2011 FORD KUGA Index

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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Transfer Case Fluid Level Check
MaterialsSpecification
Name
8U7J-19G518-BA
Rear Axle Oil SAE 75W-
90
Inspection
1. Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2.
E139436
3. Material: Rear Axle Oil SAE 75W-90
(8U7J-19G518-BA) transmission fluid
•
• Correct the rear axle oil level if neccessary.
• 20ml~1mm
0mm0mm
E114595
4. NOTE:
Make sure that a new component is
installed.
Torque: 34
Nm
E139434
G1164988en2008.50 Kuga8/2011
307-07- 9
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 9
GENERAL PROCEDURES
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Transfer Case Connecting Sleeve
Special Tool(s) / General Equipment308-784
Installer, Halfshaft Seal
E115803
Special Tool(s) / General Equipment308-785
Installer, Halfshaft Seal
E115804
Copper Hammer
Flat-bladed screwdriver
Hot Air Gun
Puller
Punch
Removal
G1164990en2008.50 Kuga8/2011
307-07-10
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 10
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

1.Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2. Refer to: Transfer Case (307-07 Transfer Case
- Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, Removal).
3. General Equipment: Puller
2.
2
1
2
1
E115596
4. General Equipment: Flat-bladed screwdriver
E115627
5.General Equipment: Punch
E115597
Installation
1.General Equipment: Hot Air Gun
175
150175
150
E115598
2.
General Equipment: Copper Hammer
E115599
G1164990en2008.50 Kuga8/2011
307-07- 11
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 11
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

3.Special Tool(s): 308-785
308-785
60
308-785
60
E115600
4.
E115601
5.Special Tool(s): 308-784
308-784308-784
E114369
6.Refer to: Transfer Case (307-07 Transfer Case
- Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, Installation).
7. Refer to: Transfer Case Fluid Level Check
(307-07 Transfer Case - Vehicles With:
5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle -
6DCT450, General Procedures).
G1164990en2008.50 Kuga8/2011
307-07- 12
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 12
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transfer Case Connecting Sleeve Seals — Vehicles With: 5-SpeedAutomatic Transaxle - AW55 AWD
Removal
1.Refer to: Transfer Case Connecting Sleeve
(307-07 Transfer Case - Vehicles With:
5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle -
6DCT450, Removal and Installation).
Installation
1. To install, reverse the removal procedure.
G1164991en2008.50 Kuga8/2011
307-07- 13
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 13
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transfer Case Rear Seal
Removal
1.Refer to: Transfer Case Rear Seal (307-07
Transfer Case - Vehicles With: 5-Speed
Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450, Removal
and Installation).
Installation
1.Refer to: Transfer Case Rear Seal (307-07
Transfer Case - Vehicles With: 5-Speed
Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450, Removal
and Installation).
G1164992en2008.50 Kuga8/2011
307-07- 14
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 14
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL