2011 FORD KUGA brake pads

Action
Possible Sources
Symptom
• BLEED the brake system.REFER to: Brake System
Pressure Bleeding (206-00
Brake System - General
Information, General Proced-
ures).
REFER to: (206-00 Brake
System - General Information)
Brake System Bleeding (General Procedures),
Component Bleeding (General
Procedures).
• Air in the system.
• Pedal eases down slowly
• GO toPinpoint Test B.
• Malfunctioning brake master
cylinder.
• Low engine vacuum (stationary).
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn brake shoes or brake
pads.
• Pedal is low or feels spongy
• CHECK for leaks. BLEED thebrake system. REFER to: (206-
00 Brake System - General
Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General Proced-
ures),
Component Bleeding (General
Procedures).
• Air in the system.
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Glazed or worn brake shoes or
brake pads.
• Brake lockup during light brake
pedal force
• GO toPinpoint Test C.
• Brake booster.
• Low engine vacuum.
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn brake shoes or brake
pads.
• Excessive or erratic pedal
travel
• CARRY OUT a brake discrunout check.
• Wheel bearings
G1058975en2008.50 Kuga8/2011
206-00-
8
Brake System - General Information
206-00- 8
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Action
Possible Sources
Symptom
• ADJUST the parking brakecable or switch
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
• Incorrectly adjusted parking
brake or brake pedal switch
• Brake drag
• REFER to brake booster opera-tion check in this procedure.
• Brake booster.
• INSTALL a new wheel cylinderor brake caliper.
REFER to: Brake Caliper (206-
03 Front Disc Brake,
Removal and Installation).
• Seized wheel cylinder or brake
caliper.
• INSTALL a new brake caliper.REFER to: Brake Caliper (206-
03 Front Disc Brake,
Removal and Installation).
• Seized brake caliper slide pins.
• INSTALL new parking brakecables.
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
• Seized parking brake cables.
• Check the parking brake leaverposition and make sure there
are no obstructions.
• Parking brake not fully
released.
• Check all brake hose(s) forcorrect fitment.
REFER to: Rear Brake Flexible
Hose (206-04 Rear Disc
Brake, Removal and Installa-
tion)
/ Front Brake Flexible Hose
(206-03 Front Disc Brake,
Removal and Installation).
• Brake hose incorrectly fitted.
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Worn or contaminated brake
shoes or brake pads.
• Excessive brake pedal effort
• INSTALL a new brake vacuumpump.
• Malfunctioning vacuum pump
(diesel).
• CONNECT or INSTALL a newbrake booster vacuum pipe as
necessary.
• Disconnected or damaged
brake booster vacuum pipe.
• GO toPinpoint Test D.
• Brake booster.
G1058975en2008.50 Kuga8/2011
206-00- 9
Brake System - General Information
206-00- 9
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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.
• Brake noise
• GO toPinpoint Test E.
• Brake booster.
• GO toPinpoint Test F.
• Brake booster.
• Seized brake pedal pivot.
• Slow or incomplete brake pedal
return
Pinpoint Tests
PINPOINT TEST A : PEDAL GOES DOWN FAST
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A1: PRESSURIZE THE SYSTEM
1 Pump the foot brake rapidly five times.
• Does the brake pedal height build up and then hold?
zYe s
CHECK parking brake adjustment and
ADJUST as necessary.
REFER to: Parking Brake Cable Adjustment
(206-05 Parking Brake and Actuation,
General Procedures).
If the condition still exists. BLEED the brake
system. REFER to: (206-00 Brake System -
General Information)
Brake System Bleeding (General Procedures),
Brake System Pressure Bleeding (General
Procedures),
Component Bleeding (General Procedures).
TEST the system for normal operation.
zNo
GO to A2.
G1058975en2008.50 Kuga8/2011
206-00- 10
Brake System - General Information
206-00- 10
DIAGNOSIS AND TESTING
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

Brake Disc Runout Check(12 221 0)
Special Tool(s) / General EquipmentDial Indicator Gauge (Metric)
205-069 (15-046)
15046
Holding Fixture, Dial Indicator
Gauge
205-070 (15-022A)
15022A
Holding Fixture, Dial Indicator
Gauge (Disc Brake)
206-003 (12-003)
12003
Micrometer 0-125 mm
Check
1. NOTE: The total dial indicator gauge readingshould not exceed 0.05 mm.
Using the special tools, measure the brake
disc runout on the inner face of the brake
disc (wheel and tire shown removed for
clarity).
1. Position the dial indicator gauge so that it contacts the brake disc approximately 10 mm
from the outer edge. 2. Slowly rotate the wheel and tire and note the
readings.
TIE0036133
2
206-0031
205-0701
205-0691
2. NOTE: Using paint or typing correction fluid,mark the position of the wheel in relation to
the wheel hub.
Remove the wheel and tire.
For additional information, refer to: Wheel
and Tire (204-04 Wheels and Tires, Removal
and Installation).
3. Remove the brake pads. For additional information, refer to:Brake
Caliper - Detach (206-03 Front Disc Brake,
Removal and Installation)
/ Brake Caliper -Detach (206-04 Rear Disc
Brake, Removal and Installation).
4. Install the wheel nuts and tighten the wheel nuts to 10 Nm, to hold the brake disc in
place.
5. NOTE: The total dial indicator gauge reading should not exceed 0.05 mm.
Using the special tools, measure the brake
disc runout on the inner and outer faces of
the brake disc (outer face measurement
shown).
1. Position the dial indicator gauge so that it contacts the brake disc approximately 10 mm
from the outer edge.
G1076535en2008.50 Kuga8/2011
206-00- 20
Brake System - General Information
206-00- 20
GENERAL PROCEDURES
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SECTION 206-03 Front Disc Brake
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
REMOVAL AND INSTALLATION
206-03-2
(12 234 0)
Brake Pads ........................................................................\
.............................
206-03-4
(12 243 0)
Brake Caliper ........................................................................\
..........................
206-03-5
Front Brake Flexible Hose ........................................................................\
..........................
206-03-1
Front Disc Brake
206-03- 1
.
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Brake Pads(12 234 0)
Special Tool(s)206-005
Retractor, Brake Caliper
Piston
12014
Materials
Specification
Name
WSS-M6C57-A2
Brake Fluid - Super
DOT4
WSS-M12A4-A2 / 1C1J-
19584-BA
Lubricating Paste
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.
E100314
4. WARNING: The brake caliper housing Torx bolts must not be removed.
CAUTION: Make sure that no load is
placed on the brake hose.
Torque: 28
Nm
E94825
12
3
5.
E100312
6.
E100313
G1001203en2008.50 Kuga8/2011
206-03- 2
Front Disc Brake
206-03- 2
REMOVAL AND INSTALLATION
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Brake Caliper(12 243 0)
General EquipmentHose Clamp(s)
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. General Equipment: Hose Clamp(s)
Loosen: 90°
E94932
4.Refer to: Brake Pads (206-03 Front Disc Brake,
Removal and Installation).
5. Torque: 22,5
Nm
E95017
6. WARNING: Make sure that the brake
hose is not twisted and is correctly
located.
NOTE: This step is only necessary when
installing a new component.
Refer to: Front Brake Flexible Hose (206-03
Front 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).
G1001204en2008.50 Kuga8/2011
206-03- 4
Front Disc Brake
206-03- 4
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

SECTION 206-04 Rear Disc Brake
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
REMOVAL AND INSTALLATION
206-04-2
(12 238 0)
Brake Pads ........................................................................\
.............................
206-04-4
(12 253 0)
Brake Caliper ........................................................................\
..........................
206-04-5
Rear Brake Flexible Hose ........................................................................\
...........................
206-04-1
Rear Disc Brake
206-04- 1
.
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL