Rear suspension FORD KUGA 2011 1.G Workshop Manual

Noise Conditions
• Gear noise is typically a howling or whining dueto gear damage or incorrect bearing preload. It
can occur at various speeds and driving
conditions, or it can be continuous.
• Chuckle is a particular rattling noise that sounds like a stick against the spokes of a spinning
bicycle wheel. It occurs while decelerating from
64 km/h (40 mph) and can usually be heard all
the way to a stop. The frequency varies with
vehicle speed.
• Knock is very similar to chuckle, though it may be louder and occurs on acceleration or
deceleration. The teardown will disclose what
has to be corrected.
Clicking, popping or grinding noises may be caused
by the following:
• worn, damaged or incorrectly installed wheel bearing, suspension or brake component.
Check and rule out tires, exhaust and trim items
before disassembling the transmission to diagnose
and correct gear noise.
The noises described under Road Test usually
have specific causes that can be diagnosed by
observation as the unit is disassembled. The initial
clues are the type of noise heard on the road test
and driving conditions.
Vibration Conditions
Vibration at highway speeds may be caused by
the following:
• out-of-balance front or rear wheels.
• out-of-round tires.
Shudder or vibration during acceleration may be
caused by the following:
• damaged powertrain/drivetrain mounts.
• excessively high constant velocity (CV) joint operating angles caused by incorrect ride height.
Check ride height, verify correct spring rate and
check items under inoperative conditions.
Road Test
A gear-driven unit will produce a certain amount
of noise. Some noise is acceptable and may be
audible at certain speeds or under various driving
conditions, as on a newly paved asphalt road. The slight noise is in no way detrimental and must be
considered normal.
The road test and customer interview (if available)
provide information needed to identify the condition
and give direction to the correct starting point for
diagnosis.
1. Make notes throughout the diagnosis routine.
Make sure to write down even the smallest bit
of information, because it may turn out to be the
most important.
2. Do not touch anything until a road test and a thorough visual inspection of the vehicle have
been carried out. Leave the tire pressures and
vehicle load just where they were when the
condition was first observed. Adjusting tire
pressures, vehicle load or making other
adjustments may reduce the condition(s)
intensity to a point where it cannot be identified
clearly. It may also inject something new into
the system, preventing correct diagnosis.
3. Make a visual inspection as part of the preliminary diagnosis routine, writing down
anything that does not look right. Note tire
pressures, but do not adjust them yet. Note
leaking fluids, loose nuts and bolts, or bright
spots where components may be rubbing
against each other. Check the load space for
unusual loads.
4. Road test the vehicle and define the condition by reproducing it several times during the road
test.
5. Carry out the Road Test Quick Checks as soon as the condition is reproduced. This will identify
the correct diagnostic procedure. Carry out the
Road Test Quick Checks more than once to
verify they are providing a valid result.
Remember, the Road Test Quick Checks may
not tell where the concern is, but they will tell
where it is not.
Road Test Quick Checks
1. 24-80 km/h (15-50 mph): with light acceleration,a moaning noise is heard and possibly a
vibration felt in the front floor panel. It is usually
worse at a particular engine speed and at a
particular throttle setting during acceleration at
that speed. It may also produce a moaning
sound, depending on what component is
causing it. REFER to Tip-in Moan in the
Driveline Noise and Vibration Symptom Chart.
2. Acceleration/Deceleration: With slow acceleration and deceleration, a shake is
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Noise, Vibration and Harshness
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SECTION 204-00 Suspension System - General
Information
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DIAGNOSIS AND TESTING
204-00-2
Suspension System ........................................................................\
....................................
204-00-2
Inspection and Verification ........................................................................\
..........................
204-00-2
Symptom Chart ........................................................................\
...........................................
204-00-5
Pinpoint Tests ........................................................................\
.............................................
204-00-12
Component Tests ........................................................................\
........................................
GENERAL PROCEDURES 204-00-15
(14 117 3)
Front Toe Adjustment ........................................................................\
.............
204-00-16
(15 211 3)
Rear Toe Adjustment ........................................................................\
..............
204-00-1
Suspension System - General Information
204-00- 1
.
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Suspension System
Special Tool(s)Alignment Pins, Subframe
205-316 (15-097A)
15097A
Inspection and Verification
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanicaldamage.
Visual Inspection Chart
Mechanical
Tire pressure(s) Wheel and tires
Mechanical
Wheel knuckles Tie-rod ends
Front suspension lower arm ball joints Front suspension lower arm bushings Front strut and spring assemblies
Front and rear stabilizer bar and connecting links Rear springs
Rear shock absorbers
Rear suspension lower arms
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 cause is not visually evident, verify the symptom and refer to the Symptom Chart.
Symptom Chart
Symptom Chart
Action
Possible Sources
Symptom
• Vehicles without load levellingshock absorbers, CHECK for
abnormal loading, spring sag
or non-standard springs.
• Vehicles with load levelling shock absorbers, GO to
Pinpoint Test C.
• Vehicle attitude incorrect (front
or rear / left or right is high or
low).
• Drift left or right
• CHECK the steering system.REFER to: Steering System
(211-00 Steering System -
General Information,
Diagnosis and Testing).
• Steering gear or linkage worn
or damaged.
• CHECK the brake system.REFER to: Brake System (206-
00 Brake System - General
Information, Diagnosis and
Testing).
• Brake system.
• Using the special tool, CHECKthe front subframe alignment..
• Incorrect front crossmember
alignment.
• CHECK the wheel bearings.
• Worn front wheel bearings.
• GO toPinpoint Test A.
• Wheel and tires.
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Action
Possible Sources
Symptom
• Vehicles without load levellingshock absorbers, CHECK for
abnormal loading, spring sag
or non-standard springs.
• Vehicles with load levelling shock absorbers, GO to
Pinpoint Test C.
• Vehicle attitude incorrect (front
or rear is high or low).
• Steering wheel off center
• CHECK the steering system.REFER to: Steering System
(211-00 Steering System -
General Information,
Diagnosis and Testing).
• Steering gear or linkage worn
or damaged.
• CARRY OUT the Ball JointInspection Component Test in
this procedure.
• Suspension lower arm ball joint.
• ADJUST the wheel alignment.REFER to: Front Toe Adjust-
ment (204-00 Suspension
System - General Informa-
tion, General Procedures)
/ Rear Toe Adjustment (204-00
Suspension System - General
Information, General Proced-
ures).
• Incorrect wheel alignment.
• CARRY OUT the Strut orShock Absorber Testing
component test in this
procedure.
• CHECK and INSTALL new suspension components as
necessary.
REFER to: Front Strut and
Spring Assembly (204-01
Front Suspension, Disas-
sembly and Assembly).
• Front strut and spring assem-
blies.
• Rough ride
• CHECK and INSTALL newsuspension components as
necessary. REFER to:
Front Strut and Spring Assembly (204-01 Front
Suspension, Disassembly
and Assembly),
Rear Stabilizer Bar (204-02
Rear Suspension, Removal
and Installation).
• Front or rear stabilizer bar
connecting links or bushings.
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Action
Possible Sources
Symptom
• INSTALL a new lower arm.REFER to: Lower Arm (204-01
Front Suspension, Removal
and Installation).
• Front suspension lower arm
bushings.
• CHECK and INSTALL newcomponents as necessary.
REFER to: Rear Stabilizer Bar
Bushing (204-02 Rear
Suspension, Removal and
Installation).
• Rear suspension arm bushings.
• CARRY OUT the Strut orShock Absorber Testing
component test in this
procedure.
• CHECK and INSTALL new suspension components as
necessary.
• Rear shock absorbers.
• GO toPinpoint Test B.
• Front strut and spring assembly
or rear shock absorber and
spring upper mounting bolts or
nuts loose or broken.
• Excessive noise
• GO toPinpoint Test B.
• Shock absorbers leaking.
• GO toPinpoint Test B.
• Shock absorbers performance
incorrect.
• GO toPinpoint Test B.
• Stabilizer bar components.
• GO toPinpoint Test B.
• Strut and spring assembly and
springs.
• GO toPinpoint Test B.
• Springs moving on springs
upper or lower seats.
• GO toPinpoint Test B.
• Suspension bushings.
• GO toPinpoint Test B.
• Lower arm ball joint.
• GO toPinpoint Test B.
• Worn front wheel bearings
• GO toPinpoint Test B.
• Wheels and tires.
• CHECK and INSTALL newsuspension components as
necessary.
• Front or rear suspension
damage.
• Incorrect tire wear
• ADJUST the wheel alignment.REFER to: Front Toe Adjust-
ment (204-00 Suspension
System - General Informa-
tion, General Procedures)
/ Rear Toe Adjustment (204-00
Suspension System - General
Information, General Proced-
ures).
• Incorrect wheel alignment.
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Suspension System - General Information
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
always be maintained on the steering wheel. Failure to follow these instructions may result
in personal injury.
NOTE: The following conditions must be met when evaluating the vehicle.
NOTE: The tire swapping procedures are for bi-directional rotating tires only.
A1: SWAP THE FRONT WHEEL AND TIRE ASSEMBLIES
1 Raise and support the vehicle. REFER to: (100-
02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
– Swap the front left-hand wheel and tire assembly with the front right-hand wheel and
tire assembly.
– Road test the vehicle.
• Does the vehicle drift?
zYe s GO to A2.
zNoThe concern has been corrected.
A2: SWAP THE REAR WHEEL AND TIRE ASSEMBLIES
1 Raise and support the vehicle. REFER to: (100-
02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
– Swap the rear left-hand wheel and tire assembly with the rear right-hand wheel and
tire assembly.
– Road test the vehicle.
• Does the vehicle drift?
zYe s GO to A3.
zNoThe concern has been corrected.
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A3: SWAP THE LEFT-HAND WHEEL AND TIRE ASSEMBLIES
1 Raise and support the vehicle. REFER to: (100-
02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
– Swap the front left-hand wheel and tire assembly with the rear left-hand wheel and
tire assembly.
– Road test the vehicle.
• Does the vehicle drift?
zYe s GO to A4.
zNoThe concern has been corrected.
A4: SWAP THE RIGHT-HAND WHEEL AND TIRE ASSEMBLIES
1 Raise and support the vehicle. REFER to: (100-
02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
– Swap the front right-hand wheel and tire assembly with the rear right-hand wheel and
tire assembly.
– Road test the vehicle.
• Does the vehicle drift?
zYe s GO to A5.
zNoThe concern has been corrected.
A5: SWAP THE FRONT LEFT-HAND WHEEL AND TIRE ASSEMBLY
1 Raise and support the vehicle. REFER to: (100-
02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
– Swap the front left-hand wheel and tire assembly with the rear right-hand wheel and
tire assembly.
– Road test the vehicle.
• Does the vehicle drift?
zYe s GO to A6.
zNoThe concern has been corrected.
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A6: SWAP THE FRONT RIGHT-HAND WHEEL AND TIRE ASSEMBLY
1 Raise and support the vehicle. REFER to: (100-
02 Jacking and Lifting)
Jacking (Description and Operation),
Lifting (Description and Operation).
– Swap the front right-hand wheel and tire assembly with the rear left-hand wheel and
tire assembly.
– Road test the vehicle.
• Does the vehicle drift?
zYe s GO to A7.
zNoThe concern has been corrected.
A7: INSTALL NEW TIRES
NOTE: Install new tires only once.
1Install new tires to the four road wheels. TEST
the system for normal operation.
• Does the vehicle drift?
zYe s Verify possible sources, refer to the Symptom
Chart.
zNoThe concern has been corrected.
PINPOINT TEST B : EXCESSIVE NOISE
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B1: INSPECT ALL STRUT AND SPRING ASSEMBLY AND SHOCK ABSORBER MOUNTING BOLTS
AND NUTS
1 Inspect the strut and spring assembly and shock
absorber mounting bolts and nuts.
• Are the mounting bolts or nuts loose or broken?
zYe s TIGHTEN or INSTALL new suspension
mounting bolts.
REFER to: Specifications (204-01 Front
Suspension, Specifications).
zNo
GO to B2.
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B2: INSPECT THE STRUT AND SPRING ASSEMBLIES AND SHOCK ABSORBERS FOR LEAKS
NOTE:Make sure that the oil is not from another
source.
1 Inspect the strut and spring assemblies and
shock absorbers for signs of oil weepage or
leaks. Refer to weepage and leakage conditions
in the Strut or Shock Absorber Testing
component test in this procedure.
• Are the struts or shock absorbers leaking?
zYe s INSTALL new struts or shock absorbers as
necessary.
REFER to: Front Strut and Spring Assembly
(204-01 Front Suspension, Removal and
Installation).
zNo
GO to B3.
B3: INSPECT THE SPRINGS AND STABILIZER BAR(S)
1 Inspect the springs and stabilizer bar(s) for
damage.
• Are the springs or stabilizer bar(s) damaged?
zYe s INSTALL new springs or stabilzer bar(s).
REFER to:
Front Strut andSpring Assembly (204-01 Front
Suspension, Removal and Installation),
Front Stabilizer Bar (204-01 Front Suspension,
Removal and Installation),
Rear Stabilizer Bar Link (204-02 Rear Suspen-
sion, Removal and Installation).
zNo
GO to B4.
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DETAILS/RESULTS/ACTIONS
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B4: INSPECT THE SUSPENSION BUSHINGS
1 Inspect the suspension bushings for excessive
wear or damage.
• Are the bushings worn or damaged?
zYe s INSTALL new components as necessary.
REFER to:
Lower Arm (204-01 Front Suspension, Removal
and Installation),
Front Strut and Spring Assembly (204-01 Front
Suspension, Removal and Installation),
Front Stabilizer Bar (204-01 Front Suspension,
Removal and Installation),
Rear Stabilizer Bar Link (204-02 Rear Suspen-
sion, Removal and Installation).
zNo
GO to B5.
B5: INSPECT THE SUSPENSIONS LOWER ARM BALL JOINTS
1 Carry out the Ball Joint Inspection component
test in this procedure.
• Is the lower arm ball joint or gaiter damaged?
zYe s INSTALL new lower arm.
REFER to: Lower Arm (204-01 Front
Suspension, Removal and Installation).
TEST the system for normal operation.
zNo
GO to B6.
B6: INSPECT THE WHEEL BEARINGS
1 Check the wheel bearings.
• Are the wheel bearings damaged?
zYe s INSTALL a new wheel hub(s).
REFER to: Wheel Hub (204-01 Front
Suspension, Removal and Installation).
zNo
GO to B7.
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