Oz Focus Forums

Like the from transfer case, there are two types of rear differential. Most of the Volvo ones have the cover plate at 45 degrees while the TE Kuga one is at 90 degrees. Either one will bolt up to the rear crossmember and both share the same 2.56:1 ratio. the rear driveshafts are 26 spline on both ...

I'll start by suggesting you read the Haldex Explained article in the Technical Documents section first so you have a basic understanding of how it works. In simple terms it's a viscous coupling at the rear of the propshaft (before the differential gear) which applies drive to the rear wheels based ...

To accommodate the AWD there is a unique rear crossmember which is only found in the S40 and V50 Volvo's. Although the TE Kuga is AWD, the crossmember mounts approx 20mm rearward of the standard one and therefore doesn't center the wheel in the wheel arch. The other issue is that the Kuga one raises ...

The front crossmember looks like any normal MK2 Focus or P1 Volvo and differs only in the thickness of the bushes that mount it to the chassis. It mounts the crossmember approx 20mm lower and the reason is to give clearance of the transfer case to the steering rack.


IMG_1072.jpg

IMG_1074.jpg ...

Next to the gearbox the RHS driveshaft is the second hardest part to find. This is because you must have a manual one as the auto driveshafts are approx 15mm too short and do not engage with the splines in the diff. They are also different as they are thinner to go through the centre of the transfer ...

With the transfer cases there are two types which are virtually the same. The Volvo one generally has the cover plate at 45 degrees to the centreline of the driveshaft, while the later Kuga has it at 90 degrees. They both utilize the same 41/16 crownwheel/pinion teeth count giving a transfer case ...

On the gearbox side your diff has both a set of internal splines for the driveshaft, and an external set for the drive collar.

Standard open diff centre removed from gearbox. Note the extra length and external splined section. Note this diff is from an auto box but the principle is the same.
IMG ...

The transfer case is bolted to the gearbox and its function is to take drive from the output of the gearbox and transfer it through 90 degrees to give rotation of the propshaft. It's a fairly simple mechanical device which consists of a crownwheel & pinion in the opposite arrangement to that of a ...

TE Kuga (MK1) Workshop Manual & Wiring Diagrams

https://ozfocusforums.com/Technical/Kuga-Mk1-Workshop-Manual.pdf
https://ozfocusforums.com/Technical/Kuga-Mk1-Wiring-Diagrams.pdf

This is an early Haldex doc on the system operation which again gives a good overview.
https://ozfocusforums.com ...

First task is to see if we can get the boat crank to sit in the car block. The mains are approx 1mm smaller in diameter so the machining required was to the journal widths. Each main journal was measured and the crank put in a lathe where somewhere between 0.020 and 0.090" was removed from each ...