2011 FORD KUGA ALL

7.Torque: 25Nm
x2
x2
x2
x2
x2
x2
E114188
8.Torque:
• Stage 1: 35
Nm
• Stage 2: Loosen 360°
• Stage 3: 85Nm
E114034
9.Refer to: Differential Fluid Level Check (205-02
Rear Drive Axle/Differential, General
Procedures).
10.
E98543
x7
11 . Lower the vehicle.
G1076972en2008.50 Kuga8/2011
205-02- 37
Rear Drive Axle/Differential
205-02- 37
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Differential Support Insulator
Special Tool(s)204-598
Hydraulic Cylinder 10t
E75373
204-598-03
Adapter for 204-598
E103784
Special Tool(s)308-762
Remover/Installer, Bush RDU
E102678
Materials
Specification
Name
WSS-M2C200-D2 /
7U7J-M2C200-BA
Transmission Oil 75W
FE
Removal
1.
Refer to: Differential Case (205-02 Rear Drive
Axle/Differential, Removal and Installation).
2. Special Tool(s): 204-598, 204-598-03, 308-762
308-762
204-598
204-598-03
308-762
204-598
204-598-03
E102574
Installation
1.Special Tool(s): 204-598, 204-598-03, 308-762
Material: Transmission Oil 75W FE
(WSS-M2C200-D2 / 7U7J-M2C200-BA)
transmission fluid
308-762
204-598
204-598-03
308-762
204-598
204-598-03
E102575
2. Refer to: Differential Case (205-02 Rear Drive
Axle/Differential, Removal and Installation).
G1076973en2008.50 Kuga8/2011
205-02- 38
Rear Drive Axle/Differential
205-02- 38
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Rear Halfshaft Seal
Special Tool(s) / General Equipment303-395
Installer, Crankshaft Seal
21171
Special Tool(s) / General EquipmentTire Lever
Removal
1. Refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).
2. General Equipment: Tire Lever
E102535
3.General Equipment: Tire Lever
E102536
Installation
1.Special Tool(s): 303-395
303-395303-395
E102537
G1080736en2008.50 Kuga8/2011
205-02- 39
Rear Drive Axle/Differential
205-02- 39
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

2.Special Tool(s): 303-395
303-395303-395
E102538
3.Refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).
4. Refer to: Differential Fluid Level Check (205-02
Rear Drive Axle/Differential, General
Procedures).
G1080736en2008.50 Kuga8/2011
205-02- 40
Rear Drive Axle/Differential
205-02- 40
REMOVAL AND INSTALLATION
TO MODEL INDEX
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Drive Pinion Seal
Special Tool(s)303-293
Remover, Crankshaft Seal
21143
Special Tool(s)308-643
Installer, Input Shaft Seal
E65343
Removal
1.Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2. Refer to: Active On-Demand Coupling Module
(205-02 Rear Drive Axle/Differential, Removal
and Installation).
3. Special Tool(s): 303-293
303-293
303-293
303-293
303-293
E102546
Installation
1. CAUTION: Take extra care not to
damage the seal.
Special Tool(s): 308-643
308-643308-643
E102547
2.Refer to: Active On-Demand Coupling Module
(205-02 Rear Drive Axle/Differential, Removal
and Installation).
G1357281en2008.50 Kuga8/2011
205-02- 41
Rear Drive Axle/Differential
205-02- 41
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

20.Special Tool(s): 205-072, 303-249
Torque: 150
Nm
205-072
303-249
205-072
303-249
E102500
21. CAUTION: Make sure that the
installation marks are aligned.
1. Torque: 35Nm
2. Torque: 35Nm
3. Torque: 35Nm
3
x2
1
2
2
x3
13
x2
1
2
2
x3
1
E114197
22.
E114296
23.
20 mm1
2
20 mm1
2
E114377
G1268328en2008.50 Kuga8/2011
205-02- 47
Rear Drive Axle/Differential
205-02- 47
DISASSEMBLY AND ASSEMBLY
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

24. 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
25.Torque: 25Nm
x2
x2
x2
x2
x2
x2
E114188
G1268328en2008.50 Kuga8/2011
205-02- 48
Rear Drive Axle/Differential
205-02- 48
DISASSEMBLY AND ASSEMBLY
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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