Recommended replacement interval for the part category Brake caliper : 100000 km

Important!

This replacement procedure can be used for:
FORD Kuga Mk1 (C394) TDCi … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

All the parts you need to replace – Brake Calipers for Kuga Mk1 (C394) and other FORD models

Brake caliper

Brake caliper for Kuga Mk1 (C394) Diesel (140 hp)

Replacement: brake caliper – FORD Kuga Mk1 (C394). Tools you might need:

                        Wire brush
                      
                        WD-40 spray
                      
                        Brake cleaner 
                      
                        Copper grease 
                      
                        Brake caliper guide pins grease
                      
                        Combination spanner #9
                      
                        Flare nut spanner №14
                      
                        HEX bit no.H7.
                      
                        Wheel impact socket #19
                      
                        Ratchet wrench
                      
                        Torque wrench
                      
                        Brake hose clip
                      
                        Flat Screwdriver
                      
                        Crow bar
                      
                        Brake bleeder kit
                      
                        Wheel chock

Buy tools

Replacement: brake caliper – FORD Kuga Mk1 (C394). Professionals recommend:

The replacement procedure is identical for the left and right brake calipers on the same axle.
All work should be done with the engine stopped.

Carry out replacement in the following order:

Step 1

Open the bonnet. Unscrew the brake fluid reservoir cap.

Step 2

Secure the wheels with chocks.
Step 3

Loosen the wheel mounting bolts. Use wheel impact socket #19.
Step 4

Raise the front of the car and secure on supports.

Step 5

Unscrew the wheel bolts.

AUTODOC recommends:
Important! Hold the wheel while unscrewing the fastening bolts. FORD Kuga Mk1 (C394)
Step 6

Remove the wheel.
Step 7

Detach the brake caliper retaining spring. Use a flat screwdriver.
Step 8

Remove the dust boot caps of the brake caliper guide pins. Use a flat screwdriver.
Step 9

Clean the area where the brake hose is connected to the caliper, and the guide pins area. Use a brake cleaner.

Replacement: brake caliper – FORD Kuga Mk1 (C394). AUTODOC recommends:
After applying the spray, wait a few minutes.
Step 10

Clamp the brake hose off using a brake hose clamp.
Step 11

Loosen the brake hose fastening. Use a flare nut spanner #14.
Step 12

Clean the brake caliper fasteners. Use a wire brush. Use WD-40 spray.

Step 13

Unscrew the brake caliper fastening. Use HEX No.H7. Use a ratchet wrench.
Step 14

Remove the guide pins from the brake caliper.

Step 15

Spread the brake pads. Use a crowbar.
Step 16

Remove the brake caliper.

Replacement: brake caliper – FORD Kuga Mk1 (C394). Tip from AUTODOC experts:
When replacing the brake caliper, it is recommended to check the brake hose for damages and, if necessary, to replace it with a new one.When replacing a brake caliper it is recommended to replace brake pads, check the state of the brake discs and replace them with new ones if necessary.Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.Don't press the brake pedal after the brake caliper has been removed. As a result, the piston can fall out from the brake cylinder, and brake fluid leakage and depressurization of the system may occur.
Step 17

Remove the brake pads.
Step 18

Unscrew the brake hose from the brake caliper. Use a flare nut spanner #14.
Step 19

Disconnect the brake hose.
Step 20

Treat the brake hose. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake caliper – FORD Kuga Mk1 (C394). After applying the spray, wait a few minutes.
Step 21

Install and fix the brake hose into a new caliper. Use a flare nut spanner #14.
Step 22

Remove the brake hose clamp.
Step 23

Clean the brake caliper bracket from dirt and dust. Use a wire brush. Use a brake cleaner.

Step 24

Install the brake pads.

Replacement: brake caliper – FORD Kuga Mk1 (C394). AUTODOC experts recommend:
If going to use the old brake pads, clean them.
Step 25

Install the brake caliper and fix it.
Step 26

Clean the brake caliper guide pins.
Step 27

Treat the brake caliper guide pins. Use the brake caliper guide pin grease.

Replacement: brake caliper – FORD Kuga Mk1 (C394). Tip from AUTODOC:
If no new guide pins were supplied in a kit with the new brake calipers, use the old pins.
Step 28

Screw in the guide pins.
Step 29

Tighten the brake caliper fasteners. Use HEX No.H7. Use a torque wrench. Tighten it to 30 Nm torque.
Step 30

Install the dust boot caps of the brake caliper guide pins.
Step 31

Clean the brake caliper surface.

Step 32

Tighten the fastener connecting the brake pipe to the brake caliper. Use a flare nut spanner #14. Use a torque wrench. Tighten it to 18 Nm torque.
Step 33

Connect the brake bleeder kit to the brake bleeder screw.
Step 34

Undo the brake bleeder screw. Use a combination spanner #9.
Step 35

Bleed the brake caliper system. Without starting the engine, press the brake pedal several times until you feel significant resistance.
Step 36

Tighten the brake caliper bleed screw. Use a combination spanner #9. Use a torque wrench. Tighten it to 9 Nm torque.
Step 37

Disconnect the brake bleeder kit.

Step 38

Clean dirt from the brake hose bolt. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake caliper – FORD Kuga Mk1 (C394). After applying the spray, wait a few minutes.
Step 39

Install the brake caliper retaining spring.
Step 40

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 41

Clean the brake disk surface. Use a brake cleaner.

Replacement: brake caliper – FORD Kuga Mk1 (C394). Tip:
After applying the spray, wait a few minutes.
Step 42

Install the wheel.

AUTODOC recommends:
Warning! To avoid injury, hold the wheel while screwing in the fastening bolts on the car. FORD Kuga Mk1 (C394)
Step 43

Screw in the wheel bolts. Use wheel impact socket #19.
Step 44

Lower the car and working in a cross order, tighten the wheel bolts. Use wheel impact socket #19. Use a torque wrench. Tighten it to 120 nm torque.
Step 45

Remove the jacks and chocks.

AUTODOC recommends:
Important! Replacement: brake caliper – FORD Kuga Mk1 (C394). Check the brake fluid level in the reservoir and top up if necessary.
Step 46

Tighten the brake fluid reservoir cap. Close the hood.

Replacement: brake caliper – FORD Kuga Mk1 (C394). AUTODOC recommends:
Without starting the engine, press the brake pedal several times until you feel significant resistance.

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