Front suspension FORD KUGA 2011 1.G Repair Manual

Upper control arm
E98616
The following components may be renewed:
• Lower arms
During removal and installation or renewal of the
lower arm, pay attention to the following:
• After completing the work, the suspensiongeometry of the vehicle must be checked and
corrected as necessary.
Rear lower arm and spring lower pad
E98615
The following components may be renewed:
• Lower arms
During removal and installation or renewal of the
lower arm, pay attention to the following:
• After completing the work, the suspensiongeometry of the vehicle must be checked and
corrected as necessary.
Front lower arm
E98614
The following components may be renewed:
• Lower arms
During removal and installation or renewal of the
lower arm, pay attention to the following:
• After completing the work, the suspensiongeometry of the vehicle must be checked and
corrected as necessary.
G1000191en2008.50 Kuga8/2011
204-02- 4
Rear Suspension
204-02- 4
DESCRIPTION AND OPERATION
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Front Lower Arm(15 690 0)
General EquipmentTransmission Jack
Removal
NOTE: Removal steps in this procedure may
contain installation details. 1.
Refer to: Spring(204-02 Rear Suspension,
Removal and Installation).
2. Fabricate a spacer.
E69209
226
40
3.General Equipment: Transmission Jack
1
2
E93313
G1000225en2008.50 Kuga8/2011
204-02- 11
Rear Suspension
204-02- 11
REMOVAL AND INSTALLATION
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Action
Possible Sources
Symptom
• ROTATE the wheel and tireassemblies.
• Wheel and tire assemblies
need rotating.
• ADJUST the wheel alignment.REFER to: Suspension System
(204-00 Suspension System
- General Information,
Diagnosis and Testing).
• Incorrect wheel alignment.
• CORRECT as necessary.
• Vehicle overloaded.
• TIGHTEN or INSTALL newsuspension components as
necessary.
REFER to: Front Strut and
Spring Assembly (204-01
Front Suspension, Disas-
sembly and Assembly).
• Loose or leaking front strut and
spring assembly.
• INSTALL new wheel bearingsas necessary.
REFER to: Front Wheel
Bearing (204-01 Front
Suspension, Removal and
Installation).
• Wheel bearings worn.
• CHECK or INSTALL newsuspension components as
necessary.
• Suspension components,
bushings and ball joints.
• BALANCE the wheel and tireassemblies. Using a suitable
dial indicator gauge and holding
fixture, CHECK 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.
• INSPECT the wheel rims fordamage. BALANCE the wheel
and tire assemblies. Using a
suitable dial indicator gauge
and holding fixture, CHECK
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).
• Damaged wheel.
• Wobble or shimmy affecting
wheel runout
G1061329en2008.50 Kuga8/2011
204-04- 8
Wheels and Tires
204-04- 8
DIAGNOSIS AND TESTING
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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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Action
Possible Sources
Symptom
• CLEAN mounting surfaces.
• Foreign material between
wheel mounting face and hub
mounting surface.
• CHECK or INSTALL new wheelbearings as necessary.
REFER to: Front Wheel
Bearing (204-01 Front
Suspension, Removal and
Installation).
• Front wheel bearing.
• CAUTION: Do not permitlubricant to get on cone sets of
stud holes or on cone angle of
wheel nuts. If corrosion is
slight, wire brush away. If
corrosion is excessive,
INSTALL new wheel studs and
nuts.
REFER to: Wheel and Tire
(204-04 Wheels and Tires,
Removal and Installation).
If the condition persists,
LUBRICATE the first three
threads of each wheel stud with
a graphite-based lubricant.
• Corrosion.
• Seized wheel nuts
• CORRECT as necessary.
• Vehicle overloaded
G1061329en2008.50 Kuga8/2011
204-04- 10
Wheels and Tires
204-04- 10
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
DIAGNOSIS AND TESTING
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Action
Possible Sources
Symptom
• CHECK ride height, VERIFYcorrect spring rate and CHECK
items under Halfshaft Joint
Pullout. REPAIR or INSTALL
new as necessary.
• Excessively high CV joint oper-
ating angles caused by incor-
rect ride height.
• Shudder Vibration During
Acceleration.
• INSPECT and INSTALL newas necessary.
• Excessively worn or damaged
inboard front wheel driveshaft
joint or outboard front wheel
driveshaft joint.
• INSPECT and REPAIR orINSTALL new as necessary.
• Inboard driveshaft bearing
retainer circlip missing or not
correctly seated in differential
side gear.
• Halfshaft Joint Pullout
• CHECK engine mounts fordamage or wear. REPAIR or
INSTALL new as necessary.
• Engine/transaxle assembly
mispositioned.
• CHECK underbody dimensions.REFER to REFER to
Section 501-00 [Body System
-General Information] .
• Frame rail or strut tower out of
position or damaged.
• CHECK for worn bushings orbent components (front stabil-
izer bar, front suspension lower
arm). REPAIR or INSTALL new
as necessary.
• Front suspension components
worn or damaged.
G17442en2008.50 Kuga8/2011
205-04- 4
Front Drive Halfshafts
205-04- 4
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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
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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
GENERAL PROCEDURES
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E53340
1
2
3
Description
Item
Tuning fork exciter
1
Suspension
2
Measuring side
3
Due to the special way in which it works. the
combined yaw rate sensor and lateral acceleration
sensor/longitudinal acceleration sensor must be
installed the right way up in the designated location
specified by the manufacturer. Any slight deviation
in the installation position and/or installation
location could lead to impaired functionality and
thereby possible failure of the stability assist.
Front wheel sensor
E96823
Active sensors are used to determine the rotational
speeds of the wheels at the hub. After the ignition
is switched on, the ABS module supplies the
sensors with power. The sensors work in
accordance with the Hall effect principle and
G1001304en2008.50 Kuga8/2011
206-09B- 14
Anti-Lock Control - Stability Assist
206-09B- 14
DESCRIPTION AND OPERATION
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