2011 FORD KUGA AIR CON

307-01-72
Output Shaft Speed (OSS) Sensor ........................................................................\
.............
307-01-73
Torque Converter Seal ........................................................................\
................................
307-01-75
Transmission Fluid Pan ........................................................................\
..............................
307-01-77
Transmission Range (TR) Sensor ........................................................................\
..............
307-01-81
Turbine Shaft Speed (TSS) Sensor ........................................................................\
............
REMOVAL 307-01-82
Transmission ........................................................................\
..............................................
INSTALLATION 307-01-91
Transmission ........................................................................\
..............................................
307-01-3
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 3
.
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Transmission Description – Overview
Components of the AW55 automatic
transaxle
E112298
Description
Item
Torque converter
1
Differential
2
The OSS (output shaft speed) sensor
3Description
Item
Planetary gear set.
4
The TSS (turbine shaft speed) sensor
5
Control valve assembly
6
TCM (transmission control module)
7
General overview
G1163604en2008.50 Kuga8/2011
307-01- 6
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 6
DESCRIPTION AND OPERATION
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23
4
5
6
7
1

E125525
Design:
• The gear ratios are achieved by means of acombined planetary gear set on the input side
and a Simpson set on the output side.
– The combined planetary gear set consists oftwo different, simple planetary gear sets. It
has a similar structure to a Ravigneaux set,
but with just one sun gear that engages with
the front planetary gears.
• Three multi-plate clutches
• Four multi-plate brakes • One band brake
• Two one-way clutches
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.
The TCM features a self-learning strategy.
This leads to lower fuel consumption together with
improved comfort through smoother gear changes
and lower noise levels.
Gear ratios of the individual gears
Transmission Ratio
Gear
4.576
First
2.980
Second
1.948
Third
1.318
Fourth
1.000
5th
5.024
Reverse
1.018
Intermediate shaft
2.652
Differential
G1163604en2008.50 Kuga8/2011
307-01- 7
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 7
DESCRIPTION AND OPERATION
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Transaxle cooling
1
2
3
4
E112583
Description
Item
The transmission fluid cooler.
1
Quick-release couplings
2Description
Item
From transmission fluid cooler to
transmission
3
From transmission to transmission fluid
cooler
4
The transmission fluid cooler is mounted on the
radiator. The transmission fluid cooler and the
automatic transaxle are connected via two hose
lines, which are equipped with quick-release
couplings. The transmission fluid cooler operates according
to the heat exchanger principle. The ram air
passing through the radiator withdraws heat from
the transmission fluid.
External shift mechanism
G1163604en2008.50 Kuga8/2011
307-01-
8
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 8
DESCRIPTION AND OPERATION
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1
234
5
6
8
9
7
E112582
Description
Item
Gear selector mechanism
1
Selector lever cable guide
2
Selector cable
3
Damper weight
4Description
Item
Adjusting mechanism for selector lever
cable
5
Shift valve shaft lever
6
Selector lever cable bracket
7
Retaining clip
8
Emergency release lever
9
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 'P' or 'N' position.
The selector cable adjustment mechanism is at the
transmission end of the selector cable.
Components of the electronic control
G1163604en2008.50 Kuga8/2011
307-01-
9
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 9
DESCRIPTION AND OPERATION
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E112323
1
2
7
6
4
5
3
10
9
11
12
Description
Item
The TSS sensor
1
The OSS sensor
2
PWM (pulse width modulation)- solenoid
valve – TCC (torque converter clutch)
(SLU)
3
PWM solenoid valve – shift pressure (SLS)
4
Shift solenoid S1
5
Shift solenoid S4
6Description
Item
Shift solenoid S3
7
Shift solenoid S5
8
Shift solenoid S2
9
The TFT (transmission fluid temperature)
sensor
10
PWM solenoid valve for main line pressure
(SLT)
11
TCM with integrated TR sensor
12
Depending on the input signals, the TCM mounted
on the transaxle actuates the solenoid valves
S1-S5 in the valve body. The solenoid valves are
either in the "open" or "closed" state.
The (SLT and SLS) control valves regulate the
hydraulic pressure according to the pulse/pause
ratio of the electrical PWM signal. The controlled
hydraulic pressure enables smooth shifting or the
generation of a defined slip through actuation of
the relevant clutches and brakes. The shift timing is calculated by the TCM using the
accelerator pedal position and vehicle speed.
Under normal conditions, gear shifting and torque
converter lockup occur at low engine speeds to
reduce fuel consumption.
If the accelerator pedal is pressed down quickly,
the TCM switches automatically into kickdown
mode.
G1163604en2008.50 Kuga8/2011
307-01-
10
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 10
DESCRIPTION AND OPERATION
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Function of the shift solenoids in the gears
S5
S4
S3
S2
S1
Gear
Off
Off
On
On
On
1
Off
Off
On
Off
Off
2
Off
On
On
Off
Off
3
Off
On
Off
Off
Off
4
Off
On
Off
On
Off
5
Overview of the brakes, clutches and
one-way clutches
E112793
1234
5
12
13
Description
Item
Clutch C2: Connects the input shaft with
the sun gear.
1
Clutch C1: Connects the input shaft with
the rear gear.
2
Brake B3: Locks the annulus of the front
planetary gear.
3
One-way clutch F2: Locks the front
annulus in the counterclockwise direction.
4
Brake B2: Prevents the sun gear on the
input shaft from turning counterclockwise.
5Description
Item
Brake B1: Locks the sun gear on the input
shaft.
6
One-way clutch F1: Prevents the sun gear
on the input shaft turning counterclockwise
when B2 is activated.
7
Park System
8
Clutch C3: Connects the sun gear with the
front planetary gear carrier on the output
shaft.
9
Brake band B4: Blocks the the sun gear
on the output shaft.
10
G1163604en2008.50 Kuga8/2011
307-01-
11
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 11
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E112805
59
13
2
6
10
14
3
7
11
15
4
8
12
16
17
19202118
1
Description
Item
TCM1
GEM (generic electronic module)
2Description
Item
Instrument Cluster
3
PCM (powertrain control module)
4
G1163604en2008.50 Kuga8/2011
307-01- 13
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 13
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL