Torque FORD KUGA 2011 1.G Manual Online

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
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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
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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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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
SPECIFICATIONS
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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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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

21.
E132268
22. N O T E :This step is only necessary when
installing a new component.
Special Tool(s): 205-071-01
General Equipment: Puller
205-071-01205-071-01
E132270
Installation
1. NOTE: This step is only necessary when
installing a new component.
Special Tool(s): 204-602
Torque: 45
Nm
G1076961en2008.50 Kuga8/2011
205-04- 11
Front Drive Halfshafts
205-04- 11
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3
4
1
204-605
204-159
90
2
205-775
2
50
6
5
3
4
1
204-605
204-159
90
2
205-775
2
50
6
5
E132304
4.Torque: 90Nm
E99255
5.Special Tool(s): 204-605
E97732
204-605
6.Remove the Special Tool(s): 204-609
E81908
204-609
G1076961en2008.50 Kuga8/2011
205-04- 13
Front Drive Halfshafts
205-04- 13
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

7.
E132381
8.Torque: 83Nm
E97635
9. WARNING: Make sure that a new nut is
installed.
CAUTION: Make sure that the ball joint
ball does not rotate.
Torque: 80
Nm
E99197
10. N O T E : This step is only necessary when
installing a new component. NOTE:
Only tighten the nut finger tight at this
stage.
E132273
11 . If equipped.
Torque: 8
Nm
E125279
12.Torque: 5Nm
E132305
G1076961en2008.50 Kuga8/2011
205-04- 14
Front Drive Halfshafts
205-04- 14
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13.
E67589
14.Torque: 120Nm
x2x2
E132307
15.
E101039
16.
17.If equipped.
E98543
x7
18.Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
19. Lower the Vehicle.
20. N O T E : This step is only necessary when
installing a new component.
Torque: 270
Nm
E99195
G1076961en2008.50 Kuga8/2011
205-04- 15
Front Drive Halfshafts
205-04- 15
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL