BACK TO CHAPTER INDEX FORD KUGA 2011.

0MY WORKSHOP REPAIR MANUAL

TO MODEL INDEX
205-02-7 Rear Drive Axle/Differential 205-02-7
DESCRIPTION AND OPERATION
General overview reduced to a minimum up to a throttle position of
approx. 50%. A prerequisite for this is that there is
Haldex clutches of the 3rd and 4th generations are no difference in speed in the Haldex clutch between
used in the Ford Kuga. the input and output shafts.
The development of the third generation Haldex
clutch represents a big step forward in modern
all-wheel technology. The Haldex clutch is
Operation
electro-hydraulically controlled. Additional
information is taken into consideration during
3 4
control tasks via the all-wheel drive control unit.
Slip alone is no longer decisive for the distribution 2
of the propulsive forces; the vehicle's driving 5
dynamics are also taken into consideration. The
control unit accesses the driving-related data via
the data bus. With this data, the control unit has
all the essential information about speed, cornering,
coasting or traction operation, and can optimally 1 6
react to every driving situation.
Compared with the previous generation, the 4th E100645
generation Haldex clutches operate with higher
pressure and achieve shorter response times when Item Description
distributing the drive forces.
1 Output shaft
Advantages of the Haldex clutch:
2 Working piston
Permanent all-wheel drive with
electronically-controlled multi-plate clutch 3 Plates
Fast response 4 Ring piston pump
No straining when parking and manoeuvring 5 Control Valve
Compatible with different tyres (e.g. emergency
spare wheel) 6 Input shaft
Fully combinable with driving dynamic control Within the Haldex clutch is a plate assembly and
systems a so-called ring piston pump with a pump plunger
The driveshaft is connected to the input shaft of and a working piston.
the Haldex clutch. Within the Haldex clutch, the Fluid supply is started if there is a speed difference
input shaft is separated from the output shaft to between the input and output shafts.
the rear axle differential by means of a multi-plate
This fluid pressure is transmitted to the working
clutch. Torque is only transmitted to the rear axle
piston and in this way the plate assembly is
differential when the plate assembly of the Haldex
compressed.
clutch is closed.
The multi-plate clutch is electro-hydraulically
controlled via the all-wheel drive control unit. For Design of the 3rd generation Haldex
ecological driving, the torque to the rear axle is clutch

2008.50 Kuga 8/2011 G1076981en

BACK TO CHAPTER INDEX FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
TO MODEL INDEX
205-02-8 Rear Drive Axle/Differential 205-02-8
DESCRIPTION AND OPERATION

3
2

4
11

11

10

5
6
7

E100664

Item Description Item Description

1 Multiplate clutch 6 Electric feed pump
2 Ring piston pump 7 Fluid filter
3 All-wheel drive control unit 8 Pressure accumulator
4 Pressure relief valve (high pressure) 9 Pressure relief valve (low pressure)
5 Input shaft 10 Preload valve
11 High-pressure valves

2008.50 Kuga 8/2011 G1076981en

BACK TO CHAPTER INDEX FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
TO MODEL INDEX
205-02-9 Rear Drive Axle/Differential 205-02-9
DESCRIPTION AND OPERATION
The Haldex clutch is based on the principle of a A mechanical component, comprising input and
simple wet clutch that distributes the torque variably output shafts, the plate assembly (clutch) as
between the front and rear axles. well as the cam plate and the roller bearing.
Three components are linked within the Haldex A hydraulic component, essentially comprising
clutch: pressure valves, a pressure accumulator, the
control valve, the ring pistons and a fluid filter.
The electronic control comprises the electric
fluid pump and the all-wheel drive control unit
with integrated pressure/temperature sensor
and an actuator motor for the control valve.

Design of the multi-plate clutch

A
5
4

1
9 10 11

6
B 12 13
8

7
E100662

Item Description Item Description

A Pump plunger assembly 6 Input shaft
B Working piston assembly 7 Cam disc
1 Output shaft 8 Springs
2 Inner plates 9 Pump plunger roller
3 Outer plates 10 Pump plunger roller
4 Disc drum 11 Pump plunger
5 Contact plate 12 Working piston roller
13 Working piston

2008.50 Kuga 8/2011 G1076981en

BACK TO CHAPTER INDEX FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
TO MODEL INDEX
205-02-10 Rear Drive Axle/Differential 205-02-10
DESCRIPTION AND OPERATION
All-wheel drive control unit The temperature sensor of the Haldex clutch is
installed near the control valve in the control unit
and is surrounded by the hydraulic fluid. The
temperature is transmitted to the control module
5
1 and is used for adaptation to the changing viscosity
4
of the hydraulic fluid. If the hydraulic fluid is cold,
the control valve has to be opened slightly more
than requested. This allowance has to be reduced
as the temperature increases. The normal working
3 temperature of the hydraulic fluid is between +40
C and +60 C. If the temperature rises above 100
C, the clutch is depressurised; if the temperature
falls below 95 C, the clutch is pressurised again.
All-wheel drive is deactivated and a diagnostic
trouble code set if a fault occurs in the temperature
sensor.
With Haldex Generations I and II, the control valve
was actuated via a stepper motor. With Haldex
2 Generation III, the stepper motor has been omitted.
E100663
The control valve is now actuated via a solenoid
Item Description valve. The solenoid valve is actuated by the control
module in the all-wheel drive control unit by means
1 Electronic Control Unit of pulse width modulation. The pulse width
2 Control valve modulation determines the position of the
adjustment spindle and thus the opening cross
3 Pressure/temperature sensor section of the return hole. This is how the pressure
4 Electrical connection CAN (controller area at the working piston of the plates is determined.
network) databus If the return hole is fully closed, maximum pressure
is applied to the plates. If the return hole is fully
5 Electric feed pump connection open, the plates are unpressurized.
The all-wheel drive control unit is bolted directly to
the housing of the Haldex clutch. Electric feed pump
It forms one unit made up of the control valve, a
pressure/temperature sensor, and a control The electric feed pump is installed in the clutch
module. It receives signals from the PCM and from unit. It works according to the gerotor principle.
the ABS control module via the CAN data bus. The The main purpose of the feed pump is to fill the
control module in the control unit uses these pressure accumulator and the space behind the
signals to determine the fluid pressure that is pump plunger with hydraulic fluid, thereby ensuring
needed to actuate the clutch plates depending on a fast response time of the Haldex clutch. The feed
the requirement. This determines how much torque pump used in the third generation is designed to
should be transmitted to the rear wheels. All-wheel achieve an even higher pressure than the base
drive is deactivated if a fault occurs in the all-wheel pressure of 4 bar. It is supplied with current by the
drive control unit. control module in the all-wheel drive control unit
when the engine is running above approx. 400 rpm.
A preload of approx. 80 Nm is always present at
the Haldex clutch.
Pressure control - 3rd generation
Haldex clutch

2008.50 Kuga 8/2011 G1076981en

BACK TO CHAPTER INDEX FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
TO MODEL INDEX
205-02-11 Rear Drive Axle/Differential 205-02-11
DESCRIPTION AND OPERATION

3 4 A
B
C
D
1
2

7
8
6

9
10

E100539

Item Description Item Description

A Barometric Pressure 4 Control valve
B Base pressure 5 Pressure accumulator
C Increased base pressure (preload) 6 Electric feed pump
Drive Operating pressure 7 Filters
1 Plate assembly and ring piston pump 8 Preload valve
2 High-pressure valves 9 Pressure relief valve (low pressure)
3 Pressure Sensor 10 Pressure relief valve (high pressure)

Base pressure

2008.50 Kuga 8/2011 G1076981en

BACK TO CHAPTER INDEX FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
TO MODEL INDEX
205-02-12 Rear Drive Axle/Differential 205-02-12
DESCRIPTION AND OPERATION

E100540

Item Description Item Description

A Barometric Pressure C Increased base pressure (preload)
B Base pressure Drive Operating pressure

The hydraulic fluid is drawn from the sump of the pressure of 4 bar and compensates pressure
hydraulic system and directed through a filter. The fluctuations. A compensating spring works in the
feed pump pressurises the system and pumps opposite direction and prevents the plate discs
hydraulic fluid into the pump plungers. This base becoming blocked by the force of the working
pressure of 4 bar presses the rollers for the pump piston. This restricts the transferable torque to
plungers against the cam disc. At the same time, approx. 7 Nm. This value can, however, deviate
hydraulic fluid flows into the working piston. This slightly due to temperature and/or the difference
eliminates the play in the clutch plates. The Haldex in speed between the input and output shafts.
clutch can respond quickly and distribute the torque
within fractions of a second. The spring force in
the pressure accumulator determines the base Increased base pressure (preload)

2008.50 Kuga 8/2011 G1076981en

BACK TO CHAPTER INDEX FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
TO MODEL INDEX
205-02-13 Rear Drive Axle/Differential 205-02-13
DESCRIPTION AND OPERATION

E100541

Item Description Item Description

A Barometric Pressure C Increased base pressure (preload)
B Base pressure Drive Operating pressure

To ensure very fast torque transmission, a higher (second generation). To protect the pump from
voltage is applied to the electric feed pump and overloading, the pressure is restricted to approx.
the control valve fully closed before the shaft-driven 10 bar by the pressure relief valve. The hydraulic
pump is brought into operation. As a result, the fluid flows back into the sump via the pressure
maximum pressure is raised above the base accumulator.
pressure, and a torque of up to 80 Nm applied to
the multi-plate clutch. This achieves significantly
faster pressure build-up than with older systems Pressure build-up

2008.50 Kuga 8/2011 G1076981en

BACK TO CHAPTER INDEX FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
TO MODEL INDEX
205-02-14 Rear Drive Axle/Differential 205-02-14
DESCRIPTION AND OPERATION

E100542

Item Description Item Description

A Barometric Pressure C Increased base pressure (preload)
B Base pressure Drive Operating pressure

The pump plungers generate the operating is mechanically controlled by means of the
pressure that is controlled by the control valve as pressure relief valve.
a function of the difference in speed between the
input and output shafts. The control valve works
progressively from fully open to fully closed. The Design of the 4th generation Haldex
fluid pressure can be approx. 67 bar when the clutch
control valve is fully open. The maximum pressure
General overview

2008.50 Kuga 8/2011 G1076981en

BACK TO CHAPTER INDEX FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
TO MODEL INDEX
205-02-15 Rear Drive Axle/Differential 205-02-15
DESCRIPTION AND OPERATION

4
3
E115887

Item Description Item Description

1 Fluid filter 3 Electric feed pump
2 All-wheel drive control unit 4 Pressure accumulator

The electric feed pump is an axial piston pump The 4th generation Haldex has a larger fluid filter
which is more robustly designed than the gerotor which contains a non-return valve.
pump in the 3rd generation Haldex. The higher The all-wheel drive control unit no longer contains
feed pressure means that the ring piston pump at a pressure sensor in the 4th generation Haldex.
the clutch plate assembly, the pressure relief
valves, preload valve and the high pressure valves
are no longer necessary. Pressure control - 4th generation Haldex
The pressure accumulator on the 4th generation clutch
Haldex is larger and is designed for the higher
pressure.

2008.50 Kuga 8/2011 G1076981en

BACK TO CHAPTER INDEX FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
TO MODEL INDEX
205-02-16 Rear Drive Axle/Differential 205-02-16
DESCRIPTION AND OPERATION

8
6

4
9 1
3 11

10 2

E114914

Item Description Item Description

1 Haldex clutch fluid 6 Control valve
2 Inlet filter 7 Dished washer
3 Electric feed pump 8 Ring piston
4 Filters 9 Clutch plate pack
5 Pressure accumulator 10 Return pressure accumulator
11 Return control valve

Full torque is available at any time on the 4th and function of the control valve. The control valve
generation Haldex clutch because the pressure is distributes the pressure, depending on the
not dependent on the difference in the speeds of requirements, across its three outlet openings
rotation. This is used for instance to activate the (storage pressure, working pressure, return).
Haldex clutch for better traction when moving off. From the storage pressure (30 bar) and depending
On the 4th generation Haldex clutch, the preload on the requirements, the control valve regulates a
function which applied 80 Nm to the plates in the working pressure of 0 - 17 bar, which is applied to
3rd generation is no longer required. the ring piston. At 17 bar working pressure, the
maximum torque of 1000 Nm is transferred to the
On request from the control unit and at engine
rear wheels. The all-wheel drive control unit
speeds above 400 rpm, the electric feed pump runs
ensures the best possible performance under all
and maintains the storage pressure at about 30
driving conditions, for all road conditions and
bar.
independent of the speed.
A pressure reducing valve acts as a control valve,
allowing the all-wheel drive control unit to control
the pressure with much greater precision. The
all-wheel drive control unit monitors the position

2008.50 Kuga 8/2011 G1076981en

BACK TO CHAPTER INDEX FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
TO MODEL INDEX
205-02-17 Rear Drive Axle/Differential 205-02-17
GENERAL PROCEDURES

Differential Fluid Level Check

3. Material: Rear Axle Oil SAE 80W-90 F
Materials
(WSP-M2C197-A / 4U7J-M2C197-AA)
Name Specification transmission fluid
Rear Axle Oil SAE 80W- WSP-M2C197-A / 4U7J- Correct the rear axle oil level if neccessary.
90 F M2C197-AA 24 ml ~ 1 mm

1. Refer to: Health and Safety Precautions (100-00

General Information, Description and
Operation).
2.

E104195

E104196

2008.50 Kuga 8/2011 G1087340en