off
Off-On
Off
On
On
Off
Off
On
2<=>3
Off
On
Of

f
On
Off
On
On
Off
Off
On
3
Off
On
Off
On-Off
Off
On
On
Off-On
Off
On
3<=>4
Off
On
Off
Off
Off
On
On
On
Off
On
4
Off
On-Off
Off
Off
Off
On
On-Off
On
Off-On
On
4<=>5
Off
Off
Off
Off
Off
On
Off
On
On
On
5
V = vehicle speed in km/h
x<=>x = gear change up/down
TCM
E112322
The TCM with integral TR sensor is mounted on
the transaxle casing.
Input and output signals at the TCM
G1163604en2008.50 Kuga8/2011
307-01- 12
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 12
DESCRIPTION AND OPERATION
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Description
Item
ABS (anti-lock brake system)
5
Speed control
6
Select-shift switch module
7
PCM
8
Selector lever lock
9
PWM solenoid valve – shift pressure (SLS)
10
PWM solenoid valve for main line pressure
(SLT)
11
PWM- solenoid valve – TCC (SLU)
12Description
Item
Shift solenoid S1 (open when dormant)
13
Shift solenoid S2 (closed when dormant)
14
Shift solenoid S3 (closed when dormant)
15
Shift solenoid S4 (open when dormant)
16
Shift solenoid S5 (closed when dormant)
17
The TSS sensor
18
The OSS sensor
19
The TFT sensor
20
TR sensor in TCM
21
Knowing and Understanding Customer
Concerns
Knowing and understanding customer concerns is
necessary in order to perform diagnosis.
First of all, ask the customer under which operating
conditions the problem occurs. If possible, try to
reproduce the concern by road testing the vehicle
with the customer.
You should be familiar with the following operating
conditions:
• Engine operating state
– Cold, warm-up phase, or at operatingtemperature
• Ambient temperature – Below 0 °C (32 °F), 0 to 20 °C (32 to 68 °F),or above 20 °C (68 °F)
• Road conditions – Good, poor, or off-road
• Vehicle load status – Unloaded, loaded, or fully loaded
• Transaxle status in manual mode – Upshift, downshift, overrun or acceleration
Testing Possible Causes of Transmission
Control Faults
Before performing a symptom-based diagnosis,
first carry out checks to eliminate various other
potential causes of the fault.
These situations include:
• Battery state of charge
• Defective fuses • Loose or corroded cables or electrical
connectors
• Ground connections to the transmission
• Retrofitted add-on units which are not approved by Ford, such as air conditioning, car telephone,
cruise control
• Unapproved tire sizes
• Incorrect tire size programmed with IDS (Integrated Diagnostic System)
• Engine tuning
IDS Diagnosis
NOTE: Customer concerns relating to the transaxle
can also be caused by engine-related faults.
The transmission control system of the AW55 is
closely linked to the engine management system.
Faults in the engine management system may
affect the transmission control system.
Before repairing the transaxle, it should be ensured
that the fault is not caused by the engine
management system or other non-transaxle
components.
The diagnosis can be performed on the AW55 with
the aid of von IDS.
visual inspection
A thorough visual inspection of the transaxle is
necessary for successful diagnosis.
A visual inspection is made of the following
components:
• Connectors and plug connections
• Ease of operation of the selector lever
G1163604en2008.50 Kuga8/2011
307-01- 14
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 14
DESCRIPTION AND OPERATION
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E77584
NOTE:Due to static charging, measurements
inside the transaxle using a multimeter are
prohibited.
Stored DTCs in the engine management system
may affect transmission control. As a result, faults
in the transmission control system and engine
management system must be rectified in
accordance with the symptom-based diagnosis in
FordEtis IDS.
Applications of IDS Standard include:
• Resetting the counter for fluid change intervals.
• Programming the selector lever position 'N'.
• Resetting the values learned by the TCM.
Resetting the counter for fluid change
intervals.
This function must be performed if the transmission
fluid has been changed or a new automatic
transaxle has been installed with the previous TCM.
This function resets the values stored for the
pollution level of the transmission fluid.
Programming the 'N' position of the TR
sensor
This function must be executed if
• the TCM with integrated TR sensor is renewed,
• a new automatic transaxle is installed with the previous TCM.
• the selector lever cable or the selector mechanism assembly is renewed
• TR have been set due to a fault in the selector lever assembly or in the DTC (diagnostic trouble
code) sensor.
The TCM learns and stores the voltage value in
the 'N' position when this function is executed.
Resetting the values learned by the TCM
This function must be executed if
• a new automatic transaxle is installed with the previous TCM.
• a component of the automatic transaxle has been renewed.
G1163604en2008.50 Kuga8/2011
307-01- 19
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 19
DESCRIPTION AND OPERATION
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Description
Item
The TR sensor
3
The TSS sensor
4
The TFT sensor
5
TCM6Description
Item
OSS (output shaft speed) sensor
7
Solenoid valves in valve body
8
Clutches and brakes
9
TCC
10
The function is divided into an electronic and a
hydraulic control system.
Electronic Control System
Depending on the input signals, the TCM mounted
on the transmission actuates the solenoid valves
in the valve body. The TCM calculates and stores
adaptive data, fault codes and values for diagnosis.
The TR sensor is integrated in the TCM.
Hydraulic Control System
When the engine is running, a fluid pump integrated
in the transaxle housing generates the hydraulic pressure required for controlling the automatic
transaxle.
Through actuation of the solenoid valves, hydraulic
pressure is applied to the clutches and brakes via
hydraulic channels in the valve body and the
transaxle. The control valves regulate the hydraulic
pressure in accordance with the duty cycle of the
electrical PWM signal. The controlled hydraulic
pressure enables smooth shifting or the generation
of a defined slip through actuation of the relevant
clutches and brakes.
Solenoid valves are either in the 'open' or 'closed'
state.Type plate
E125523
The transaxle identification is located on the
rear/top of the transaxle housing in the direction of
travel.
G1163605en2008.50 Kuga8/2011
307-01-
24
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 24
DESCRIPTION AND OPERATION
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Serial number of the transmission
Example:09HV70001
• 09: year of manufacture, 2009 •
H: code letter for the month of manufacture,
August
• V7: automatic transaxle type 55-51SN
• 00001 : Production number for the specified
month
Identification letter coding
January
A
February
B
March
C
April
D
May
E
June
F
July
G
August
H.
September
J
October
K
November
left-hand
December
Ground
Markings on the TCM
E125774
The name plate is located on the TCM.
Serial number of the TCM
Example: 082200001
• 08: year of manufacture, 2008
• 22: code for the calendar week
• 00001 : Production number for the specified
calendar week
Transmission Control
Depending on the input signals, the TCM mounted
on the transmission actuates the solenoid valves
in the valve body. The TCM calculates and stores
adaptive data, fault codes and values for diagnosis.
The TR sensor is integrated in the TCM.
G1163605en2008.50 Kuga8/2011
307-01- 25
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 25
DESCRIPTION AND OPERATION
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00.2 1.0 0.80.60.4
0
0.2 1.0
0.80.60.40
0.2 1.0 0.80.60.40
0.2 1.0 0.80.60.4
E125990
1
2
Description
Item
Hydraulic pressure
1
Average current (A)
2
The PWM solenoid valve for main line pressure
(SLT) is actuated proportionally by the TCM.
The TCM evaluates the accelerator pedal position
and the current engine torque.
The main line pressure is adapted proportionally
by the TCM via the PWM solenoid valve. This
measure enables judder-free gearshifts.
The PWM solenoid valve is open when
de-energized. In the case of faults and failure of
the control system, the PWM solenoid valve
remains fully open. The maximum main line
pressure is applied.
Consequences of signal failure
E125992
2
1
Description
Item
PWM solenoid valve for main line pressure
(SLT)
1
TCM connector 'C'
2
The system pressure increases to the maximum
value in the event of interruptions, which leads to
hard gearshifts when shifting to another gear. The
valve is then fully open.
If the PWM solenoid valve – main line pressure
(SLT) fails, the MIL is activated and the vehicle can
be driven in emergency mode 1.
TCC
Installation position
The TCC is an integral component of the torque
converter.
Operation
The TCM controls the PWM via the TCC solenoid
valve for the TCC (SLU). Based on the signals for
engine speed and accelerator pedal position as
G1163605en2008.50 Kuga8/2011
307-01- 52
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 52
DESCRIPTION AND OPERATION
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well as vehicle speed, driving comfort is improved
by linear actuation of the TCC.
Selector lever with integrated select-shift
switch module
E112332
The selector lever unit is located in the central
console. It is mechanically connected to the
transmission by a selector cable which moves the
gear selector shaft in the TR sensor.
The following components are integrated in the
selector lever assembly:
• Select-shift switch module
• Selector lever lock solenoid.
• Switch contact for selector lever position 'P'
• LED for the selector lever position display
The selector lever has the following positions:
• P: Park position
• R: Reverse gear.
• N: Neutral position
• D: Automatically shift between all gears
• S: Sport and select-shift mode (manual gearchanging)
If the selector lever is not in the 'P' position when
the vehicle is exited, a signal is transmitted to the
instrument cluster via the switch contact for selector
lever position 'P'. When the driver door is opened,
a message to move the selector lever to the 'P'
position appears in the instrument cluster and the
warning buzzer sounds. The vehicle cannot be
electrically locked if the selector lever is not moved
to the 'P' position.
G1163605en2008.50 Kuga8/2011
307-01- 53
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 53
DESCRIPTION AND OPERATION
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Overview of the select-shift switch module
E112331
The select-shift switch module is located on the
upper trim of the selector lever unit. The module
is supplied with power by the TCM.
It uses the LIN databus to interact with the TCM,
for instance to activate the selector lever position
display.
It allows the automatic transmission gears to be
changed up and down manually via the signals of
the Hall sensors.
The select-shift switch module detects the selector
lever position 'P' and 'S' via the integrated selector
lever position sensors (Hall sensors).
A cable leading from the TCM passes directly to
the select-shift switch module and is used to control
the solenoid of the selector lever lock. The
switching solenoid receives its voltage supply
directly from the module.
In the event of a fault, a signal is transmitted to the
TCM where all DTCs are stored.
Oil pump
E68097
1
2
3
45
Description
Item
Fluid pump rotor, outer
1
Fluid pump rotor, inner
2
G1163605en2008.50 Kuga8/2011
307-01- 54
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 54
DESCRIPTION AND OPERATION
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