ECT FORD KUGA 2011 1.G Workshop Manual

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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2. Slowly rotate the brake disc and note thereadings.
TIE0035481
2
206-0031
205-0701
205-0691
6. NOTE: If any of the readings vary by morethan 0.015 mm or the brake disc thickness
is less than the specified minimum, a new
brake disc must be installed and the brake
disc runout re-checked.
Check the brake disc thickness variation.
For additional information, refer to:Specifications (206-00 Brake System -
General Information, Specifications).
• Using a suitable micrometer, measure the brake disc thickness at eight positions, 45
degrees apart and approximately 15 mm from
the outer edge of the brake disc.
MPU1201004
7. If all the brake disc runout measurementsand the thickness variation are within the
specifications, check the wheel balance.
8. If just the brake disc runout measurement with the wheel and tire fitted exceeds the
specification, the wheel and tire must be
rotated through 90 degrees in relation to the
brake disc and the brake disc runout
re-checked.
• If the brake disc runout measurement still exceeds the specification, repeat the wheel and tire rotation and checking process until
the measurement is within specification.
9. If the brake disc runout measurement without the wheel and tire fitted is outside the
specification, check the wheel hub face
runout.
10. NOTE: Using paint or typing correction fluid, mark the position of the brake disc in
relation to the wheel hub.
Remove the brake disc.
11. NOTE: Make sure that the wheel hub face is clean and free of rust and foreign
material.
NOTE: Re-position the dial indicator gauge so that
it contacts the wheel hub approximately 10 mm
from the outer edge of the wheel hub.
Check the wheel hub face runout.• Slowly rotate the wheel hub and note the readings.
TIE0035482
12. If the wheel hub runout exceeds 0.03 mm, install a new wheel hub.
For additional information, refer to: Wheel
Hub (204-01 Front Suspension, Removal
and Installation)
/ Wheel Bearing and Wheel Hub (204-02
Rear Suspension, Removal and
Installation).
13. If the wheel hub face runout is within specification, install a new brake disc.
G1076535en2008.50 Kuga8/2011
206-00- 21
Brake System - General Information
206-00- 21
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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 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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Front Brake Flexible Hose
Removal
CAUTION:
Refer to:Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
NOTE: Removal steps in this procedure may
contain installation details. 1.
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
2. WARNINGS:
Make sure that no load is placed on the
brake hose.
Be prepared to collect escaping fluid.
CAUTION: Make sure that all openings
are sealed.
1. Torque: 15
Nm
4. Torque: 23Nm
E99419
1
2
3
4
Installation
1. To install, reverse the removal procedure.
2. Refer to: Component Bleeding (206-00 Brake
System - General Information, General
Procedures).
G1001206en2008.50 Kuga8/2011
206-03- 5
Front Disc Brake
206-03- 5
REMOVAL AND INSTALLATION
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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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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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Rear Brake Flexible Hose
Removal
CAUTION:
Refer to:Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
NOTE: Removal steps in this procedure may
contain installation details. 1.
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
2. WARNINGS:
Make sure that no load is placed on the
brake hose.
Be prepared to collect escaping fluid.
CAUTION: Make sure that all openings
are sealed.
1. Torque: 15
Nm
E99425
1
2
3
G1001210en2008.50 Kuga8/2011
206-04- 5
Rear Disc Brake
206-04- 5
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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
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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