2011 FORD KUGA 206-00

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
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

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

DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
A3: CHECK FOR WORN BRAKE SHOES OR PADS
1 Inspect the brake shoes or pads for excessive
wear.
REFER to:
Specifications (206-00 Brake System
- General Information, Specifications).
• Are the brake shoe linings or brake pads OK?
zYe s GO to A4.
zNoINSTALL new brake shoes or pads.
REFER to: Brake Pads (206-04 Rear Disc
Brake, Removal and Installation).
TEST the system for normal operation.
A4: CHECK FOR DAMAGED PARKING BRAKE CABLES
1 Inspect the parking brake cables and conduits
for damage, rust or fraying.
• Are the parking brake cables and conduits OK?
zYe s CHECK for other causes such as loose
parking brake control or conventional brake
system components.
zNoREPAIR or INSTALL cables and conduit as
necessary. TEST the system for normal
operation.
PINPOINT TEST B : THE PARKING BRAKE WILL NOT RELEASE
DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B1: CHECK PARKING BRAKE CONTROL
1 Raise and support the vehicle on a lift with the
parking brake fully applied.
– With the aid of another technician, release the parking brake and check the operation of the
brake cables and levers.
• Did the parking brake release?
zYe s CHECK the other causes such as conventional
brake system components. REPAIR or
INSTALL new components as necessary.
zNoGO to B2.
G1063696en2008.50 Kuga8/2011
206-05- 6
Parking Brake and Actuation
206-05- 6
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL

DETAILS/RESULTS/ACTIONS
TEST CONDITIONS
B4: CHECK REAR PARKING BRAKE CABLES
1 Disconnect the parking brake at the rear brakes,
one at a time.
– Rotate the wheel affected by the disconnected parking brake.
• Did the wheel turn freely?
zYe s INSTALL a new parking brake control lever
on the rear drum brakes or caliper assembly
on rear disc brakes.
REFER to: Parking Brake Control (206-05
Parking Brake and Actuation, Removal and
Installation)
/ Brake Caliper (206-04 Rear Disc Brake,
Removal and Installation).
TEST the system for normal operation.
zNo
REFER to: Brake System (206-00 Brake
System - General Information, Diagnosis
and Testing).
G1063696en2008.50 Kuga8/2011
206-05- 8
Parking Brake and Actuation
206-05- 8
DIAGNOSIS AND TESTING
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E114811
2
1
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).
G1174985en2008.50 Kuga8/2011
206-06- 7
Hydraulic Brake Actuation
206-06- 7
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Anti-Lock Control – Component Location
NOTE:
Refer to:Brake System (206-00 Brake System -
General Information, Description and Operation).
E96610
G1001298en2008.50 Kuga8/2011
206-09A- 2
Anti-Lock Control
206-09A- 2
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E99307
x4
1
2
3
9.Torque: 9Nm
E69769
x3
10.Refer to: Stability Assist Module (206-09
Anti-Lock Control - Stability Assist, Removal
and Installation).
Installation
1. CAUTION: If accidentally dropped or knocked install a new hydraulic control
unit (HCU) and module.
The blanking caps/plugs must not be
removed until the brake tubes are ready to
be connected. 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).
G1001225en2008.50 Kuga8/2011
206-09B- 18
Anti-Lock Control - Stability Assist
206-09B- 18
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FORD KUGA 2011.0MY WORKSHOP REPAIR MANUAL