2011 FORD KUGA general procedures

Brake Caliper(12 253 0)
General EquipmentHose Clamp(s)
Materials
Specification
Name
WSS-M6C57-A2
Brake Fluid - Super
DOT4
Removal
NOTE: Removal steps in this procedure may
contain installation details.
1. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
2. Refer to: Wheel and Tire (204-04 Wheels and
Tires, Removal and Installation).
3.
E70112
1
2
4. General Equipment: Hose Clamp(s)
1.
2. Torque: 28
Nm
3. Torque: 35Nm
E70110
1
2
x2
3
5. CAUTION: Make sure that all openings
are sealed.
NOTE: Note the position of each component
before removal.
E70111
6. NOTE: This step is only necessary when
installing a new component.
Refer to: Rear Brake Flexible Hose (206-04
Rear Disc Brake, Removal and Installation).
Installation
1. To install, reverse the removal procedure.
2. Refer to: Brake System Bleeding (206-00 Brake
System - General Information, General
Procedures).
Refer to: Brake System Pressure Bleeding
(206-00 Brake System - General Information,
General Procedures).
3.
CAUTION: Make sure that the mating
faces are clean and free of foreign
material.
Depress the brake pedal, check the brake fluid
level in the brake fluid reservoir and top up as
necessary with brake fluid.
Material: Brake Fluid - Super DOT4 (WSS-M6C57-A2) brake fluid
G1001208en2008.50 Kuga8/2011
206-04- 4
Rear Disc Brake
206-04- 4
REMOVAL AND INSTALLATION
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3.Torque: 28Nm
E99426
Installation
1.To install, reverse the removal procedure.
2. Refer to: Component Bleeding (206-00 Brake
System - General Information, General
Procedures).
G1001210en2008.50 Kuga8/2011
206-04- 6
Rear Disc Brake
206-04- 6
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

SECTION 206-05 Parking Brake and Actuation
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
DESCRIPTION AND OPERATION
206-05-2
Parking Brake (Overview) ........................................................................\
...........................
206-05-2
Overview ........................................................................\
.....................................................
206-05-2
Parking brake cable ........................................................................\
....................................
206-05-3
Parking brake control ........................................................................\
..................................
DIAGNOSIS AND TESTING 206-05-4
Parking Brake ........................................................................\
.............................................
206-05-4
Inspection and Verification ........................................................................\
..........................
206-05-4
Symptom Chart ........................................................................\
...........................................
206-05-5
Pinpoint Tests ........................................................................\
.............................................
GENERAL PROCEDURES 206-05-9
Parking Brake Cable Adjustment ........................................................................\
................
REMOVAL AND INSTALLATION 206-05-11
(12 664 0)
Parking Brake Control ........................................................................\
............
206-05-12
Parking Brake Rear Cables ........................................................................\
........................
206-05-1
Parking Brake and Actuation
206-05- 1
.
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The following instructions must be followed when
removing, installing or renewing the parking brake
cable:
• If the parking brake cable is removed, installedor renewed, the parking brake must be adjusted
after the work is completed.
Refer to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation, General
Procedures).
Parking brake control
E103687
The following instructions must be followed when
removing, installing or renewing the parking brake
lever:
• If the parking brake lever is removed, installed or renewed, the parking brake must be adjusted
after the work is completed.
Refer to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation, General
Procedures).
G1058325en2008.50 Kuga8/2011
206-05- 3
Parking Brake and Actuation
206-05- 3
DESCRIPTION AND OPERATION
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Pinpoint Tests
PINPOINT TEST A : THE PARKING BRAKE WILL NOT APPLY
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A1: CHECK PARKING BRAKE CABLE ADJUSTMENT
1 Release the parking brake and measure the gap
between the lever and the caliper.
• Is the gap 1.2mm?
zYe s
E83778
1.2 mm
Vehicle OK
zNo REFER to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation,
General Procedures).
A2: CHECK FUNCTION OF PARKING BRAKE ON BRAKE CALIPER
1 Raise and support the vehicle on a lift with the
parking brake fully applied.
REFER to:
Lifting(100-02 Jacking and Lifting,
Description and Operation).
– With the aid of another technician, release the parking brake and check the operation of the
brake cables and levers.
• Are the left-hand (LH) and right-hand (RH) parking brake levers moving a similar distance?
zYe s
CHECK the other causes such as conventional
brake system components. REPAIR or
INSTALL new components as necessary.
zNoREFER to: Brake Caliper (206-04 Rear Disc
Brake, Removal and Installation).
TEST the system for normal operation.
G1063696en2008.50 Kuga8/2011
206-05- 5
Parking Brake and Actuation
206-05- 5
DIAGNOSIS AND TESTING
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Parking Brake Cable Adjustment
1.Fully apply the parking brake.
1.
2. Fully release the parking brake control.
2.
E92650
3. NOTE: This step is only necessary if the parking
brake cable was removed.
1. Torque: 2
Nm
E102065
21
G1001211en2008.50 Kuga8/2011
206-05- 9
Parking Brake and Actuation
206-05- 9
GENERAL PROCEDURES
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4.Loosen the parking brake cable adjustment
nut to the end of the parking brake cable
thread.
2.
E102067
2
P1
5.
Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
6. NOTE: This step requires the aid of another
technician.
1. Insert a 1.2 mm feeler gauge between the parking brake lever and the brake caliper
abutment, on both sides.
2. Tighten the parking brake cable adjustment nut until movement is observed on one of the
parking brake levers.
3. Remove the feeler gauges.
4. Rotate the rear wheels and tires and check for brake drag. If brake drag is felt, loosen
the parking brake cable adjustment nut to
the end of the parking brake cable thread,
clean the parking brake cables and repeat
the parking brake cable adjustment
procedure.
5. If brake drag is still felt after, repeat the adjustment using a 1.0 mm feeler gauge. If
brake drag is still felt, loosen the parking
brake adjustment nut and reduce the feeler
gauge measurement by 0.2 mm each time,
until no brake drag can be felt at the rear
wheels and tires.
E83778
1.2 mm
G1001211en2008.50 Kuga8/2011
206-05- 10
Parking Brake and Actuation
206-05- 10
GENERAL PROCEDURES
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Parking Brake Control(12 664 0)
Removal
1.Refer to: Floor Console (501-12 Instrument
Panel and Console, Removal and Installation).
2. Release the parking brake.
3.
3
33
2
1
4
E93308
Installation
1. Torque: 35Nm2.
3.NOTE: Only tighten the nut finger tight at this
stage.
2
22
3
4
1
E93328
2. Refer to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation, General
Procedures).
3. Refer to: Floor Console (501-12 Instrument
Panel and Console, Removal and Installation).
G1058318en2008.50 Kuga8/2011
206-05- 11
Parking Brake and Actuation
206-05- 11
REMOVAL AND INSTALLATION
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