2011 FORD KUGA 100

Transmission Fluid Cooler Tubes — Vehicles With: 5-SpeedAutomatic Transaxle - AW55 AWD
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2.
x4x4
E114919
3. If equipped.
2.
1212
E114920
4. CAUTION: Make sure that all openings
are sealed.
E114922
5.Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
6.
E98183
G1163668en2008.50 Kuga8/2011
307-02- 8
Transmission/Transaxle Cooling
— Vehicles With: 5-Speed
Automatic Transaxle - AW55 AWD/6-Speed Automatic Transaxle - 6DCT450
307-02- 8
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Selector Lever Cable — Vehicles With: 5-Speed AutomaticTransaxle - AW55 AWD
General Equipment
Knife
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2.
E114436
3. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
4.
E98543
x7
5.
x2
x2
x2
x2
x2
x2
E100948
6.
x4x4
E114517
G1163686en2008.50 Kuga8/2011
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
307-05-
7
Automatic Transmission/Transaxle External
Controls
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450
307-05-7
.

7.
E114513
8.Lower the Vehicle.
9. Refer to: Floor Console Extension - Vehicles
With: Center Armrest (501-12 Instrument
Panel and Console, Removal and Installation).
10.
E114518
11 . Torque: 25Nm
x4x4
E100949
12.
E114519
13.Torque: 25Nm
x4x4
E114516
14.
x4x4
E101415
G1163686en2008.50 Kuga8/2011
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
307-05-
8
Automatic Transmission/Transaxle External
Controls
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450
307-05-8
.

Installation
CAUTION: Gearshift cables must not be
kinked or bent.
1. To install, reverse the removal procedure.
2. Torque: 25
Nm1.
2. Torque: 25
Nm
3. Torque: 30Nm
4. Torque: 25Nm
4
x2
2x2
1
3
x2
4
x2
2x2
1
3
x2
E100960
Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD (307-05 Automatic
Transmission/Transaxle External Controls -
Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, General Procedures).
G1163686en2008.50 Kuga8/2011
REMOVAL AND INSTALLATION
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3.
Refer to: Selector Lever Cable Adjustment -
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
307-05-10
Automatic Transmission/Transaxle External
Controls
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450
307-05-10
.

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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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
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

1.Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
Refer to: Transfer Case (307-07 Transfer Case
- Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, Removal).
2. Special Tool(s): 303-293
303-293303-293
E115696
Installation
1. Install the Special Tool(s): 308-788
1.
3. Special Tool(s): 204-351
2308-788
1
204-351/1
3
204-351/2
3
2308-788
1
204-351/1
3
204-351/2
3
E115697
2. Remove the Special Tool(s): 308-788
3. Refer to: Transfer Case (307-07 Transfer Case
- Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD/6-Speed Automatic Transaxle
- 6DCT450, Installation).
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).
G1164993en2008.50 Kuga8/2011
307-07- 16
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 16
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Make sure that the exhaust flexible pipe
is not forcibly bent.
2. Torque: 47
Nm
3. Torque: 28Nm
E112609
x3
1
2
3
6. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
7.
E65299
8. General Equipment: Cable Ties
TIE0014991
9.
E66050
10.Torque: 30Nm
E112254
G1079152en2008.50 Kuga8/2011
309-00- 4
Exhaust System— 2.5L Duratec (147kW/200PS) - VI5309-00-
4
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL