Suspension FORD KUGA 2011 1.G Repair Manual

Front Strut and Spring Assembly(14 781 0; 14 782 0)
Special Tool(s)204-159
Lever, Wheel Knuckle
14039
204-605
Separator, Lower Arm Ball
Joint
E63772
Removal
NOTE:Removal steps in this procedure may
contain installation details.
1. Refer to: Cowl Panel Grille (501-02 Front End
Body Panels, Removal and Installation).
2.
E101070
G1000210en2008.50 Kuga8/2011
204-01- 26
Front Suspension
204-01- 26
REMOVAL AND INSTALLATION
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3.Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
4. If equipped.
Torque: 8
Nm
E75215
5. CAUTION: Make sure that the ball joint
ball does not rotate.
Torque: 47Nm
E99103
6.Torque: 90Nm
E99108
7.Special Tool(s): 204-159, 204-605
G1000210en2008.50 Kuga8/2011
204-01- 27
Front Suspension
204-01- 27
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E99109
1
204-159
204-605
2
8. WARNING: This step requires the aid ofanother technician.
Torque: 35Nm
E99147
x3
Installation
1.To install, reverse the removal procedure.
G1000210en2008.50 Kuga8/2011
204-01- 28
Front Suspension
204-01- 28
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Front Strut and Spring Assembly(14 783 4)
Special Tool(s)204-167
Compressor, Coil Spring
14042
204-167-01
Adapter for 204-167
1404201
Disassembly
WARNING: Take extra care when handling
the compressed spring.
1. Install the Special Tool(s): 204-167, 204-167-01
E97819
204-167-01
204-167
1
2
2. NOTE: Note the position of each component
before removal.
E132038
G1000221en2008.50 Kuga8/2011
204-01- 29
Front Suspension
204-01- 29
DISASSEMBLY AND ASSEMBLY
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Assembly
WARNING: Take extra care when handling
the compressed spring.
3. To assemble, reverse the disassembly
procedure.
4. NOTE: Only tighten the nut finger tight at this
stage.
E98495
5. NOTE: Make sure that these components are
installed to the noted removal position.
NOTE: Make sure that the spring is correctly
located in the lower spring seat.
NOTE: Make sure that the installation marks
are aligned.
E131947
G1000221en2008.50 Kuga8/2011
204-01- 30
Front Suspension
204-01- 30
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6. CAUTION: Use an Allen key to preventthe piston rod from rotating.
Torque: 55Nm
E98495
7.Remove the Special Tool(s): 204-167,
204-167-01
G1000221en2008.50 Kuga8/2011
204-01- 31
Front Suspension
204-01- 31
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SECTION 204-02 Rear Suspension
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
SPECIFICATIONS
204-02-2
Specifications ........................................................................\
..............................................
DESCRIPTION AND OPERATION 204-02-3
Rear Suspension (Overview) ........................................................................\
......................
204-02-3
Overview ........................................................................\
.....................................................
204-02-4
Upper control arm ........................................................................\
.......................................
204-02-4
Rear lower arm and spring lower pad ........................................................................\
.........
204-02-4
Front lower arm ........................................................................\
..........................................
204-02-5
Stabilizer bar ........................................................................\
...............................................
REMOVAL AND INSTALLATION 204-02-6
Wheel Bearing and Wheel Hub ........................................................................\
..................
204-02-9
(15 701 0)
Upper Arm ........................................................................\
..............................
204-02-11
(15 690 0)
Front Lower Arm ........................................................................\
.....................
204-02-13
(15 705 0)
Rear Lower Arm ........................................................................\
.....................
204-02-15
(15 752 0)
Rear Stabilizer Bar ........................................................................\
.................
204-02-17
Rear Stabilizer Bar Link ........................................................................\
..............................
204-02-18
Rear Stabilizer Bar Bushing ........................................................................\
.......................
204-02-19
Wheel Knuckle — LHD FWD/RHD FWD ........................................................................\
....
204-02-22
Wheel Knuckle — LHD 4WD/RHD 4WD ........................................................................\
....
204-02-25
(15 621 0)
Spring ........................................................................\
.....................................
204-02- 1
Rear Suspension
204-02- 1
.
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Rear Wheel Alignment 2WD
MaximumVari-
ance
Left or Right
Setting
or
Nominal
Toler-
ance
Range
Measurem
ents
Descri
ption
1°15'
-1°32'
-2°47'
to -
0°17'
Degrees
and
minutes
Camber
angle
1.25°
-1.54°
-2.79°
to -
0.29°
Decimal
degrees
-1.4
Toe-in ±0.6
1.4 ±
1.3
mm
Single
wheel toe
-
0°11'
Toe-in
± 0°05'
0°11' ±
0°10'
Degrees
and
minutes
-
0.19°
Toe-in
± 0.08°
0.19° ±
0.18°
Decimal
degrees
-2.8
Toe-in ±1.1
2.8 ±
2.6
mm
To t a l
toe
-
0°23'
Toe-in
± 0°09'
0°23' ±
0°21'
Degrees
and
minutes
-
0.38°
Toe-in
± 0.15°
0.38° ±
0.35°
Decimal
degrees Rear Wheel Alignment 4WDMaximum
Vari-
ance
Left or Right
Setting
or
Nominal
Toler-
ance
Range
Measurem
ents
Descri
ption
1°15'
-1°32'
-2°.47'
to -
0°17'
Degrees
and
minutes
Camber
angle
1.25°
-1.54°
-2.79°
to -
0.29°
Decimal
degrees
-1.4
Toe-in ±0.6
1.4 ±
1.3
mm
Single
wheel toe
-
0°11'
Toe-in
± 0°05'
0°11' ±
0°10'
Degrees
and
minutes
-
0.19°
Toe-in
± 0.08°
0.19° ±
0.18°
Decimal
degrees
-2.8
Toe-in ±1.1
2.8 ±
2.6
mm
To t a l
toe
-
0°23'
Toe-in
± 0°09'
0°23' ±
0°21'
Degrees
and
minutes
-
0.38°
Toe-in
± 0.15°
0.38° ±
0.35°
Decimal
degrees
Torque Specifications
lb-in
lb-ft
Nm
Item
160
14
18
Rear Shock Absorber - Upper Fixing
1018
85
11 5
Rear Shock Absorber - Lower Fixing
G1000727en2008.50 Kuga8/2011
204-02- 2
Rear Suspension
204-02- 2
SPECIFICATIONS
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Rear Suspension – Overview
Overview
E98609
1
23
4
5
7
6
8
9
10
Description
Item
Subframe
1
Rear lower arm and spring lower pad
2
Spring
3
Stabilizer bar link
4
Front lower arm
5Description
Item
Wheel knuckle
6
Tie-bar
7
Shock absorber
8
Upper control arm
9
Stabilizer bar, bushings and clamps
10
G1000191en2008.50 Kuga8/2011
204-02- 3
Rear Suspension
204-02- 3
DESCRIPTION AND OPERATION
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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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