Hi, I am trying to change the oil and filter on the Gen IV Haldex coupler fitted to my Kuga 1 (4x4 automatic).
Unfortunately my vehicle is fitted with the LARGE harmonic balancer which blocks access to remove the oil pump. Has anyone managed to remove the Haldex oil pump with the large harmonic balance fitted? (I have seen plenty of videos of the pump removal with the smaller balancer fitted - tight but doable).
If I have to remove the balancer can anyone tell me how you split the prop-shaft flange from the Haldex input flange. I have undone the six securing bolts but the flanges will not separate. I have seen threads talking about the problem but cannot find the solution.
Photos below. Any help appreciated.

2 hours ago, NickGS said:

If I have to remove the balancer can anyone tell me how you split the prop-shaft flange from the Haldex input flange. I have undone the six securing bolts but the flanges will not separate. I have seen threads talking about the problem but cannot find the solution.

I speak from experience as my daughter has the same AWD Kuga.

Yes you do have to remove the propshaft to gain assess and it's not easy. Before removing the allen head bolts on the rear flange, you first have to remove the lower engine mount completely. Next undo the fixings in the middle of the shaft and lastly the rear bolts. Now for the crazy bit. You have to push the whole of the engine forward towards the radiator. This in theory allows just enough clearance for the propshaft to be pulled clear of the rear flange.

Did I succeeded when I tried ? NO !!!

I could not get the propshaft to pull free. Perhaps I didn't have the engine moved far enough forward. After two full days of trying everything I could think of to gain an extra half inch clearance I had to admit defeat.

We took it to a garage who specialise in this (mostly VW) who took almost a full day and charged about £1300 if I remember correctly.

.....and here is my story in full, pictures.

 

51 minutes ago, unofix said:

I speak from experience as my daughter has the same AWD Kuga.

Yes you do have to remove the propshaft to gain assess and it's not easy. Before removing the allen head bolts on the rear flange, you first have to remove the lower engine mount completely. Next undo the fixings in the middle of the shaft and lastly the rear bolts. Now for the crazy bit. You have to push the whole of the engine forward towards the radiator. This in theory allows just enough clearance for the propshaft to be pulled clear of the rear flange.

Did I succeeded when I tried ? NO !!!

I could not get the propshaft to pull free. Perhaps I didn't have the engine moved far enough forward. After two full days of trying everything I could think of to gain an extra half inch clearance I had to admit defeat.

We took it to a garage who specialise in this (mostly VW) who took almost a full day and charged about £1300 if I remember correctly.

 

Thank you very much for the feedback. Sorry to hear that you had such horrendous problems. I am getting conflicting information, as some say the balancer should come apart without dismantling the font but you have tangible experience that it wont. I read another thread that said you place a rod into each of the two holes at the rear of the coupling and can push the front flange off that way. Whatever the solution its amazingly awkward to get at it!

Hi Unifix, Just to follow up on your helpful comments above, I would be grateful if you could clarify...
When you pulled the engine forward to allow more space for the harmonic balancer to be dismantled, was the resultant problem that:

a) you still couldn't separate the coupler at all or;

b) you could separate the coupler but not generate enough space to pull the front flange down and away from the rear flange?
 

If b), how did you separate the front flange from the rear flange? Did it just pull apart or did you have to use force?

Thanks Nick

6 minutes ago, NickGS said:

a) you still couldn't separate the coupler at all

Answer "A" still couldn't separate it. 🙁

Thank you very much for your help. Nick