brake FORD KUGA 2011 1.G Service Manual

Action
Possible Sources
Symptom
• CHECK or INSTALL new wheelbearings as necessary.
REFER to: Front Wheel
Bearing (204-01 Front
Suspension, Removal and
Installation).
• Front wheel bearing.
• CHECK or INSTALL newsuspension components as
necessary.
• Suspension components.
• Excessive vehicle vibration,
rough steering
• ADJUST the tire pressure(s).
• Incorrect tire pressure(s).
• Vehicle vibrations from wheels
and tires
• BALANCE the wheel and tireassemblies.
• Wheel or tire imbalance.
• INSTALL a new tire(s) asnecessary.
REFER to: Wheel and Tire
(204-04 Wheels and Tires,
Removal and Installation).
• Uneven tire wear.
• CHECK the brake disc forforeign material.
• Brake disc imbalance.
• REMOVE the water.
• Water in tire(s).
• INSTALL a new wheel and tireassembly.
REFER to: Wheel and Tire
(204-04 Wheels and Tires,
Removal and Installation).
• Bent wheel.
• SPIN the wheel on the vehicle.EXAMINE the area where the
tire and the wheel meet. If that
section of the tire appears to
waver while being rotated, the
tire bead may not be correctly
seated on the wheel. REMOVE
the tire and CLEAN the bead
seat areas on both wheel and
tire.
• Incorrectly seated tire bead.
• BALANCE the wheel and tireassemblies. Using a suitable
dial indicator gauge and holding
fixture, CHECK the lateral and
radial runout of the wheel and
tire assemblies. INSTALL new
wheel and tire assemblies as
necessary.
REFER to: Wheel and Tire
(204-04 Wheels and Tires,
Removal and Installation).
• Excessive lateral or radial
runout of wheel or tire.
G1061329en2008.50 Kuga8/2011
204-04- 9
Wheels and Tires
204-04- 9
DIAGNOSIS AND TESTING
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Front Drive Halfshafts
Inspection and Verification
NOTE:New front wheel drive halfshafts should not
be installed unless disassembly and inspection
reveals unusual wear.
1. Inspect front wheel driveshaft joint boots for evidence of cracks, tears or splits.
NOTE: While inspecting the front wheel driveshaft
CV joint boots, watch for indentations (dimples) in
the boot convolutions. If an indentation is observed,
it must be removed.
2. Inspect the underbody for any indication of grease splatter in the vicinity of the front wheel
driveshaft CV joint boots outboard and inboard
locations, which is an indication of front wheel
driveshaft CV joint boot and/or front wheel
driveshaft CV joint boot clamp damage. 3. Inspect for inboard CV joint stub shaft pilot
bearing housing seal leakage at the front wheel
driveshaft CV joint.
4. Make sure front axle wheel hub retainer is the correct prevailing torque type.
5. The silicone front wheel driveshaft CV joint boot will sweat during operation, causing a light film
of grease to show on the outside of the front
wheel driveshaft CV joint boot. This condition
is normal.
NOTE: Halfshafts are not balanced and do not
contribute to rotational vibration.
6. If the concerns remain after the inspection, determine the symptoms and go to the Symptom
Chart. For additional Noise, Vibration and
Harshness (NVH). REFER to Section 100-04
[Noise, Vibration and Harshness] .
Symptom Chart
Action
Possible Sources
Symptom
• INSPECT, CLEAN andLUBRICATE as necessary.
• Inadequate or contaminated
lube in outboard/inboard front
wheel driveshaft CV joint.
• Clicking, Popping or Grinding
Noises While Turning
• INSPECT and REPAIR asnecessary.
• Another component contacting
driveshaft assembly.
• INSPECT and REPAIR asnecessary. REFER to
Section 204-00 [Suspension
System - General Information]
/ 206-00 [Brake System -
General Information] /211-00
[Steering System - General
Information] .
• Wheel bearings, brakes,
suspension or steering
components.
• REPAIR or INSTALL new asnecessary. REFER to
Section 204-04 [Wheels and
Tires] .
• Out of balance front wheels or
tires.
• Vibration at Highway Speeds
• REPAIR or INSTALL new asnecessary. REFER to
Section 204-04 [Wheels and
Tires] .
• Out-of-round tires.
• REPAIR or INSTALL new asnecessary.
REFER to Halfshaft Disas-
semblv and Assembly in this
section.
• Incorrectly seated outboard
front wheel driveshaft CV joint
in front wheel hub.
G17442en2008.50 Kuga8/2011
205-04- 3
Front Drive Halfshafts
205-04- 3
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2.Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3. NOTE: This step is only necessary when
installing a new component.
E99269
4.
E101039
5. WARNING: Make sure that no load is placed on the brake hose.
E100801
G1076961en2008.50 Kuga8/2011
205-04- 6
Front Drive Halfshafts
205-04- 6
REMOVAL AND INSTALLATION
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4.
E102106
5. WARNING: Make sure that no load isplaced on the brake hose.
E100801
G1076962en2008.50 Kuga8/2011
205-04- 17
Front Drive Halfshafts
205-04- 17
REMOVAL AND INSTALLATION
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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
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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
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SECTION 206-00 Brake System - General Information
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
206-00-2
Specifications ........................................................................\
..............................................
206-00-2
Front Brake Disc Specification ........................................................................\
................
206-00-2
Rear Disc Brake Specification ........................................................................\
................
DESCRIPTION AND OPERATION 206-00-3
Brake System (Overview) ........................................................................\
...........................
206-00-3
Brake System ........................................................................\
.............................................
DIAGNOSIS AND TESTING 206-00-4
Brake System ........................................................................\
.............................................
206-00-4
Inspection and Verification ........................................................................\
..........................
206-00-4
Road Test ........................................................................\
...................................................
206-00-10
Pinpoint Tests ........................................................................\
.............................................
206-00-17
Component Tests ........................................................................\
........................................
206-00-17
Brake System Check ........................................................................\
..................................
206-00-17
Brake Booster Functional Test ........................................................................\
....................
GENERAL PROCEDURES 206-00-20
(12 221 0)
Brake Disc Runout Check ........................................................................\
......
206-00-20
Check ........................................................................\
.........................................................
206-00-22
Component Bleeding ........................................................................\
..................................
206-00-27
Brake System Bleeding ........................................................................\
..............................
206-00-32
(12 154 0;
12 154 4)
Brake System Draining and Filling
.................................................................
206-00-35
Brake System Pressure Bleeding ........................................................................\
...............
206-00-1
Brake System - General Information
206-00- 1
.
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Lubricants, Fluids, Sealers and Adhesives
Specification
ESD-M6C57-A /
WSSM6C57- A2
Super DOT 4 brake fluid
Front Brake Disc Specification
mm 300
Brake disc diameter
25
New brake disc nominal thickness
23
Worn brake disc discard thickness *
0.025
Maximum brake disc thickness variation
1.5
Worn brake pad discard thickness**
0.015
Maximum brake disc runout (installed)
* When the discard thickness has been reached, install a new brake disc and brake pads.
** When the discard thickness has been reached, install new brake pads.
Rear Disc Brake Specification
mm
Description
302
Brake disc diameter
11
New brake disc nominal thickness
9
Worn brake disc discard thickness *
0.025
Maximum brake disc thickness variation
1.5
Worn brake pad discard thickness **
0.1
Maximum brake disc runout (installed)
* When the discard thickness has been reached, install a new brake disc and brake pads.
** When the discard thickness has been reached, install new brake pads.
G1001201en2008.50 Kuga8/2011
206-00- 2
Brake System - General Information
206-00- 2
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Brake System – Overview
Brake System
E96610
G1001202en2008.50 Kuga8/2011
206-00-3
Brake System - General Information
206-00- 3
DESCRIPTION AND OPERATION
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Brake System
General EquipmentPressure/vacuum gauge set
The Ford approved diagnostic tool
The brake system operates by transferring effort
applied to the brake pedal by the driver to the
brakes at each wheel.
The braking effort is distributed to each wheel,
using a hydraulic system. The system is assisted
using a vacuum brake booster that reduces pedal
effort and increases hydraulic pressure.
The parking brake operates on the rear wheels
and is applied using a hand operated control.
Inspection and Verification
NOTE: Before carrying out any diagnosis, make
sure that the brake system warning indicator is
functional.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.
Visual Inspection Chart
Electrical
Mechanical
• Electricalconnector(s)
• Wiring harness(s)
• Switch(es)
• Tire pressure(s)
• Wheels and tires
• Fluid leak(s)
3. If an obvious cause for an observed or reported concern is found, correct the case (if possible)
before proceeding to the next step.
4. If the cause if not visually evident, verify the symptom and refer to the Symptom Chart.
Road Test
Carry out a road test to compare actual vehicle
braking performance with the performance
standards expected by the driver. The ability of the
test driver to make valid comparisons and detect
performance deficiencies will depend on
experience.
The driver should have a thorough knowledge of
the brake system operation and accepted general performance guidelines to make good comparisons
and detect performance concerns.
An experienced technician will always establish a
route that will be used for all brake diagnosis road
tests. The road selected will be reasonably smooth
and level. Gravel or bumpy roads are not suitable
because the surface does not allow the tires to grip
the road equally. Crowned roads should be avoided
because of the large amount of weight shifted to
the low set of wheels on this type of road. Once
the route is established and consistently used, the
road surface variable can be eliminated from the
test results.
Before a road test, get a complete description of
the customer concerns or suspected condition.
From the description, the technician will be able to
match possible causes with symptoms. Certain
components will be identified as possible sources
while others will be eliminated by the evidence.
More importantly, the customer description can
reveal unsafe conditions which should be checked
or corrected before a road test. The description will
also help form the basic approach to the road test
by narrowing the concern to specific components,
vehicle speed or conditions.
Begin the road test with a general brake
performance check. Using the description of the
concern, test the brakes at different vehicle speeds
using both light and heavy pedal pressure.
Determine if the concern is in the front or rear
braking system. First use the foot brake and then
the parking brake. If the condition (i.e. pull,
vibration, pulsation) occurs only on operation of
the parking brake, the concern is in the rear brake
system. If the condition occurs when the foot brake
is depressed, the concern is in the front brake
system.
Avoid locking the brakes and sliding the tires. This
condition will not indicate brake efficiency. A heavily
braked but turning wheel will stop the vehicle in a
shorter distance than locked wheels.
If the concern becomes evident during this check,
make sure it fits the description given before the
road test. If the concern is not evident, attempt to
duplicate the condition using the information from
the description.
If a concern exists, use the Brake System Symptom
Chart in order to isolate it to a specific sub-system
and condition description. From this description, a
list of possible sources can be used to further
G1058975en2008.50 Kuga8/2011
206-00-
4
Brake System - General Information
206-00- 4
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