Awd FORD KUGA 2011 1.G Workshop Manual

SECTION 205-02 Rear Drive Axle/Differential
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
205-02-2
Rear Drive Axle and Differential (Component Location) .....................................................
205-02-6
Rear Drive Axle and Differential (System Operation and Component Description) ...........
205-02-6
System Operation ........................................................................\
.......................................
205-02-6
General Information ........................................................................\
................................
205-02-6
Driving situations ........................................................................\
....................................
205-02-6
Haldex clutch ........................................................................\
..........................................
205-02-7
General overview ........................................................................\
....................................
205-02-7
Operation ........................................................................\
................................................
205-02-7
Design of the 3rd generation Haldex clutch ....................................................................
205-02-9
Design of the multi-plate clutch ........................................................................\
...............
205-02-10
All-wheel drive control unit ........................................................................\
......................
205-02-10
Electric feed pump ........................................................................\
..................................
205-02-10
Pressure control - 3rd generation Haldex clutch .............................................................
205-02-11
Base pressure ........................................................................\
.........................................
205-02-12
Increased base pressure (preload) ........................................................................\
.........
205-02-13
Pressure build-up ........................................................................\
....................................
205-02-14
Design of the 4th generation Haldex clutch ...................................................................
205-02-14
General overview ........................................................................\
....................................
205-02-15
Pressure control - 4th generation Haldex clutch .............................................................
GENERAL PROCEDURES 205-02-17
Differential Fluid Level Check ........................................................................\
.....................
205-02-19
Active On-Demand Coupling Fluid Level Check ................................................................
REMOVAL AND INSTALLATION 205-02-21
Differential Case ........................................................................\
.........................................
205-02-25
Active On-Demand Coupling Module ........................................................................\
.........
205-02-32
Differential Input Shaft Seal ........................................................................\
........................
205-02-38
Differential Support Insulator ........................................................................\
......................
205-02-39
Rear Halfshaft Seal ........................................................................\
.....................................
205-02-41
Drive Pinion Seal ........................................................................\
........................................
DISASSEMBLY AND ASSEMBLY
205-02-42
Active On-Demand Coupling — Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450 ...............................................................
205-02-1
Rear Drive Axle/Differential
205-02- 1
.
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Active On-Demand Coupling Fluid Level Check
MaterialsSpecification
Name
8U7J-8708687-AA
Transmission Oil AWD
Activation
5. Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
6. NOTE: This component does not have a drain
plug because the fluid does not need to be
drained or changed. 7.
E102723
8.
Material: Transmission Oil AWD
(8U7J-8708687-AA) transmission fluid
•
• Correct the oil level if neccessary.
• 24ml~1mm
5mm5mm
E102724
G1087341en2008.50 Kuga8/2011
205-02-
19
Rear Drive Axle/Differential
205-02- 19
GENERAL PROCEDURES
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Active On-Demand Coupling Module
MaterialsSpecification
Name
8U7J-8708687-AA
Transmission Oil AWD
Removal
All vehicles
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).
Vehicles with 2.0L diesel engine
3.
x2x2
E102531
4.
1
2x6x3
1
2x6x3
E101687
5.
x4
x2
x4
x2
E102544
G1076971en2008.50 Kuga8/2011
205-02- 25
Rear Drive Axle/Differential
205-02- 25
REMOVAL AND INSTALLATION
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All vehicles
14.
E102545
Installation
All vehicles
1.Material: Transmission Oil AWD
(8U7J-8708687-AA) transmission fluid
E102554
Vehicles with 2.0L diesel engine
2. Torque: 25Nm
x4
x2
x4
x2
E102544
G1076971en2008.50 Kuga8/2011
205-02- 28
Rear Drive Axle/Differential
205-02- 28
REMOVAL AND INSTALLATION
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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
DISASSEMBLY AND ASSEMBLY
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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
DISASSEMBLY AND ASSEMBLY
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Crankshaft Rear Seal(21 468 4)
Special Tool(s)303-1181
Installer, Crankshaft Rear
Seal
E62048
303-254
Locking Tool, Flywheel
21135
303-293
Remover, Crankshaft Seal
21143
Removal
Vehicles with manual transmission
1.
Vehicles with automatic transmission
2.Refer to: Transmission (307-01 Automatic
Transmission/Transaxle - Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD,
Removal).
All vehicles
3. Special Tool(s): 303-254
E64889
4.Special Tool(s): 303-293
E64890
303-293
G1268481en2008.50 Kuga8/2011
303-01- 56
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
56
REMOVAL AND INSTALLATION
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Installation
1.Special Tool(s): 303-1181
E64891
303-1181
Vehicles with manual transmission
2. CAUTIONS:
Make sure that new bolts are installed.
Make sure that no excess sealant
residue is evident.
NOTE: Make sure that the locating pin on the
crankshaft is aligned with the guide hole in the
flywheel or flexplate.
Special Tool(s): 303-254
Torque:
• Stage 1: 45
Nm
• Stage 2: 65°
E124911
1
2
3
4
5
67
8
9
10
3.
Vehicles with automatic transmission
4. CAUTIONS:
Make sure that new bolts are installed.
Make sure that no excess sealant
residue is evident. NOTE:
Make sure that the locating pin on the
crankshaft is aligned with the guide hole in the
flywheel or flexplate.
Special Tool(s): 303-254
Torque:
• Stage 1: 45
Nm
• Stage 2: 50°
E124911
1
2
3
4
5
67
8
9
10
5. Refer to: Transmission (307-01 Automatic
Transmission/Transaxle - Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD,
Removal).
G1268481en2008.50 Kuga8/2011
303-01- 57
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
57
REMOVAL AND INSTALLATION
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54.
E66050
55.
E112254
56. CAUTION: Make sure that the exhaustflexible pipe is not forcibly bent.
E112253
x2
57.Remove the following items:
1. Refer to: Transfer Case (307-07 Transfer
Case - Vehicles With: 5-Speed Automatic
Transaxle - AW55 AWD/6-Speed Automatic
Transaxle - 6DCT450, Removal).
2. Refer to: Front Halfshaft LH (205-04 Front
Drive Halfshafts, Removal and Installation).
3. Refer to: Accessory Drive Belt (303-05
Accessory Drive - 2.5L Duratec
(147kW/200PS) - VI5, Removal and
Installation).
58.
x2x2
E114619
G1191240en2008.50 Kuga8/2011
303-01- 73
Engine— 2.5L Duratec (147kW/200PS) - VI5303-01-
73
REMOVAL
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL