AIR CON FORD KUGA 2011 1.G Workshop Manual

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
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206-05- 9
Parking Brake and Actuation
206-05- 9
GENERAL PROCEDURES
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Parking Brake Control(12 664 0)
Removal
1.Refer to: Floor Console (501-12 Instrument
Panel and Console, Removal and Installation).
2. Release the parking brake.
3.
3
33
2
1
4
E93308
Installation
1. Torque: 35Nm2.
3.NOTE: Only tighten the nut finger tight at this
stage.
2
22
3
4
1
E93328
2. Refer to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation, General
Procedures).
3. Refer to: Floor Console (501-12 Instrument
Panel and Console, Removal and Installation).
G1058318en2008.50 Kuga8/2011
206-05- 11
Parking Brake and Actuation
206-05- 11
REMOVAL AND INSTALLATION
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Parking Brake Rear Cables
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Fully release the parking brake control.
2.
E92650
3. Loosen the parking brake cable adjustment nut
to the end of the parking brake cable thread.
E92651
4.Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
4x4
5. Torque: 25Nm
E101187
x2
x4
1
2
3
4x2
6.Torque: 25Nm
E101189
x4
G1072319en2008.50 Kuga8/2011
206-05- 12
Parking Brake and Actuation
206-05- 12
REMOVAL AND INSTALLATION
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SECTION 206-06 Hydraulic Brake Actuation
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
REMOVAL AND INSTALLATION
206-06-2
Brake Pedal and Bracket — RHD 4WD/RHD FWD ...........................................................
206-06-5
(12 343 0)
Brake Master Cylinder — 2.5L Duratec (147kW/200PS) - VI5 .......................
206-06-1
Hydraulic Brake Actuation
206-06- 1
.
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Brake Pedal and Bracket — RHD 4WD/RHD FWD
Removal
NOTE:Removal steps in this procedure may
contain installation details.
Panel and Console, Removal and Installation).
2.
E101395
G1065459en2008.50 Kuga8/2011
206-06- 2
Hydraulic Brake Actuation
206-06- 2
REMOVAL AND INSTALLATION
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1. Refer to: Floor Console Extension - Vehicles
With: Center Armrest (501-12 Instrument

Brake Master Cylinder — 2.5L Duratec (147kW/200PS) -VI5(12 343 0)
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. Connect one end of a suitable piece of clear
plastic pipe to the brake caliper bleed nipple
1.
and place the other end into a suitable
container.
2. Loosen the bleed nipple.
3. Depress the brake pedal until no more brake fluid comes through the bleed nipple.
4. Tighten the bleed nipple.
5. Repeat the draining procedure on the opposite side brake caliper.
E86914
Left-hand drive vehicles
3. CAUTION: Make sure that all openings are sealed.
1. Torque: 18Nm
2.NOTE: Make sure that new components are
installed.
Torque: 25
Nm
G1174985en2008.50 Kuga8/2011
206-06- 5
Hydraulic Brake Actuation
206-06- 5
REMOVAL AND INSTALLATION
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SECTION 206-07 Power Brake Actuation
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
REMOVAL AND INSTALLATION
206-07-2
(12 451 0)
Brake Booster — 2.5L Duratec (147kW/200PS) - VI5, RHD 4WD/RHD FWD .
206-07-7
Brake Vacuum Hose — 2.5L Duratec (147kW/200PS) - VI5 ..............................................
206-07-9
(12 414 0)
Brake Vacuum Pump — 2.5L Duratec (147kW/200PS) - VI5 ........................
206-07-1
Power Brake Actuation
206-07- 1
.
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