2011 FORD KUGA Transfer box

Rear Drive Axle and Differential – Component Location
Powertrain
6
6
1
2
3
3
4
5
6
6
E102416
Description
Item
Transmission assembly
1
Transfer box,
2
Halfshaft - front axle
3Description
Item
Drive shaft
4
Rear axle
5
Halfshaft - rear axle
6
G1076980en2008.50 Kuga8/2011
205-02- 2
Rear Drive Axle/Differential
205-02- 2
DESCRIPTION AND OPERATION
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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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Transfer Case – Component Location
Powertrain overview
6
6
1
2
3
3
4
5
6
6
E102416
Description
Item
Transaxle with front axle differential
1
Transfer box
2
Front wheel half shafts
3Description
Item
Drive shaft
4
Rear drive axle
5
Rear wheel half shafts
6
G1164985en2008.50 Kuga8/2011
307-07- 3
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 3
DESCRIPTION AND OPERATION
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Transfer box
1
23
E115223
Description
Item
Transfer box
1
Heat deflector
2
Bracket, transfer box to engine
3
G1164985en2008.50 Kuga8/2011
307-07- 4
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 4
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Transfer box seals
1
2
3
4
5
E115284
Description
Item
Output drive shaft flange retaining bolt
1
Output drive flange
2Description
Item
Hollow shaft seals, left
3
Hollow shaft seals, right
4
Output differential pinion gear seal
5
G1164985en2008.50 Kuga8/2011
307-07- 5
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 5
DESCRIPTION AND OPERATION
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Hollow shaft seal, left
E115285
Hollow shaft seals, right
12
3
45
E
Description
Item
Transfer box
1
Bolt
2Description
Item
Locking device
3
Adjustable bearing, transfer box
4
Oil seals
5
G1164985en2008.50 Kuga8/2011
307-07- 6
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 6
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Differential/drive - transfer box
1
2
3
4
5
2
E102901
Description
Item
Taper roller bearing - differential
1
Differential case
2Description
Item
Drive teeth - transfer box
3
Differential pinion gears
4
Spur gear
5
G1164985en2008.50 Kuga8/2011
307-07- 7
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 7
DESCRIPTION AND OPERATION
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Transfer Case – System Operation and Component Description
System Operation
1
2
3
E103728
Description
Item
Hollow shaft
1
Output shaft
2
Output drive flange
3
NOTE: From the start of series production, the
transfer box will be subject to a "Black Box Phase"
and will therefore not be repaired.
To realise the all-wheel drive, a transfer box has
been flange-mounted to the manual transaxle. The
transfer box is designed as an angular gear to
transfer the torque from the transaxle to the rear
axle. The hollow shaft of the transfer box is inserted
in a tooth on the gear case. From the hollow shaft,
torque is transferred to the driveshaft through the
output shaft/output flange via crown gear and
differential pinion gear.
G1164987en2008.50 Kuga8/2011
307-07- 8
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 8
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL