DRIVESHAFT FORD KUGA 2011 1.G Workshop Manual

SECTION 205-01 Driveshaft
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
REMOVAL AND INSTALLATION
205-01-2
(15 514 0)
Driveshaft ........................................................................\
...............................
205-01-1
Driveshaft
205-01- 1
.
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Driveshaft(15 514 0)
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).
3.
E98543
x7
Vehicles with 2.0L diesel engine
4.
E114034
Vehicles with 2.5L engine
5.
E114375
All vehicles
6.
x2
x2
x2
x2
x2
x2
E114188
G1070580en2008.50 Kuga8/2011
205-01- 2
Driveshaft
205-01- 2
REMOVAL AND INSTALLATION
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7.
1
2x6
x3
1
2x6
x3
E101018
Vehicles with 2.0L diesel engine
8.
1
2x6x3
1
2x6x3
E101687
9.
20 mm1
2
20 mm1
2
E114035
Vehicles with 2.5L engine
10.
1
2x6
x3
1
2x6
x3
E114196
G1070580en2008.50 Kuga8/2011
205-01-3
Driveshaft
205-01- 3
REMOVAL AND INSTALLATION
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11 .
20 mm1
2
20 mm1
2
E114376
All vehicles
12.
E114295
13.
x2x2
E102254
Installation
All vehicles
1.
x2x2
E102243
2.
E114296
G1070580en2008.50 Kuga8/2011
205-01-4
Driveshaft
205-01- 4
REMOVAL AND INSTALLATION
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Vehicles with 2.0L diesel engine
3. CAUTION: Make sure that theinstallation marks are aligned.
1. Torque: 35Nm
2. Torque: 35Nm
3. Torque: 35Nm
3
1
2
2x3
13
1
2
2x3
1
E101688
4.
20 mm1
2
20 mm1
2
E114036
Vehicles with 2.5L engine
5. CAUTION: Make sure that theinstallation marks are aligned.
1. Torque: 35Nm
2. Torque: 35Nm
3. Torque: 35Nm
3
1
2
2
13
1
2
2
1
E114197
6.
20 mm1
2
20 mm1
2
E114377
G1070580en2008.50 Kuga8/2011
205-01- 5
Driveshaft
205-01- 5
REMOVAL AND INSTALLATION
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All vehicles
7. 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
8.Torque: 25Nm
x2
x2
x2
x2
x2
x2
E114188
G1070580en2008.50 Kuga8/2011
205-01- 6
Driveshaft
205-01- 6
REMOVAL AND INSTALLATION
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Vehicles with 2.0L diesel engine
9.Torque:
• Stage 1: 35
Nm
• Stage 2: Loosen 360°
• Stage 3: 85Nm
E114034
Vehicles with 2.5L engine
10.
11 .Torque:
• Stage 1: 35
Nm
• Stage 2: Loosen 360°
• Stage 3: 85Nm
E114375
All vehicles
12.
E98543
x7
13.Lower the vehicle.
G1070580en2008.50 Kuga8/2011
205-01- 7
Driveshaft
205-01- 7
REMOVAL AND INSTALLATION
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Rear Drive Axle and Differential – System Operation andComponent Description
System Operation
General Information
The powertrain with all-wheel drive consists of the
following main components:
• engine
• transaxle with front axle differential
• transfer box
• halfshafts and driveshafts
• Haldex clutch
• rear axle differential
The Haldex clutch guarantees continuous variable
torque transmission to the rear axle under all
driving conditions. The Haldex clutch reacts
immediately and equally quickly with slow or fast
wheel slip.
A difference in angle of rotation of 90° between the
input and output shafts is required to build up
maximum pressure at the multi-plate clutch or to
transmit maximum torque.
The advantage of vehicles with all-wheel drive is
that they distribute the drive between all four
wheels. They therefore have a higher tractive
power. They feature improved cornering behaviour,
as the grip at all four wheels can be better utilised.
Thus, the wheels contribute to a greater degree
towards cornering stability.
The engine torque is transmitted from the transfer
box to the rear axle via a driveshaft. The driveshaft
is flange-mounted to the input side of the Haldex
clutch.
Driving situations
Pulling away and accelerating
• When pulling away and accelerating, as muchall-wheel drive as necessary must be available
immediately in the short-term. During
acceleration, the electronic system detects slip
at the front axle. This slip is counter-controlled
and thus the propulsive force optimally
distributed to the two axes.
Cornering • A sporty driving style, in particular dynamic
cornering, demands stable cornering behaviour.
The all-wheel system distributes the propulsive
force to all four wheels and by so doing boosts
the high cornering forces so that the vehicle
makes optimum contact with the road surface.
Snow and black ice
• Snow and black ice require particularly high grip. Under these conditions, the Haldex clutch
always distributes the propulsive force to the
axle with the better traction. The all-wheel
system reacts intelligently and quickly to all
driving situations.
Trailer operation
• When driving with a trailer, the trailer weight (support load) is transmitted to the rear axle via
the towbar. This reduces the load on the front
wheels, which means they can slip. The
electronic system detects this difference and
distributes most of the propulsive force to the
rear axle.
Haldex clutch
E100642
G1076981en2008.50 Kuga8/2011
205-02- 6
Rear Drive Axle/Differential
205-02- 6
DESCRIPTION AND OPERATION
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General overview
Haldex clutches of the 3rd and 4th generations are
used in the Ford Kuga.
The development of the third generation Haldex
clutch represents a big step forward in modern
all-wheel technology. The Haldex clutch is
electro-hydraulically controlled. Additional
information is taken into consideration during
control tasks via the all-wheel drive control unit.
Slip alone is no longer decisive for the distribution
of the propulsive forces; the vehicle's driving
dynamics are also taken into consideration. The
control unit accesses the driving-related data via
the data bus. With this data, the control unit has
all the essential information about speed, cornering,
coasting or traction operation, and can optimally
react to every driving situation.
Compared with the previous generation, the 4th
generation Haldex clutches operate with higher
pressure and achieve shorter response times when
distributing the drive forces.
Advantages of the Haldex clutch:
• Permanent all-wheel drive withelectronically-controlled multi-plate clutch
• Fast response
• No straining when parking and manoeuvring
• Compatible with different tyres (e.g. emergency spare wheel)
• Fully combinable with driving dynamic control systems
The driveshaft is connected to the input shaft of
the Haldex clutch. Within the Haldex clutch, the
input shaft is separated from the output shaft to
the rear axle differential by means of a multi-plate
clutch. Torque is only transmitted to the rear axle
differential when the plate assembly of the Haldex
clutch is closed.
The multi-plate clutch is electro-hydraulically
controlled via the all-wheel drive control unit. For
ecological driving, the torque to the rear axle is reduced to a minimum up to a throttle position of
approx. 50%. A prerequisite for this is that there is
no difference in speed in the Haldex clutch between
the input and output shafts.
Operation
E100645
16
3
25
4
Description
Item
Output shaft
1
Working piston
2
Plates
3
Ring piston pump
4
Control Valve
5
Input shaft
6
Within the Haldex clutch is a plate assembly and
a so-called ring piston pump with a pump plunger
and a working piston.
Fluid supply is started if there is a speed difference
between the input and output shafts.
This fluid pressure is transmitted to the working
piston and in this way the plate assembly is
compressed.
Design of the 3rd generation Haldex
clutch
G1076981en2008.50 Kuga8/2011
205-02- 7
Rear Drive Axle/Differential
205-02- 7
DESCRIPTION AND OPERATION
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Differential Case
General EquipmentCable Ties
Removal
All vehicles
1. Refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).
Vehicles with 2.0L diesel engine
2.
1
2x6x3
1
2x6x3
E101687
3.
E101709
Vehicles with 2.5L engine
4. Refer to: Driveshaft (205-01 Driveshaft,
Removal and Installation).
5.
E114256
6.
x2x2
E114255
G1061458en2008.50 Kuga8/2011
205-02- 21
Rear Drive Axle/Differential
205-02- 21
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL