2011 FORD KUGA suspension

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
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Wheels and Tires
Inspection and Verification
Visual Inspection Chart
MechanicalWheel(s)Tire(s)
Tire pressure(s) * Wheel nuts
Wheel studs
* Vehicles equipped with a tire deflation detection system (DDS) must be inspected for correct operation using the Ford approved diagnostic tool.
To maximize tire performance, inspect the tires for
signs of incorrect inflation and uneven wear which
may indicate a need for balancing, rotation or
suspension alignment. Tires should also be
checked frequently for cuts, stone bruises,
abrasions, blisters and for objects that may have
become embedded in the tread. More frequent
inspections are recommended when rapid or
extreme temperature changes occur or when road
surfaces are rough or occasionally littered with
foreign material.
As a further visible check of tire condition, tread
wear indicators are molded into the bottom of the
tread grooves. When these indicator bands become
visible, new tires must be installed.
Tire Wear Diagnosis
Uneven wear is usually caused by either excessive
camber or excessive toe on tires.
Sometimes incorrect toe settings or worn struts will
cause severe `cupping' or `scalloped' tire wear on
non-driven wheels.
Severely incorrect toe settings will also cause other
unusual wear patterns.
Tire Vibration Diagnosis
A tire vibration diagnostic procedure always begins
with a road test. The road test and customer
interview (if available) will provide much of the
information needed to find the source of a vibration. During the road test, drive the vehicle on a road
that is smooth and free of undulations. If vibration
is apparent, note and record the following:
– the speed at which the vibration occurs.
– what type of vibration occurs in each speed
range.
– mechanical or audible
– how the vibration is affected by changes in the following:
– engine torque
– vehicle speed
– engine speed
– type of vibration - sensitivity: – torque sensitive
– vehicle speed sensitive
– engine speed sensitive
The following explanations help isolate the source
of the vibration.
Torque Sensitive
This means that the condition can be improved or
made worse by accelerating, decelerating,
coasting, maintaining a steady vehicle speed or
applying engine torque.
Vehicle Speed Sensitive
This means that the vibration always occurs at the
same vehicle speed and is not affected by engine
torque, engine speed or the transmission gear
selected.
G1061329en2008.50 Kuga8/2011
204-04- 6
Wheels and Tires
204-04- 6
DIAGNOSIS AND TESTING
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Engine Speed Sensitive
This means that the vibration occurs at varying
vehicle speeds when a different transmission gear
is selected. It can sometimes be isolated by
increasing or decreasing engine speed with the
transmission in NEUTRAL or by stall testing with
the transmission in gear. If the condition is engine
speed sensitive, the cause is probably not related
to the tires.
If the road test indicates that there is tire whine,
but no shake or vibration, the noise originates with
the contact between the tire and the road surface.A thumping noise usually means that the tire is flat
or has soft spots making a noise as they slap the
roadway. Tire whine can be distinguished from axle
noise. Tire whine remains the same over a range
of speeds.
A complete road test procedure is described in
Section 100-04.
REFER to:
Noise, Vibration and Harshness (NVH)
(100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
Symptom Chart
Action
Possible Sources
Symptom
• ADJUST the tire pressure andreset the DDS. For additional
information REFER to the
owners guide.
• Loss of tire pressure.
• DDS warning lamp illuminated
• REFER to the DDS resetprocedure. For additional
information REFER to the
owners guide.
• The DDS reset procedure was
not carried out after adjustment
of the tire pressure.
• DDS warning lamp illuminated
with the correct tire pressure
• ADJUST the tire pressure andreset the DDS. For additional
information REFER to the
owners guide.
• The DDS reset procedure was
carried out under incorrect tire
conditions.
• DDS warning lamp not illumin-
ated when one or more tire(s)
have the incorrect tire pressure
• REFER to the DDS resetprocedure. For additional
information REFER to the
owners guide.
• The DDS reset procedure was
not completed.
• DDS reset command was not
confirmed
• REFER to the Ford approveddiagnostic tool.
• Anti-lock brake system (ABS)
module.
• DDS failure warning display
• ADJUST the tire pressure(s).
• Tire(s) under-inflated.
• Tire(s) show excess wear on
edge of tread
• CORRECT as necessary.
• Vehicle overloaded.
• ADJUST the wheel alignment.REFER to: Suspension System
(204-00 Suspension System
- General Information,
Diagnosis and Testing).
• Incorrect wheel alignment.
• ADJUST the tire pressure(s).
• Tire(s) over-inflated.
• Tire(s) show excess wear in
center of tread
• ADJUST the tire pressure(s).
• Incorrect tire pressure(s).
• Other excessive tire wear
concerns
G1061329en2008.50 Kuga8/2011
204-04- 7
Wheels and Tires
204-04- 7
DIAGNOSIS AND TESTING
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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
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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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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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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL