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EddieM
One can only admire the perseverance here... I would probably have rented my body out by now, and of course hope to be able to afford a new push bike, sometime in the 2020's 
Mk2 Kuga Powershift (title edited)
- Thread starter Keithmac
- Start date
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EddieM
This thread is better than Dallas, showing my age.
Andy
More like game of thrones... I hope the last episode doesn't disappoint.
Ah yes, my apologies I recall that now.....you dont need the later driveshaft I guess.
Has the later box any particular reliability issues that you know of?
John
The 2017 is the latest revision and they've sorted the "design" faults from the early versions so fingers crossed!.
Driveshafts and AWD transfer case are the same as the earlier Mk2 Kugas (luckily!).
The engine + gearbox combo is 10mm wider but this has been taken up 5mm both sides so no need to alter the driveshafts.
I had to split the difference with the AWD coupling tube but 5mm less spline engagement on both ends was negligible.
Driveshafts and AWD transfer case are the same as the earlier Mk2 Kugas (luckily!).
The engine + gearbox combo is 10mm wider but this has been taken up 5mm both sides so no need to alter the driveshafts.
I had to split the difference with the AWD coupling tube but 5mm less spline engagement on both ends was negligible.
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Great stuff matey, you’re almost there!
Do lets know how the coding goes, and indeed whats involved.
John
Do lets know how the coding goes, and indeed whats involved.
John
Great stuff matey, you’re almost there!
Do lets know how the coding goes, and indeed whats involved.
John
And then start making conversion kits for the "experienced gearbox repairers"
Unbelievable persistence and skill, Keith
Well what a weekend I've had with the Kuga!.
Starter motor looked a good fit and mesh on the ring-gear but didn't work correctly, luckily I found out Friday morning and got a second hand one delivered on Saturday (ironically it was from the same car as the flywheel!).
Next up I had to modify the starter to fit, did that after work in Sat and fit to gearbox.
Got the car running on Sunday, had ABS/ Torque sensor faults, the 2017 uses a different CAN instruction set it seems..
Spent 2 hours trying to reflash with Ford IDS before biting the bullet. Front of car off on Sunday afternoon and my old Mechatronic unit fitted (really didn't want to use any of the old box but hey ho..).
It started raining Sunday night so rushed into fitting the Mecatronic. It has a rotary encoder that reads gear selector postion and I could have sworn it is indexed in Park position...
Got up and out at 6am to put front end back together (can do that with my eyes shut now!).
Took kids to school and hopped into the Kuga, Gear Selector in Park/ dashboard says drive (bxllxcks!).
Drain gearbox down AGAIN, managed to get the sump off the front and down enough to access the position sensor and eventually got it correct (after the penny droped about being set up in Drive..).
Our 1 year old Labrador wandered off down the street when I left the gate open so decided when it was back together I'll wait for my wife to come home from work before doing anything else.
Anyway, drove it off the drive (lumpy clutch engagement!), turned it around and then set about a Clutch and Gear learn with FORScan. All went OK and just taken it around the block for a quick drive.
Smooth as silk!. Don't know whether to laugh or cry. Been a long hard fight.
Starter motor looked a good fit and mesh on the ring-gear but didn't work correctly, luckily I found out Friday morning and got a second hand one delivered on Saturday (ironically it was from the same car as the flywheel!).
Next up I had to modify the starter to fit, did that after work in Sat and fit to gearbox.
Got the car running on Sunday, had ABS/ Torque sensor faults, the 2017 uses a different CAN instruction set it seems..
Spent 2 hours trying to reflash with Ford IDS before biting the bullet. Front of car off on Sunday afternoon and my old Mechatronic unit fitted (really didn't want to use any of the old box but hey ho..).
It started raining Sunday night so rushed into fitting the Mecatronic. It has a rotary encoder that reads gear selector postion and I could have sworn it is indexed in Park position...
Got up and out at 6am to put front end back together (can do that with my eyes shut now!).
Took kids to school and hopped into the Kuga, Gear Selector in Park/ dashboard says drive (bxllxcks!).
Drain gearbox down AGAIN, managed to get the sump off the front and down enough to access the position sensor and eventually got it correct (after the penny droped about being set up in Drive..).
Our 1 year old Labrador wandered off down the street when I left the gate open so decided when it was back together I'll wait for my wife to come home from work before doing anything else.
Anyway, drove it off the drive (lumpy clutch engagement!), turned it around and then set about a Clutch and Gear learn with FORScan. All went OK and just taken it around the block for a quick drive.
Smooth as silk!. Don't know whether to laugh or cry. Been a long hard fight.
WELL DONE KEITH!
Now sell it.
Andy
Now sell it.
Andy
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EddieM
Let's hope you get many years of hassle free motoring from now on, an epic journey indeed. I'm tired just reading this thread. Etis IDS huh? I used to be the software delivery manager for that "work of art" !!
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EddieM
I have a similar issue with my car, had it a long time now, ok loads of non essential items no longer work on it, but it's a bit like an old dog, it make smell a bit and be a bit slow and ineffiecent, but you couldnt "shoot it in the face" poor thing.
Amazing, once again many congrats!
Time for some nice steady miles to let everything bed in. Fingers crossed!
John
Time for some nice steady miles to let everything bed in. Fingers crossed!
John
First weekend I've not worked on a car in a long while!.
Handed it back to my wife on Saturday and she's been all over in it, says the gear shifting is much better than before (before it broke!).
Took both of my girls for a walk on Monday, first time both out together on leads and that was "interesting" to say the least!.
Handed it back to my wife on Saturday and she's been all over in it, says the gear shifting is much better than before (before it broke!).
Took both of my girls for a walk on Monday, first time both out together on leads and that was "interesting" to say the least!.
Have you kept a record of the running total costs Keith - including lube, filters or whatever since the fault first appeared?
Still looking good so far!
John
Still looking good so far!
John
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