2011 FORD KUGA ASSEMBLY

E100539
34
2
1
9
8
10
7
6
5A
B
C
D
Description
Item
Barometric Pressure
A
Base pressure
B
Increased base pressure (preload)
C
Operating pressure
Drive
Plate assembly and ring piston pump
1
High-pressure valves
2
Pressure Sensor
3Description
Item
Control valve
4
Pressure accumulator
5
Electric feed pump
6
Filters7
Preload valve
8
Pressure relief valve (low pressure)
9
Pressure relief valve (high pressure)
10
Base pressure
G1076981en2008.50 Kuga8/2011
205-02- 11
Rear Drive Axle/Differential
205-02- 11
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

1
2
3
4
E115887
Description
Item
Fluid filter
1
All-wheel drive control unit
2Description
Item
Electric feed pump
3
Pressure accumulator
4
The electric feed pump is an axial piston pump
which is more robustly designed than the gerotor
pump in the 3rd generation Haldex. The higher
feed pressure means that the ring piston pump at
the clutch plate assembly, the pressure relief
valves, preload valve and the high pressure valves
are no longer necessary.
The pressure accumulator on the 4th generation
Haldex is larger and is designed for the higher
pressure. The 4th generation Haldex has a larger fluid filter
which contains a non-return valve.
The all-wheel drive control unit no longer contains
a pressure sensor in the 4th generation Haldex.
Pressure control - 4th generation Haldex
clutch
G1076981en2008.50 Kuga8/2011
205-02-
15
Rear Drive Axle/Differential
205-02- 15
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Active On-Demand Coupling — Vehicles With: 5-Speed AutomaticTransaxle - AW55 AWD/6-Speed Automatic Transaxle -
6DCT450
Special Tool(s) / General Equipment
205-072
Universal Flange Holding
Wrench
15030A
Special Tool(s) / General Equipment303-249
Remover, Crankshaft Timing
Pulley
21132
Puller
Materials
Specification
Name
8U7J-8708687-AA
Transmission Oil AWD
Disassembly
G1268328en2008.50 Kuga8/2011
205-02- 42
Rear Drive Axle/Differential
205-02- 42
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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: Lifting(100-02 Jacking and Lifting,
Description and Operation).
3.
E114257
4. WARNING: Be prepared to collect escaping fluid.
E124748
5.
E124778
6. WARNING: Be prepared to collectescaping fluid.
x2x2
E124749
7.
E128365
G1268328en2008.50 Kuga8/2011
205-02- 43
Rear Drive Axle/Differential
205-02- 43
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

8.
E98543
x7
9.
E114375
10.
x2
x2
x2
x2
x2
x2
E114188
11 .
1
2x6
x3
1
2x6
x3
E101018
G1268328en2008.50 Kuga8/2011
205-02-44
Rear Drive Axle/Differential
205-02- 44
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12.
20 mm1
2
20 mm1
2
E114376
13.
E114295
14.
1
2x6
x3
1
2x6
x3
E114196
15.Special Tool(s): 205-072, 303-249
205-072
303-249
205-072
303-249
E102495
G1268328en2008.50 Kuga8/2011
205-02- 45
Rear Drive Axle/Differential
205-02- 45
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

16.General Equipment: Puller
E114331
17. WARNING: Be prepared to collect
escaping fluid.
x2x2
E124753
Assembly
18.Material: Transmission Oil AWD
(8U7J-8708687-AA) transmission fluid
E124752
19. Torque: 6Nm
x2x2
E124753
G1268328en2008.50 Kuga8/2011
205-02- 46
Rear Drive Axle/Differential
205-02- 46
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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
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL