2011 FORD KUGA 2.5L

Action
Possible Sources
Symptom
• INSTALL a new brake mastercylinder.
REFER to: Brake Master
Cylinder - 2.5L Duratec
(147kW/200PS) - VI5 (206-06
Hydraulic Brake Actuation,
Removal and Installation).
• Leaking brake master cylinder
primary piston cup.
• FREE UP and ADJUST theparking brake cable.
REFER to: Parking Brake
Cable Adjustment (206-05
Parking Brake and Actuation,
General Procedures).
INSTALL new components as
necessary.
• Parking brake control not fully
released.
• REFER to:Anti-Lock Control
(206-09 Anti-Lock Control,
Diagnosis and Testing).
• Malfunctioning anti-lock braking
system (ABS).
• REFER to:Instrument Cluster
(413-01 Instrument Cluster,
Diagnosis and Testing).
• Shorted indicator circuit.
• INSTALL new brake shoes orbrake pads.
REFER to: Brake Pads (206-03
Front Disc Brake, Removal
and Installation).
• Grease or fluid on the brake
shoes or brake pads; glazed
linings.
• Vibration when the brakes are
applied
• 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.
• TIGHTEN the caliper mountingbolt(s).
• Loose caliper mounting bolt(s).
•
• Excessive brake disc thickness
variation or brake disc runout.
• CHECK the tires. BALANCE orINSTALL new tires as neces-
sary.
REFER to: Wheels and Tires
(204-04 Wheels and Tires,
Diagnosis and Testing).
• Wheels and tires.
• TIGHTEN or INSTALL newwheel hub bolts as necessary.
• Loose or missing wheel hub
bolts.
• CARRY OUT a brake discrunout check.
• Worn or damaged brake drums
or brake discs.
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Brake System - General Information
206-00- 6
DIAGNOSIS AND TESTING
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DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake and clutch system
leaks. Refer to Brake Master Cylinder
Component Test in this procedure.
• Are any leaks present?
zYe s REPAIR as necessary. ADD fluid and 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 A3.
A3: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a brake master cylinder bypass
Condition Test. Refer to the Brake Master
Cylinder Component Test in this procedure.
• Was a concern found?
zYe s INSTALL a new brake master cylinder.
REFER to: Brake Master Cylinder - 2.5L
Duratec (147kW/200PS) - VI5 (206-06
Hydraulic Brake Actuation, Removal and
Installation).
TEST the system for normal operation.
zNo
VERIFY the customer concern.
PINPOINT TEST B : PEDAL EASES DOWN SLOWLY
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B1: CHECK THE BRAKE PEDAL OPERATION
1 Depress the brake pedal.
• Does the pedal ease down slowly?
zYe s GO to B2.
zNoRefer to the Brake Master Cylinder
Component Test in this procedure.
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Brake System - General Information
206-00- 11
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B2: CHECK FOR BRAKE SYSTEM LEAKS
1 Check for external brake system leaks.
• Are any leaks present?
zYe s REPAIR as necessary. ADD fluid and 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 B3.
B3: PERFORM A BRAKE MASTER CYLINDER BYPASS CONDITION TEST
1 Carry out a brake master cylinder bypass
Condition Test. Refer to the Brake Master
Cylinder Component Test in this procedure.
• Was a concern found?
zYe s INSTALL a new brake master cylinder.
REFER to: Brake Master Cylinder - 2.5L
Duratec (147kW/200PS) - VI5 (206-06
Hydraulic Brake Actuation, Removal and
Installation).
TEST the system for normal operation.
zNo
GO to B4.
B4: CHECK THE BRAKE BOOSTER CHECK VALVE
1 Disconnect the brake booster check valve
vacuum hose at the manifold.
2Blow into the hose attached to the brake booster
check valve.
• Does air pass through the valve?
zYe s INSTALL a new brake booster check valve.
zNoGO to B5.
B5: CHECK THE BRAKE BOOSTER CHECK VALVE VACUUM
1 Run the engine at idle.
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Brake System - General Information
206-00- 12
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too close to the fluid level indicator assembly,
or float assembly damage.
Bypass Condition Test
1. Check the fluid in the brake master cylinderreservoir. Fill the brake master cylinder reservoir
if low or empty.
2. Observe the fluid level in the brake master cylinder reservoir. If after several brake
applications, the fluid level remains the same,
measure the wheel turning torque required to
rotate the wheels with the brakes applied as
follows:
Place the transaxle in the NEUTRAL position.
Raise and support the vehicle. REFER to: (100-02
Jacking and Lifting) Jacking (Description and Operation),
Lifting (Description and Operation).
Apply the brakes with a minimum of 445 N (100
lb) and hold for approximately 15 seconds. With
the brakes still applied, exert a torque on the front
wheels of 10.1 Nm (75 lb ft). If either wheel rotates,
install a new brake master cylinder.
REFER to: Brake Master Cylinder - 2.5L Duratec
(147kW/200PS) - VI5 (206-06 Hydraulic Brake
Actuation, Removal and Installation).
Non-Pressure Leaks
Any empty brake master cylinder reservoir
condition may be caused by two types of
non-pressure external leaks.
Type 1: An external leak may occur at the brake
master cylinder reservoir cap because of incorrect
positioning of the gasket and cap. Reposition the
cap and gasket.
Type 2: An external leak may occur at the brake
master cylinder reservoir mounting seals. Service
such a leak by installing new seals.
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206-00- 19
Brake System - General Information
206-00- 19
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

SECTION 206-06 Hydraulic Brake Actuation
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
REMOVAL AND INSTALLATION
206-06-2
Brake Pedal and Bracket — RHD 4WD/RHD FWD ...........................................................
206-06-5
(12 343 0)
Brake Master Cylinder — 2.5L Duratec (147kW/200PS) - VI5 .......................
206-06-1
Hydraulic Brake Actuation
206-06- 1
.
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Brake Master Cylinder — 2.5L Duratec (147kW/200PS) -VI5(12 343 0)
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. Connect one end of a suitable piece of clear
plastic pipe to the brake caliper bleed nipple
1.
and place the other end into a suitable
container.
2. Loosen the bleed nipple.
3. Depress the brake pedal until no more brake fluid comes through the bleed nipple.
4. Tighten the bleed nipple.
5. Repeat the draining procedure on the opposite side brake caliper.
E86914
Left-hand drive vehicles
3. CAUTION: Make sure that all openings are sealed.
1. Torque: 18Nm
2.NOTE: Make sure that new components are
installed.
Torque: 25
Nm
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206-06- 5
Hydraulic Brake Actuation
206-06- 5
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SECTION 206-07 Power Brake Actuation
VEHICLE APPLICATION:2008.50 Kuga
PA G E
CONTENTS
REMOVAL AND INSTALLATION
206-07-2
(12 451 0)
Brake Booster — 2.5L Duratec (147kW/200PS) - VI5, RHD 4WD/RHD FWD .
206-07-7
Brake Vacuum Hose — 2.5L Duratec (147kW/200PS) - VI5 ..............................................
206-07-9
(12 414 0)
Brake Vacuum Pump — 2.5L Duratec (147kW/200PS) - VI5 ........................
206-07-1
Power Brake Actuation
206-07- 1
.
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Brake Booster — 2.5L Duratec (147kW/200PS) - VI5, RHD4WD/RHD FWD(12 451 0)
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. Torque: 24
Nm
E69829
x4
1
2
3.Refer to: Air Conditioning (A/C) System
Recovery, Evacuation and Charging (412-00
Climate Control System - General Information,
General Procedures).
Refer to: Brake Master Cylinder - 2.5L Duratec
(147kW/200PS) - VI5 (206-06 Hydraulic Brake
Actuation, Removal and Installation).
Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
4.
E65299
5. Torque:
• Stage 1: 10
Nm
• Stage 2: 25Nm
E99866
x6
6.
G1185955en2008.50 Kuga8/2011
206-07- 2
Power Brake Actuation
206-07- 2
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL