2011 FORD KUGA differential

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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Description
Item
ABS5
Cruise control
6
Select-shift switch module
7
PCM
8
Selector lever lock
9
PWM solenoid valve – shift pressure (SLS)
10
PWM solenoid valve for main line pressure
(SLT)
11
PWM- solenoid valve – TCC (SLU)
12Description
Item
Shift solenoid S1 (open when dormant)
13
Shift solenoid S2 (closed when dormant)
14
Shift solenoid S3 (closed when dormant)
15
Shift solenoid S4 (open when dormant)
16
Shift solenoid S5 (closed when dormant)
17
The TSS sensor
18
The OSS sensor
19
The TFT sensor
20
TR sensor in TCM
21
Input signals
Hard wired
• Item 18: ISS (input shaft speed) sensor
– Supplies information on the transmissioninput shaft speed. Used for calculations, for
instance the shift process, checking the
torque converter lockup and for diagnosis of
the hydraulic/mechanical operations in the
transmission.
• Item 19: OSS sensor – Supplies information on the transmissionoutput shaft speed. Used for calculations, for
instance the vehicle speed and for diagnosis
of the hydraulic/mechanical operations in the
transmission.
• Item 20: TFT sensor – Supplies information on the transmission fluidtemperature. This information is used to
adjust the shift times and the fluid pressure.
• Item 21: TR sensor – Supplies the TCM with the information on thechosen transmission range. Starting is only
possible when the selector lever is in the P
or N position. The sensor is a permanent
magnet which creates a magnetic field over
the different Hall sensors and in this way
creates a specific voltage for each shift
operation.
Via the LIN data bus
• Item 7: Selector lever module (select-shift module)
– Indicates that the selector lever is locked inposition P and supplies information on the
sport mode status. Also transmits a control
signal during select-shift gear changes and
supplies information on the fault status in the selector lever module, so that the fault codes
in the module can be stored as required.
Via the CAN data bus
• Item 4: PCM – Stop light switch ON/OFF, is used by theTCC.
– Coolant temperature, used for diagnosis of the transmission temperature sensor and for
activating the catalytic converter.
– Engine speed >400 rpm = engine running. Used for starting the transmission fluid
pressure and diagnosis functions.
– Engine rpm. Used for checking the torque converter slip and the pressure build-up,
which have an effect on the shift comfort.
– Kickdown. If the accelerator pedal is pressed down and the throttle plate is wide open, the
PCM transmits a kickdown signal to the TCM.
– Current engine speed, used to check the line pressure of the transmission.
– Throttle plate opening, used to calculate the gear changes. During sport mode and
kickdown.
– Accelerator pedal position, used to calculate the shift threshold timings.
• Item 5: ABS module – Supplies information on the vehicle speedand also on the difference in speed between
the left-hand and right-hand wheels. Prevents
changing up if the speed difference is greater
than 40 km/h, to protect the differential in the
transmission.
• Item 6: Vehicle speed control system – Is used to calculate the acceleration,depending on the position of the resume and
set buttons.
G1163605en2008.50 Kuga8/2011
307-01- 44
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 44
DESCRIPTION AND OPERATION
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Halfshaft Seal LH
Special Tool(s)303-293
Remover, Crankshaft Seal
21143
Special Tool(s)308-203
Installer, Differential Double
Lip Seal
16066
Removal
1.Refer to: Health and Safety Precautions (100-00
General Information, Description and
Operation).
2. Refer to: Front Halfshaft LH (205-04 Front Drive
Halfshafts, Removal and Installation).
3. Special Tool(s): 303-293
303-293303-293
E114366
Installation
1.Special Tool(s): 308-203
308-203308-203
E114367
2.Refer to: Front Halfshaft LH (205-04 Front Drive
Halfshafts, Removal and Installation).
3. Refer to: Transmission Fluid Level Check
(307-01 Automatic Transmission/Transaxle -
Vehicles With: 5-Speed Automatic Transaxle
- AW55 AWD, General Procedures).
G1163610en2008.50 Kuga8/2011
307-01- 67
Automatic Transmission/Transaxle
— Vehicles With:
5-Speed Automatic Transaxle - AW55 AWD
307-01- 67
REMOVAL AND INSTALLATION
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Transfer Case – Component Location
Powertrain overview
6
6
1
2
3
3
4
5
6
6
E102416
Description
Item
Transaxle with front axle differential
1
Transfer box
2
Front wheel half shafts
3Description
Item
Drive shaft
4
Rear drive axle
5
Rear wheel half shafts
6
G1164985en2008.50 Kuga8/2011
307-07- 3
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 3
DESCRIPTION AND OPERATION
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Transfer box seals
1
2
3
4
5
E115284
Description
Item
Output drive shaft flange retaining bolt
1
Output drive flange
2Description
Item
Hollow shaft seals, left
3
Hollow shaft seals, right
4
Output differential pinion gear seal
5
G1164985en2008.50 Kuga8/2011
307-07- 5
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 5
DESCRIPTION AND OPERATION
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Differential/drive - transfer box
1
2
3
4
5
2
E102901
Description
Item
Taper roller bearing - differential
1
Differential case
2Description
Item
Drive teeth - transfer box
3
Differential pinion gears
4
Spur gear
5
G1164985en2008.50 Kuga8/2011
307-07- 7
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 7
DESCRIPTION AND OPERATION
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Transfer Case – System Operation and Component Description
System Operation
1
2
3
E103728
Description
Item
Hollow shaft
1
Output shaft
2
Output drive flange
3
NOTE: From the start of series production, the
transfer box will be subject to a "Black Box Phase"
and will therefore not be repaired.
To realise the all-wheel drive, a transfer box has
been flange-mounted to the manual transaxle. The
transfer box is designed as an angular gear to
transfer the torque from the transaxle to the rear
axle. The hollow shaft of the transfer box is inserted
in a tooth on the gear case. From the hollow shaft,
torque is transferred to the driveshaft through the
output shaft/output flange via crown gear and
differential pinion gear.
G1164987en2008.50 Kuga8/2011
307-07- 8
Transfer Case
— Vehicles With: 5-Speed Automatic Transaxle - AW55
AWD/6-Speed Automatic Transaxle - 6DCT450
307-07- 8
DESCRIPTION AND OPERATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL