all FORD KUGA 2011 1.G Workshop Manual

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
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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.
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206-05- 5
Parking Brake and Actuation
206-05- 5
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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.
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Parking Brake and Actuation
206-05- 6
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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.
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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).
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206-05- 8
Parking Brake and Actuation
206-05- 8
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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).
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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
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Parking Brake and Actuation
206-05- 12
REMOVAL AND INSTALLATION
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All vehicles
7.Torque: 25Nm1.
2. Torque: 5
Nm
E101191
1
x4
2
3
8.Torque: 5Nm
E101190
x4
9.
E101192
1
2
x2
10.
E70349
2
43
1
11 .Torque: 2Nm
G1072319en2008.50 Kuga8/2011
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Parking Brake and Actuation
206-05- 13
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E101193
1
x43
2
Installation
1.To install, reverse the removal procedure.
2. Refer to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation, General
Procedures).
G1072319en2008.50 Kuga8/2011
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Parking Brake and Actuation
206-05- 14
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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