2.5L FORD KUGA 2011 1.G User Guide

Differential Case
General EquipmentCable Ties
Removal
All vehicles
1. Refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).
Vehicles with 2.0L diesel engine
2.
1
2x6x3
1
2x6x3
E101687
3.
E101709
Vehicles with 2.5L engine
4. Refer to: Driveshaft (205-01 Driveshaft,
Removal and Installation).
5.
E114256
6.
x2x2
E114255
G1061458en2008.50 Kuga8/2011
205-02- 21
Rear Drive Axle/Differential
205-02- 21
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Vehicles with 2.5L engine
6.
x2x2
E114255
7.Torque: 80Nm
E114256
8.Refer to: Driveshaft (205-01 Driveshaft,
Removal and Installation).
All vehicles
9. Refer to: Rear Halfshaft (205-05 Rear Drive
Halfshafts, Removal and Installation).
10. Refer to: Differential Fluid Level Check (205-02
Rear Drive Axle/Differential, General
Procedures).
G1061458en2008.50 Kuga8/2011
205-02- 24
Rear Drive Axle/Differential
205-02- 24
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Vehicles with 2.5L engine
6.
E98543
x7
7.
E114375
8.
x2
x2
x2
x2
E114188
9.
1
2x6
x3
1
2x6
x3
E101018
G1076971en2008.50 Kuga8/2011
205-02-26
Rear Drive Axle/Differential
205-02- 26
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

3. CAUTION: Make sure that theinstallation marks are aligned.
2. Torque: 35
E101688
4.Torque: 25Nm
x2
E102531
Vehicles with 2.5L engine
5.Torque: 25
E114254
6. CAUTION: Make sure that the
installation marks are aligned.
1. Torque: 35
2. Torque: 35
3. Torque: 35
E114296
G1076971en2008.50 Kuga8/2011
205-02- 29
Rear Drive Axle/Differential
205-02- 29
REMOVAL AND INSTALLATION
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL
TO MODEL INDEX
BACK TO CHAPTER INDEX
1. Torque: 35Nm
Nm
3. Torque: 35Nm
Nm
Nm
Nm
Nm
3
x2
1
2
2
x3
1
E114197
7.
3
1
2
2x3
1
x4

Vehicles with 2.5L engine
18.
x2x2
E132332
All vehicles
19. WARNING: Be prepared to collectescaping fluid.
CAUTIONS:
The inner constant velocity (CV) joint
must not be bent more than 18°.
The outer constant velocity (CV) joint
must not be bent more than 45°.
Special Tool(s): 204-159, 204-605
90
204-159
3
4
1
204-605
2
90
204-159
3
4
1
204-605
2
E132335
20. N O T E : This step is only necessary when
installing a new component.
Special Tool(s): 205-071-01
General Equipment: Puller
G1076962en2008.50 Kuga8/2011
205-04- 20
Front Drive Halfshafts
205-04- 20
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Vehicles with 2.5L engine
5. NOTE:Make sure that a new component is
installed.
Torque: 10
Nm
1.
2. NOTE: Make sure that a new component is
installed.
Torque: 10
Nm
3. Torque: 25Nm
4. Torque: 25Nm
2
4
13
2
4
13
E132331
All vehicles
6. Special Tool(s): 204-605
E102114
204-605
7.Remove the Special Tool(s): 204-609
E102115
204-609
8.
E132381
9.Torque: 83Nm
E102113
10. WARNING: Make sure that a new nut is
installed.
CAUTION: Make sure that the ball joint
ball does not rotate.
Torque: 80
Nm
E99197
11. NOTE: This step is only necessary when
installing a new component.
G1076962en2008.50 Kuga8/2011
205-04- 24
Front Drive Halfshafts
205-04- 24
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• INSTALL a new brake mastercylinder.
REFER to: Brake Master
Cylinder - 2.5L Duratec
(147kW/200PS) - VI5 (206-06
Hydraulic Brake Actuation,
Removal and Installation).
• Leaking brake master cylinder
primary piston cup.
• FREE UP and ADJUST theparking brake cable.
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
INSTALL new components as
necessary.
• Parking brake control not fully
released.
• REFER to:Anti-Lock Control
(206-09 Anti-Lock Control,
Diagnosis and Testing).
• Malfunctioning anti-lock braking
system (ABS).
• REFER to:Instrument Cluster
(413-01 Instrument Cluster,
Diagnosis and Testing).
• Shorted indicator circuit.
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Grease or fluid on the brake
shoes or brake pads; glazed
linings.
• Vibration when the brakes are
applied
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn or damaged brake shoes
or brake pads.
• TIGHTEN the caliper mountingbolt(s).
• Loose caliper mounting bolt(s).
•
• Excessive brake disc thickness
variation or brake disc runout.
• CHECK the tires. BALANCE orINSTALL new tires as neces-
sary.
REFER to: Wheels and Tires
(204-04 Wheels and Tires,
Diagnosis and Testing).
• Wheels and tires.
• TIGHTEN or INSTALL newwheel hub bolts as necessary.
• Loose or missing wheel hub
bolts.
• CARRY OUT a brake discrunout check.
• Worn or damaged brake drums
or brake discs.
G1058975en2008.50 Kuga8/2011
206-00- 6
Brake System - General Information
206-00- 6
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake and clutch system
leaks. Refer to Brake Master Cylinder
Component Test in this procedure.
• Are any leaks present?
zYe s REPAIR as necessary. ADD fluid and BLEED
the brake system. REFER to: (206-00 Brake
System - General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures),
Component Bleeding (General Procedures).
TEST the system for normal operation.
zNo
GO to A3.
A3: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a brake master cylinder bypass
Condition Test. Refer to the Brake Master
Cylinder Component Test in this procedure.
• Was a concern found?
zYe s INSTALL a new brake master cylinder.
REFER to: Brake Master Cylinder - 2.5L
Duratec (147kW/200PS) - VI5 (206-06
Hydraulic Brake Actuation, Removal and
Installation).
TEST the system for normal operation.
zNo
VERIFY the customer concern.
PINPOINT TEST B : PEDAL EASES DOWN SLOWLY
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B1: CHECK THE BRAKE PEDAL OPERATION
1 Depress the brake pedal.
• Does the pedal ease down slowly?
zYe s GO to B2.
zNoRefer to the Brake Master Cylinder
Component Test in this procedure.
G1058975en2008.50 Kuga8/2011
206-00- 11
Brake System - General Information
206-00- 11
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake system leaks.
• Are any leaks present?
zYe s REPAIR as necessary. ADD fluid and BLEED
the brake system. REFER to: (206-00 Brake
System - General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures),
Component Bleeding (General Procedures).
TEST the system for normal operation.
zNo
GO to B3.
B3: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a brake master cylinder bypass
Condition Test. Refer to the Brake Master
Cylinder Component Test in this procedure.
• Was a concern found?
zYe s INSTALL a new brake master cylinder.
REFER to: Brake Master Cylinder - 2.5L
Duratec (147kW/200PS) - VI5 (206-06
Hydraulic Brake Actuation, Removal and
Installation).
TEST the system for normal operation.
zNo
GO to B4.
B4: CHECK THE BRAKE BOOSTER CHECK VALVE
1 Disconnect the brake booster check valve
vacuum hose at the manifold.
2Blow into the hose attached to the brake booster
check valve.
• Does air pass through the valve?
zYe s INSTALL a new brake booster check valve.
zNoGO to B5.
B5: CHECK THE BRAKE BOOSTER CHECK VALVE VACUUM
1 Run the engine at idle.
G1058975en2008.50 Kuga8/2011
206-00-
12
Brake System - General Information
206-00- 12
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

too close to the fluid level indicator assembly,
or float assembly damage.
Bypass Condition Test
1. Check the fluid in the brake master cylinderreservoir. Fill the brake master cylinder reservoir
if low or empty.
2. Observe the fluid level in the brake master cylinder reservoir. If after several brake
applications, the fluid level remains the same,
measure the wheel turning torque required to
rotate the wheels with the brakes applied as
follows:
Place the transaxle in the NEUTRAL position.
Raise and support the vehicle. REFER to: (100-02
Jacking and Lifting) Jacking (Description and Operation),
Lifting (Description and Operation).
Apply the brakes with a minimum of 445 N (100
lb) and hold for approximately 15 seconds. With
the brakes still applied, exert a torque on the front
wheels of 10.1 Nm (75 lb ft). If either wheel rotates,
install a new brake master cylinder.
REFER to: Brake Master Cylinder - 2.5L Duratec
(147kW/200PS) - VI5 (206-06 Hydraulic Brake
Actuation, Removal and Installation).
Non-Pressure Leaks
Any empty brake master cylinder reservoir
condition may be caused by two types of
non-pressure external leaks.
Type 1: An external leak may occur at the brake
master cylinder reservoir cap because of incorrect
positioning of the gasket and cap. Reposition the
cap and gasket.
Type 2: An external leak may occur at the brake
master cylinder reservoir mounting seals. Service
such a leak by installing new seals.
G1058975en2008.50 Kuga8/2011
206-00- 19
Brake System - General Information
206-00- 19
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL