2011 FORD KUGA service

Transmission Fluid Level Check
E126079
WARNING: Beware, risk of scalding when
checking the transmission fluid.
NOTE: Refer to the service literature for the exact
procedure and specifications.
In order for the transaxle to function properly, it is
vital that the transmission fluid level is correct. If the transmission fluid level is excessively low, this
becomes noticeable by a rattling noise at the fluid
pump, etc.
Always use transmission fluid to the indicated
specification (WSS-M2C924-A).
The transmission fluid temperature is determined
using IDS.
It must be ensured that the transmission fluid
temperature is within the range specified in the
workshop literature.
The following conditions must be met in order to
carry out the transmission fluid level check
correctly:
• Ensure that the transaxle is not in limp home
mode.
• Place the vehicle on a level surface.
• Move the selector lever to the 'P' position.
• Make sure that the parking brake is fully applied.
• Run the engine at idle speed.
• Move the transmission selector lever to all positions. In doing so, wait until the transmission
engages the corresponding range.
• Move the selector lever back to the 'P' position.
• Pull out the fluid dipstick.
When the predetermined transmission fluid
temperature is reached, the fluid level shown on
the dipstick must be in the middle between 'MIN'
and 'MAX'. In this case, the fluid level is correct.
Changing the Transmission Fluid
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Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 17
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E126062
2
1
3
4
Description
Item
Fluid reservoir
1
Connection for return line from fluid cooler
2Description
Item
Connection for return line on transaxle
3
Hose
4
Under normal conditions, the transmission fluid is
filled for the service life of the transaxle and does
not need to be changed.
Under high loads (driving with a trailer or in
mountains etc.) it may be necessary to change the
transmission fluid.
To drain the transmission fluid, remove the fluid
drain plug.
Proceed as follows when topping off the
transmission fluid:
• Remove the return line from the fluid cooler to the transaxle on the transaxle. Close off the
connection on the transaxle using a plastic plug.
• Join the return line to a transparent pipe. The transparent pipe ends in the fluid reservoir in
order to collect the fluid.
• To top off the transmission fluid, insert a transparent pipe in the guide tube of the dipstick
and add approx. 2.0 liters of transmission fluid. • Move the selector lever to the 'P' position and
allow the engine to run at idle speed.
• Switch off the engine if air bubbles become visible in the transparent pipe to the fluid
reservoir.
• Top off approx. 2 liters of transmission fluid and allow the engine to run at idle speed. Switch off
the engine if air bubbles become visible in the
transparent pipe to the fluid reservoir.
• Top up the transmission fluid until the fluid level for cold fluid is indicated on the dipstick in the
middle between 'MIN' and 'MAX'.
• Then check the transmission fluid level.
Refer to the service literature for the exact
procedure and specifications.
NOTE: If the transmission fluid has been changed,
the counter for fluid change intervals must be reset
using IDS.
Diagnosis with IDS
G1163604en2008.50 Kuga8/2011
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Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
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transmission range or gear (in select-shift mode)
is indicated to the driver in the instrument panel.
In selector lever position "S", the driver can
manually select the gears (select-shift mode). Up
(+) and down (-) shifts are made by moving the
selector lever in the appropriate direction.
Hydraulic limp home modes maintain limited
operation in the event of failure of important
electrical components.Under normal conditions, the transmission fluid is
filled for the service life of the transaxle and does
not need to be changed.
A dipstick is used to check the fluid level in the
transmission.
Functionality overview
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Automatic Transmission/Transaxle
— Vehicles With:
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E112322
The TCM adapts the gear changing to ensure that
the correct gear is selected for the style of driving,
the engine load, driver requirements, vehicle speed
etc. This leads to lower fuel consumption together
with improved comfort through smoother gear
changes and lower noise levels.
The TCM receives information on the driver's
desired transmission range and type of driving
mode. In contrast to a transmission which is only
controlled hydraulically, the control module can
calculate the best times to shift gear and activate
torque converter lockup by using the signals from
the sensors in the transmission and the engine
management system.
The control module enables small changes in the
operating conditions to be made and adapts thevarious transmission functions to ensure that the
correct gear is always selected in relation to the
type of driving mode.
The TCM has adaptive capabilities. This ensures
smooth gear changes throughout the whole service
life of the transmission.
To exactly determine the activation points of the
gear shifts and torque converter lockup on the
basis of the type of driving mode chosen, the TCM
receives the following information:
• Transmission range chosen (TR sensor).
• Type of driving mode chosen
(normal/sport/select-shift).
• Transmission input shaft speed (TSS sensor).
• Transmission output shaft speed (OSS sensor).
• Transmission fluid temperature (TFT sensor).
• The engine speed and the torque as well as the throttle plate opening - from the PCM via the
CAN data bus.
• Actuation of the accelerator pedal - from the PCM via the CAN data bus.
• Coolant temperature - from the PCM via the CAN data bus.
• Vehicle speed - from the ABS via the CAN data bus.
• Actuation of the brake pedal - from the ABS via the CAN data bus.
Pin assignment for TCM connector 'A' (connection to vehicle)
11
E125669
Description
Item
Battery (+)
1
not assigned
2Description
Item
not assigned
3
not assigned
4
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21
22 20 19
15 14 13
161718 12
876
9
10
11 5
3
42121
22 20 19
15 14 13
161718 12
876
9
10
11 5
3
421
E125671
Description
Item
Shift solenoid valve S1 (+)
1
Shift solenoid valve (S2) (+)
2
PWM solenoid valve – main line pressure
(SLT) (+)
3
not assigned
4
not assigned
5
PWM solenoid valve – main pressure line
(SLT) (–)
6
PWM solendoid valve – TCC (SLU) (–)
7
not assigned
8
PWM solenoid valve – TCC (SLU) (+)
9
PWM solenoid valve – shift pressure (SLS)
(–)
10Description
Item
not assigned
11
not assigned
12
TFT sensor (–)
13
TFT sensor (+)
14
not assigned
15
PWM solenoid valve – shift pressure (SLS)
(+)
16
Shift solenoid valve (S3) (+)
17
not assigned
18
not assigned
19
not assigned
20
Shift solenoid valve (S5) (+)
21
Shift solenoid valve (S4) (+)
22
Operation
Depending on the input signals, the TCM mounted
on the transmission actuates the solenoid valves
in the valve body. The TCM calculates and stores
adaptive data, fault codes and values for diagnosis.
The TCM adapts the gear changing to ensure that
the correct gear is selected for the style of driving,
the engine load, driver requirements, vehicle speed
etc. This leads to lower fuel consumption together
with improved comfort through smoother gear
changes and lower noise levels.
The TCM receives information on the driver's
desired transmission range and type of driving
mode. In contrast to a transmission which is only controlled hydraulically, the control module can
calculate the best times to shift gear and activate
torque converter lockup by using the signals from
the sensors in the transmission and the engine
management system.
The control module enables small changes in the
operating conditions to be made and adapts the
various transmission functions to ensure that the
correct gear is always selected in relation to the
type of driving mode.
The TCM has adaptive capabilities. This ensures
smooth gear changes throughout the whole service
life of the transmission.
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Automatic Transmission/Transaxle
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To exactly determine the activation points of the
gear shifts and torque converter lockup on the
basis of the type of driving mode chosen, the TCM
receives the following information:
• Selected transmission range (TR sensor)
• Selected driving mode (normal/sport/select-shift)
• Transmission input shaft speed (TSS sensor)
• Transmission output shaft speed (OSS sensor)
• Transmission fluid temperature (TFT sensor)
• The engine speed and the torque as well as thethrottle plate opening - from the PCM via the
CAN databus
• Actuation of accelerator – from the PCM via the CAN databus
• The coolant temperature – from the PCM via the CAN databus
• Road speed – from the ABS module via the CAN databus
• Actuation of brake pedal – from the PCM via the CAN databus
Gearshift control
Adaptation
The TCM monitors every shift operation in all
driving conditions to make even and smooth gear
shifts possible. This is done by the control module,
which either lowers or increases the hydraulic line
pressure during gearshifts.
The changed pressure values are stored in the
control module memory after the engine is switched
off and retrieved during engine starting. This
improves the shift comfort and extends the service
life.
Full adaptability occurs when the following criteria
are met:
• Throttle plate opening is constant.
• Transmission fluid temperature between 65 °Cand 110 °C.
Shifting from 'P' to another transmission
range
To be able to move the selector lever from 'P' into
another transmission range, the ignition must be
switched on and the brake pedal pressed (stoplamp
switch on). The TCM detects the position of the
brake pedal via the CAN data bus and the engaged
transmission range from the TR sensor. Based on this information, the TCM transmits a
signal to the select-shift switch module. This
activates the brake shift interlock actuator in the
selector lever assembly.
When the brake shift interlock actuator is activated,
the locking pin is retracted so that another
transmission range can be selected.
The brake shift interlock actuator is deactivated
when the ignition is switched off. It is mechanically
locked when the gear selector lever is in 'P'.
Automatic transmission, selector lever in
position "D".
The TCM adapts the shift points to match the
driving conditions. Normally the TCM is in adaptive
mode and gear changes take place adapted to the
driving conditions. If special driving conditions are
detected, the TCM switches to predefined
characteristics.
When driving with normal acceleration, the TCM
uses a preset shift program which is optimized for
economical driving.
This shift program is suitable for "normal" driving
and delivers early upward changes and torque
converter lockup. Furthermore, the transmission
fluid pressure is adapted to make smooth
engagement of the gears possible.
Sport mode, selector lever in position "S"
The transmission switches from automatic
operation into sport mode. In this mode the TCM
switches to another set of characteristic curves.
These characteristic curves for control of the gear
changes are adapted to sporting calculations (e.g.
gear change at higher engine speed).
In the sport mode shift program the shift points are
set so that good performance is offered. Changing
down occurs at lower engine speeds.
Manual gear changes (select-shift mode) can be
made in sport mode by moving the selector lever
in the (+) or (-) direction.
Changing gear in select-shift mode
If you move the selector lever to 'S', the automatic
transaxle remains hydraulically in 'D' position. If
you move the gear selector lever forwards (-), the
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Automatic Transmission/Transaxle
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E127362
12
3
Input shaft:
The transmission input shaft rotates clockwise.
Clutch C2 (1) connects the transmission input shaft
with the sun gear. The sun gear rotates clockwise.
The rear planetary gear set rotates
counterclockwise. The front larger planetary gear
set rotates counterclockwise with the rear planetary
gear set as a single unit. The front smaller
planetary gear set rotates clockwise.
Brake B3 (2) blocks the ring gear in
counterclockwise direction. The front and rear
planetary gear carriers are turned clockwise by the
front smaller gear. The primary idler gear rotates
counterclockwise with the front and rear planetary
gear carriers as one unit.
Output shaft:
The secondary idler gear rotates clockwise. The
front annular gear rotates clockwise with the
secondary idler gear as a single unit. The front
planetary gear set rotates clockwise. The sun gear
rotates in counterclockwise direction.
Brake B5 (3) prevents rotation of the rear planetary
gear carrier. The rear annular gear rotates
clockwise. The front planetary gear carrier and the
final drive pinion rotate clockwise with the rearannular gear as one unit. The final drive rotates
counterclockwise.
Engine braking:
The power is transferred directly to the
transmission input shaft without one-way clutch
involvement. Engine braking is thus applied.
NOTE:
The clutch C2 and the brake B3 are only
activated at a speed below 7 km/h (approx. 4.35
mph) when shifting from a forward gear to the
reverse gear.
Service instructions
Towing procedure
Towing is only permitted travelling forwards, at a
maximum speed of 80 km/h and for up 80 km. The
gear selector lever must be in Neutral.
CAUTION: The vehicle must never be
towed backwards under any
circumstances.
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Automatic Transmission/Transaxle
— Vehicles With:
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External Controls – Overview
Transmission range selector
E112313
The transmission range selector is located on the
center console and is mechanically connected to
the transmission by a cable for operation of the
gear selector shaft and the TR (transmission range)
sensor.
As well as the positions P/R/N/D, the transmission
range selector provides a position for the sport and
select-shift mode (S). The manual gear position
can be selected at any time while driving. The gear
selected is locked until the driver selects another
gear.
The engine can only be started in positions P or
N.
The selector cable adjustment mechanism is at the
transmission end of the selector cable.
NOTE:Details of the exact procedure and
specifications can be found in the current service
literature.
Transmission range selector lever
emergency release
E114512
1
2
3
4
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307-05-
4
Automatic Transmission/Transaxle External
Controls
— Vehicles With: 5-Speed Automatic Transaxle - AW55 AWD/6-Speed
Automatic Transaxle - 6DCT450
307-05-4
.