Index FORD KUGA 2011 1.G Workshop Manual

3.Torque: 28Nm
E99426
Installation
1.To install, reverse the removal procedure.
2. Refer to: Component Bleeding (206-00 Brake
System - General Information, General
Procedures).
G1001210en2008.50 Kuga8/2011
206-04- 6
Rear Disc Brake
206-04- 6
REMOVAL AND INSTALLATION
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SECTION 206-05 Parking Brake and Actuation
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
206-05-2
Parking Brake (Overview) ........................................................................\
...........................
206-05-2
Overview ........................................................................\
.....................................................
206-05-2
Parking brake cable ........................................................................\
....................................
206-05-3
Parking brake control ........................................................................\
..................................
DIAGNOSIS AND TESTING 206-05-4
Parking Brake ........................................................................\
.............................................
206-05-4
Inspection and Verification ........................................................................\
..........................
206-05-4
Symptom Chart ........................................................................\
...........................................
206-05-5
Pinpoint Tests ........................................................................\
.............................................
GENERAL PROCEDURES 206-05-9
Parking Brake Cable Adjustment ........................................................................\
................
REMOVAL AND INSTALLATION 206-05-11
(12 664 0)
Parking Brake Control ........................................................................\
............
206-05-12
Parking Brake Rear Cables ........................................................................\
........................
206-05-1
Parking Brake and Actuation
206-05- 1
.
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Parking Brake – Overview
Overview
E103685
1
2
Description
Item
Parking brake cable
1
Parking brake control
2
The following components may be renewed
separately:
• Parking brake cable
• Parking brake control
Parking brake cable
E103686
G1058325en2008.50 Kuga8/2011
206-05- 2
Parking Brake and Actuation
206-05- 2
DESCRIPTION AND OPERATION
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The following instructions must be followed when
removing, installing or renewing the parking brake
cable:
• If the parking brake cable is removed, installedor renewed, the parking brake must be adjusted
after the work is completed.
Refer to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation, General
Procedures).
Parking brake control
E103687
The following instructions must be followed when
removing, installing or renewing the parking brake
lever:
• If the parking brake lever is removed, installed or renewed, the parking brake must be adjusted
after the work is completed.
Refer to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation, General
Procedures).
G1058325en2008.50 Kuga8/2011
206-05- 3
Parking Brake and Actuation
206-05- 3
DESCRIPTION AND OPERATION
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Parking Brake
Inspection and Verification
1. Verify the customer concern by operating theparking brake system.
2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart
Electrical
Mechanical
– Parking brakewarning circuit.
REFER to: Instru-
ment Cluster (413-
01 Instrument
Cluster, Diagnosis
and Testing).
– Parking brake
control
REFER to: Parking
Brake Control
(206-05 Parking
Brake and Actu-
ation, Removal
and Installation).
– Cable and conduit
REFER to: Parking
Brake Rear
Cables (206-05
Parking Brake and
Actuation,
Removal and
Installation). 3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the concern is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
Symptom Chart
Action
Possible Sources
Symptom
• GO toPinpoint Test A.
• Parking brake control.
• Cable and conduit.
• The parking brake will not apply
• GO toPinpoint Test A.
• Parking brake control.
• The parking brake will not hold
the vehicle
• GO toPinpoint Test B.
• Parking brake control.
• Cable and conduit.
• The parking brake will not
release
G1063696en2008.50 Kuga8/2011
206-05- 4
Parking Brake and Actuation
206-05- 4
DIAGNOSIS AND TESTING
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Pinpoint Tests
PINPOINT TEST A : THE PARKING BRAKE WILL NOT APPLY
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A1: CHECK PARKING BRAKE CABLE ADJUSTMENT
1 Release the parking brake and measure the gap
between the lever and the caliper.
• Is the gap 1.2mm?
zYe s
E83778
1.2 mm
Vehicle OK
zNo REFER to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation,
General Procedures).
A2: CHECK FUNCTION OF PARKING BRAKE ON BRAKE CALIPER
1 Raise and support the vehicle on a lift with the
parking brake fully applied.
REFER to:
Lifting(100-02 Jacking and Lifting,
Description and Operation).
– With the aid of another technician, release the parking brake and check the operation of the
brake cables and levers.
• Are the left-hand (LH) and right-hand (RH) parking brake levers moving a similar distance?
zYe s
CHECK the other causes such as conventional
brake system components. REPAIR or
INSTALL new components as necessary.
zNoREFER to: Brake Caliper (206-04 Rear Disc
Brake, Removal and Installation).
TEST the system for normal operation.
G1063696en2008.50 Kuga8/2011
206-05- 5
Parking Brake and Actuation
206-05- 5
DIAGNOSIS AND TESTING
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A3: CHECK FOR WORN BRAKE SHOES OR PADS
1 Inspect the brake shoes or pads for excessive
wear.
REFER to:
Specifications (206-00 Brake System
- General Information, Specifications).
• Are the brake shoe linings or brake pads OK?
zYe s GO to A4.
zNoINSTALL new brake shoes or pads.
REFER to: Brake Pads (206-04 Rear Disc
Brake, Removal and Installation).
TEST the system for normal operation.
A4: CHECK FOR DAMAGED PARKING BRAKE CABLES
1 Inspect the parking brake cables and conduits
for damage, rust or fraying.
• Are the parking brake cables and conduits OK?
zYe s CHECK for other causes such as loose
parking brake control or conventional brake
system components.
zNoREPAIR or INSTALL cables and conduit as
necessary. TEST the system for normal
operation.
PINPOINT TEST B : THE PARKING BRAKE WILL NOT RELEASE
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B1: CHECK PARKING BRAKE CONTROL
1 Raise and support the vehicle on a lift with the
parking brake fully applied.
– With the aid of another technician, release the parking brake and check the operation of the
brake cables and levers.
• Did the parking brake release?
zYe s CHECK the other causes such as conventional
brake system components. REPAIR or
INSTALL new components as necessary.
zNoGO to B2.
G1063696en2008.50 Kuga8/2011
206-05- 6
Parking Brake and Actuation
206-05- 6
DIAGNOSIS AND TESTING
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B2: CHECK PARKING BRAKE CABLES
1 Loosen the parking brake cable tension.
– Rotate the rear wheels by hand.
• Did the rear wheels turn freely?
zYe s INSTALL a new parking brake control.
REFER to: Parking Brake Control (206-05
Parking Brake and Actuation, Removal and
Installation).
TEST the system for normal operation.
zNo
GO to B3.
B3: CHECK FRONT PARKING BRAKE CABLE
1 Disconnect the parking brake front cable and
conduit from the rear brake cable and conduit
at the equalizer.
– Rotate the rear wheels by hand.
• Did the rear wheels turn freely?
zYe s INSTALL a new front parking brake cable and
conduit.
REFER to: Parking Brake Rear Cables (206-
05 Parking Brake and Actuation, Removal
and Installation).
TEST the system for normal operation.
zNo
GO to B4.
G1063696en2008.50 Kuga8/2011
206-05- 7
Parking Brake and Actuation
206-05- 7
DIAGNOSIS AND TESTING
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B4: CHECK REAR PARKING BRAKE CABLES
1 Disconnect the parking brake at the rear brakes,
one at a time.
– Rotate the wheel affected by the disconnected parking brake.
• Did the wheel turn freely?
zYe s INSTALL a new parking brake control lever
on the rear drum brakes or caliper assembly
on rear disc brakes.
REFER to: Parking Brake Control (206-05
Parking Brake and Actuation, Removal and
Installation)
/ Brake Caliper (206-04 Rear Disc Brake,
Removal and Installation).
TEST the system for normal operation.
zNo
REFER to: Brake System (206-00 Brake
System - General Information, Diagnosis
and Testing).
G1063696en2008.50 Kuga8/2011
206-05- 8
Parking Brake and Actuation
206-05- 8
DIAGNOSIS AND TESTING
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Parking Brake Cable Adjustment
1.Fully apply the parking brake.
1.
2. Fully release the parking brake control.
2.
E92650
3. NOTE: This step is only necessary if the parking
brake cable was removed.
1. Torque: 2
Nm
E102065
21
G1001211en2008.50 Kuga8/2011
206-05- 9
Parking Brake and Actuation
206-05- 9
GENERAL PROCEDURES
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