Rear suspension FORD KUGA 2011 1.G Service Manual

Spring(15 621 0)
Special Tool(s)204-167
Compressor, Coil Spring
14042
204-215
Adapter for 204-167
15111
Removal
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. CAUTION: Make sure that the ball joint ball does not rotate.
Torque: 70Nm
E98878
3.Install the Special Tool(s): 204-167, 204-215
E98877
1
2
204-167
204-215
Installation
1.To install, reverse the removal procedure.
G1000236en2008.50 Kuga8/2011
204-02- 25
Rear Suspension
204-02- 25
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Rear Halfshaft
Special Tool(s) / General Equipment308-759
Remover, Rear Driveshaft
E100143
Cable Ties
Special Tool(s) / General EquipmentTire Lever
Transmission Jack
Materials
Specification
Name
WSK-M2G349-A8 /
9U7J-M2G349-AA
Sealant LGN
Removal
1.
On both sides.
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
2. On both sides.
E101661
3.Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
4. WARNING: Make sure that no load is placed on the brake hose.
On both sides.
General Equipment: Cable Ties
E100132
5.On both sides.
Refer to: Spring(204-02 Rear Suspension,
Removal and Installation).
6. On both sides.
x4x4
E101639
7.On both sides.
E101640
G1058429en2008.50 Kuga8/2011
205-05- 2
Rear Drive Halfshafts
205-05- 2
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

9.On both sides.
Material: Sealant LGN (WSK-M2G349-A8 /
9U7J-M2G349-AA) adhesive
E120924
10. On both sides.
E101640
11 .On both sides.
Torque: 1
10Nm
x4x4
E101639
12.On both sides.
Refer to: Spring(204-02 Rear Suspension,
Removal and Installation).
13. WARNING: Make sure that no load is placed on the brake hose.
On both sides.
Torque: 1
10Nm
x2x2
E101662
14.On both sides.
Material: Sealant LGN (WSK-M2G349-A8 /
9U7J-M2G349-AA) adhesive
Torque: 50
Nm
E101661
G1058429en2008.50 Kuga8/2011
205-05- 7
Rear Drive Halfshafts
205-05- 7
REMOVAL AND INSTALLATION
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

narrow the cause to a specific component or condition.
Symptom Chart
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 and linings.
• Brakes pull or drift
• INSTALL a new front brakedisc.
REFER to: Brake Caliper (206-
03 Front Disc Brake,
Removal and Installation).
• Abnormal wear or distortion of
front brake disc.
• ADJUST the parking brakecable.
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
• Incorrect rear brake adjust-
ment.
• ADJUST the wheel alignment.REFER to: (204-00 Suspension
System - General Information)
Front Toe Adjustment (General
Procedures),
Rear Toe Adjustment (General
Procedures).
• Incorrect wheel alignment
adjustment.
• ADJUST or INSTALL a newwheel bearing.
REFER to: Front Wheel
Bearing (204-01 Front
Suspension, Removal and
Installation).
• Incorrect wheel bearing preload
adjustment.
• 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.
• INSTALL a new wheel cylinderor brake caliper.
REFER to: Brake Caliper (206-
04 Rear Disc Brake, Removal
and Installation).
• Stuck or seized wheel cylinders
or brake calipers.
• FILL the reservoir. CHECK thebrake and clutch system for
leaks including brake fluid in
the brake booster.
• Low brake fluid level.
• The red brake warning indicator
is always on
G1058975en2008.50 Kuga8/2011
206-00- 5
Brake System - General Information
206-00- 5
DIAGNOSIS AND TESTING
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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
GENERAL PROCEDURES
TO MODEL INDEX
BACK TO CHAPTER INDEX
FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL