2011 FORD KUGA Scr

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.
G1058975en2008.50 Kuga8/2011
206-00- 19
Brake System - General Information
206-00- 19
DIAGNOSIS AND TESTING
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Component Bleeding
General EquipmentFluid Container
Bleeding
NOTE: Make sure that the vehicle is standing on
a level surface.
1. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
Vehicles with stability assist
2. Bleed the brake system using the
BleedMASTER function in the diagnostic tool.
Vehicles without stability assist
3.
E86914
4. CAUTION: The brake fluid reservoir
must remain full with new, clean brake
fluid at all times during bleeding.
Refer to: Specifications (206-00 Brake System
- General Information, Specifications).
E139915
G1464506en2008.50 Kuga8/2011
206-00- 22
Brake System - General Information
206-00- 22
GENERAL PROCEDURES
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Brake System Bleeding
General EquipmentFluid Container
NOTE: Make sure that the vehicle is standing on
a level surface.
1. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
Vehicles with stability assist
2. Bleed the brake system using the
BleedMASTER function in the diagnostic tool.
Vehicles without stability assist
3.
E86914
4. CAUTION: The brake fluid reservoir
must remain full with new, clean brake
fluid at all times during bleeding.
Refer to: Specifications (206-00 Brake System
- General Information, Specifications).
E139915
G1057428en2008.50 Kuga8/2011
206-00- 27
Brake System - General Information
206-00- 27
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Brake System Draining and Filling(12 154 0; 12 154 4)
General EquipmentFluid Container
Draining
15. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
16.
E86914
17. Refer to: Lifting(100-02 Jacking and Lifting,
Description and Operation).
18. On both sides.
E139455
19.On both sides.
General Equipment: Fluid Container
E139454
20.On both sides.
Loosen: 180°
G1420093en2008.50 Kuga8/2011
206-00- 32
Brake System - General Information
206-00- 32
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Brake System Pressure Bleeding
General EquipmentBrake/Clutch System Pressure Bleeder/Filler
NOTE: Make sure that the vehicle is standing on
a level surface.
1. Refer to: Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
Vehicles with stability assist
2. Bleed the brake system using the
BleedMASTER function in the diagnostic tool.
Vehicles without stability assist
3.
E86914
4.Refer to: Specifications (206-00 Brake System
- General Information, Specifications).
E139915
5. CAUTION: Make sure that the pressure within the brake system does not
exceed 1 bar.Using the brake/clutch system pressure
bleeder/filler, pressure bleed the system in
accordance with the manufacturer's instructions.
General Equipment: Brake/Clutch SystemPressure Bleeder/Filler
G1057429en2008.50 Kuga8/2011
206-00- 35
Brake System - General Information
206-00- 35
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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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Front Brake Flexible Hose
Removal
CAUTION:
Refer to:Brake System Health and Safety
Precautions (100-00 General Information,
Description and Operation).
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. WARNINGS:
Make sure that no load is placed on the
brake hose.
Be prepared to collect escaping fluid.
CAUTION: Make sure that all openings
are sealed.
1. Torque: 15
Nm
4. Torque: 23Nm
E99419
1
2
3
4
Installation
1. To install, reverse the removal procedure.
2. Refer to: Component Bleeding (206-00 Brake
System - General Information, General
Procedures).
G1001206en2008.50 Kuga8/2011
206-03- 5
Front Disc Brake
206-03- 5
REMOVAL AND INSTALLATION
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL