brake pads FORD KUGA 2011 1.G User Guide

Action
Possible Sources
Symptom
• 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.
• Brake noise
• GO toPinpoint Test E.
• Brake booster.
• GO toPinpoint Test F.
• Brake booster.
• Seized brake pedal pivot.
• Slow or incomplete brake pedal
return
Pinpoint Tests
PINPOINT TEST A : PEDAL GOES DOWN FAST
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A1: PRESSURIZE THE SYSTEM
1 Pump the foot brake rapidly five times.
• Does the brake pedal height build up and then hold?
zYe s
CHECK parking brake adjustment and
ADJUST as necessary.
REFER to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation,
General Procedures).
If the condition still exists. 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 A2.
G1058975en2008.50 Kuga8/2011
206-00- 10
Brake System - General Information
206-00- 10
DIAGNOSIS AND TESTING
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Brake Disc Runout Check(12 221 0)
Special Tool(s) / General EquipmentDial Indicator Gauge (Metric)
205-069 (15-046)
15046
Holding Fixture, Dial Indicator
Gauge
205-070 (15-022A)
15022A
Holding Fixture, Dial Indicator
Gauge (Disc Brake)
206-003 (12-003)
12003
Micrometer 0-125 mm
Check
1. NOTE: The total dial indicator gauge readingshould not exceed 0.05 mm.
Using the special tools, measure the brake
disc runout on the inner face of the brake
disc (wheel and tire shown removed for
clarity).
1. Position the dial indicator gauge so that it contacts the brake disc approximately 10 mm
from the outer edge. 2. Slowly rotate the wheel and tire and note the
readings.
TIE0036133
2
206-0031
205-0701
205-0691
2. NOTE: Using paint or typing correction fluid,mark the position of the wheel in relation to
the wheel hub.
Remove the wheel and tire.
For additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires, Removal
and Installation).
3. Remove the brake pads. For additional information, refer to:Brake
Caliper - Detach (206-03 Front Disc Brake,
Removal and Installation)
/ Brake Caliper -Detach (206-04 Rear Disc
Brake, Removal and Installation).
4. Install the wheel nuts and tighten the wheel nuts to 10 Nm, to hold the brake disc in
place.
5. NOTE: The total dial indicator gauge reading should not exceed 0.05 mm.
Using the special tools, measure the brake
disc runout on the inner and outer faces of
the brake disc (outer face measurement
shown).
1. Position the dial indicator gauge so that it contacts the brake disc approximately 10 mm
from the outer edge.
G1076535en2008.50 Kuga8/2011
206-00- 20
Brake System - General Information
206-00- 20
GENERAL PROCEDURES
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SECTION 206-03 Front Disc Brake
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
REMOVAL AND INSTALLATION
206-03-2
(12 234 0)
Brake Pads ........................................................................\
.............................
206-03-4
(12 243 0)
Brake Caliper ........................................................................\
..........................
206-03-5
Front Brake Flexible Hose ........................................................................\
..........................
206-03-1
Front Disc Brake
206-03- 1
.
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Brake Pads(12 234 0)
Special Tool(s)206-005
Retractor, Brake Caliper
Piston
12014
Materials
Specification
Name
WSS-M6C57-A2
Brake Fluid - Super
DOT4
WSS-M12A4-A2 / 1C1J-
19584-BA
Lubricating Paste
Removal
NOTE:
Removal steps in this procedure may
contain installation details.
1. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
2. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3.
E100314
4. WARNING: The brake caliper housing Torx bolts must not be removed.
CAUTION: Make sure that no load is
placed on the brake hose.
Torque: 28
Nm
E94825
12
3
5.
E100312
6.
E100313
G1001203en2008.50 Kuga8/2011
206-03- 2
Front Disc Brake
206-03- 2
REMOVAL AND INSTALLATION
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Brake Caliper(12 243 0)
General EquipmentHose Clamp(s)
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
2. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3. General Equipment: Hose Clamp(s)
Loosen: 90°
E94932
4.Refer to: Brake Pads (206-03 Front Disc Brake,
Removal and Installation).
5. Torque: 22,5
Nm
E95017
6. WARNING: Make sure that the brake
hose is not twisted and is correctly
located.
NOTE: This step is only necessary when
installing a new component.
Refer to: Front Brake Flexible Hose (206-03
Front Disc Brake, Removal and Installation).
Installation
1. To install, reverse the removal procedure.
2. Refer to: Brake System Bleeding (206-00 Brake
System - General Information, General
Procedures).
Refer to: Brake System Pressure Bleeding
(206-00 Brake System - General Information,
General Procedures).
G1001204en2008.50 Kuga8/2011
206-03- 4
Front Disc Brake
206-03- 4
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

SECTION 206-04 Rear Disc Brake
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
REMOVAL AND INSTALLATION
206-04-2
(12 238 0)
Brake Pads ........................................................................\
.............................
206-04-4
(12 253 0)
Brake Caliper ........................................................................\
..........................
206-04-5
Rear Brake Flexible Hose ........................................................................\
...........................
206-04-1
Rear Disc Brake
206-04- 1
.
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Brake Pads(12 238 0)
Special Tool(s)206-012
Retractor, Rear Brake Caliper
Piston
12006
Materials
Specification
Name
WSS-M6C57-A2
Brake Fluid - Super
DOT4
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
2. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3. WARNING: Make sure that no load is placed on the brake hose.
Torque: 35Nm
E100131
4. CAUTIONS:
Make sure that the component is not
bent.
Make sure that the clips are correctly
located.
NOTE: Note the position of each component
before removal.
E70029
1
2
5. Special Tool(s): 206-012
E70030
Installation
1. 1. CAUTION: Make sure that the mating
faces are clean and free of foreign
material.
Remove the adhesive foil from the rear of
the outer brake pad.
G1001207en2008.50 Kuga8/2011
206-04- 2
Rear Disc Brake
206-04- 2
REMOVAL AND INSTALLATION
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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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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL