[keithmac]

I need to do ours as well (JTEKT rear diff).

Just weary of what fluid to use, has FORD got a specification for it anywhere?.

The Powershift is easy enough to do, just make sure you do final level set procedure correctly and DON'T open the level bung again afterwards!.

 

[keithmac]

The JTEKT cluch clamp was "mechanically operated" rather than pump and hydraulics.

But after 60,000 miles the oil will be well past it's best.

Even sucking as much as you can out and replacing with same amount on a higher milage car is a good idea imho.

The oil will shear as the "clutch" plates clamp and there must be friction plate debris in it.

Think the sealed for life has come about due to dealerships employing oil change monkeys rather than proper techs.

More chance of a diff or gearbox being destroyed within the warranty period due an incorrect oil change in the first 3 years than letting it sit in it's own dirt for 6 years..

 

[keithmac]

Getrag make the Powershift (6DCT450), unless Ford have bolted something to the side of it I can't see how it can be inside the Powershift.

I've had mine in bits and watched videos, theres only two clutches in the Powershift?.

Volvo use the same Auto gearbox, surely they aren't using Ford Intelligent AWD?.

Need to have a closer look at ours to work out what does what.

Suppose if there's no wiring to the rear diff it has to be passive and the AWD is at the front.

 

[keithmac]

As posted, did my oil change. So whilst I was under there (with a camera) took some pics of the Kuga PTU.

It is a lump, a lot bigger than the JLR ones I remember.

A few observations:

lots of cooling fins, and the under tray has a air scoop diverting air that way. (see MK2 oil filter change)
A sump plug for a oil change, and a fill point higher up, (mine I think at 50k miles)

And a wire !!!! My bet, a temp sensor or a sensor for us to watch the IAWD picture on dashboard.

Great pictures, what oil did you use and quantity.

Nice to see there's a drain and fill plug!.

 

[keithmac]

MaoVi, what oil did you use for refilling?.

I've had my Powershift gearbox out and the front transfer box is an interesting design.

The AWD torque is transferred via a hollow splined coupling, the off side diff output from the gearbox drives a shaft in the middle of the transfer box and this passes through the centre of the transfer case to the OS driveshaft.

The transfer box is not active/ "dumb", the propshaft is always live and the rear magnetic clutch in the rear diff controls the rear wheel torque output.

Can't see how it would ever get more than a 50/50 torque split to the rear though.

 

[keithmac]

Redline MTL is for the manual gearbox, used it in my GTO TT, used Redline Shock Proof Heavy in the GTO Transfer Box, maybe a bit overkill for the Kuga PTU?.

 

[keithmac]

I think for our Active JTEKT rear diff I'll use the Ford factory fill, theres plated and cone diffs but with the Ford/JTEKT is more like a motorcycle clutch with magnetic clamping.

 

[keithmac]

I'd have gone with a Dowty washer just for a bit of extra insurance but looks a nice neat job!.

Might do ours the same way.

 

[keithmac]

From the post earlier in the thread you have to remove the diff and strip the clutch unit before getting to the clutch oil.

It is a none serviceable part so Ford will not have a spec on the oil, I wonder if JTEKT themselves would release the spec?.