Recommended replacement interval for the part category Brake pad set : 30000 km

Important!

This replacement procedure can be used for:
FORD KUGA I 2.0 TDCi 4x4, FORD KUGA I 2.0 TDCi 4x4, FORD KUGA I 2.0 TDCi, FORD KUGA I 2.5 4x4, FORD KUGA I 2.0 TDCi 4x4, FORD KUGA I 2.0 TDCi, FORD KUGA I 2.5 … 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 Pads for KUGA I and other FORD models

Brake pad set

        Brake pad set for FORD KUGA I 2.5 Petrol (200 hp)
      
        Brake pad set for FORD KUGA I 2.0 TDCi Diesel (136 hp)
      
        Brake pad set for FORD KUGA I 2.0 TDCi 4x4 Diesel (136 hp)
      
        Brake pad set for FORD KUGA I 2.5 4x4 Petrol (200 hp)
      
        Brake pad set for FORD KUGA I 2.0 TDCi Diesel (140 hp)
      
        Brake pad set for FORD KUGA I 2.0 TDCi 4x4 Diesel (140 hp)
      
        Brake pad set for FORD KUGA I 2.0 TDCi 4x4 Diesel (163 hp)

Replacement: brake pads – FORD KUGA I. List of the tools you'll need:

                        Wire brush
                      
                        Brake cleaner 
                      
                        Anti-squeal paste
                      
                        Copper grease 
                      
                        HEX bit No.H7.
                      
                        Wheel impact socket #19
                      
                        Ratchet wrench
                      
                        Torque wrench
                      
                        Brake caliper wind back tool
                      
                        Crow bar
                      
                        Wheel chock

Buy tools

Replacement: brake pads – FORD KUGA I. AUTODOC experts recommend:

Perform the replacement of brake pads in complete set for each axis. This provides effective braking.
The replacement procedure is identical for all brake pads on the same axle.
All work should be done with the engine stopped.

Replacement: brake pads – FORD KUGA I. Use the following procedure:

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:
Warning! To avoid injury, hold the wheel while unscrewing the fastening bolts. FORD KUGA I
Step 6

Remove the wheel.
Step 7

Spread the brake pads. Use a crowbar.
Step 8

Detach the brake caliper retaining spring. Use a crowbar.
Step 9

Remove the dust boot caps of the brake caliper guide pins.
Step 10

Unscrew the brake caliper fastening. Use HEX No.H7. Use a ratchet wrench.
Step 11

Remove the brake caliper.

Replacement: brake pads – FORD KUGA I. AUTODOC recommends:
Tie the caliper to the suspension or to the body with a wire without disconnecting from the brake hose to prevent depressurization of the brake system.Make sure that the brake caliper is not hanging on the brake hose.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 12

Remove the brake pads.

Replacement: brake pads – FORD KUGA I. Tip:
Measure the brake disc thickness. Upon reaching the wear limit the part must be replaced.
Step 13

Press in the brake caliper piston. Use brake caliper wind back tool.
Step 14

Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary. Use a wire brush. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake pads – FORD KUGA I. After applying the spray, wait a few minutes.
Step 15

Treat the back side of the new brake pads. Treat the brake caliper bracket. Use anti-squeal paste.

Replacement: brake pads – FORD KUGA I. Tip from AUTODOC:
Make sure the disc surface is clean before installing the pads.
Step 16

Install new brake pads.

Replacement: brake pads – FORD KUGA I. Professionals recommend:
Make sure the pads are installed with linings facing the disc.
Step 17

Install the brake caliper and fix it. Use HEX No.H7. Use a torque wrench. Tighten it to 28 Nm torque.
Step 18

Install the dust boot caps of the brake caliper guide pins.
Step 19

Install the brake caliper retaining spring.

Replacement: brake pads – FORD KUGA I. Tip from AUTODOC experts:
Without starting the engine, press the brake pedal several times until you feel significant resistance.
Step 20

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 21

Install the wheel.

AUTODOC recommends:
Important! Hold the wheel while screwing in the fastening bolts. FORD KUGA I
Step 22

Screw in the wheel bolts. Use wheel impact socket #19.
Step 23

Lower the car and working in a cross order, tighten the wheel bolts. Use a torque wrench. Tighten it to 110 nm torque.
Step 24

Remove the jacks and chocks.

AUTODOC recommends:
Important! Replacement: brake pads – FORD KUGA I. Check the brake fluid level in the reservoir and top up if necessary.
Step 25

Tighten the brake fluid reservoir cap. Close the hood.

Replacement: brake pads – FORD KUGA I. AUTODOC recommends:
Slow down smoothly for first 150-200 km after the brake pads replacement. Avoid unneccessary and sharp braking to a stop.

Was this manual helpful?

Please rate this manual on a scale from 1 to 5. If you have any questions, feel free to ask us.

How to change front brake caliper on FORD KUGA I – replacement guide

Free download PDF
2.11 MB
How to change front windshield wipers on FORD Kuga Mk1 Off-Road – replacement guide

Free download PDF
1.39 MB
How to change front anti roll bar links on FORD Kuga Mk1 Off-Road – replacement guide

Free download PDF
2.01 MB
How to change the oil filter and engine oil on the FORD Kuga Mk1 Off-Road – replacement guide

Free download PDF
1.66 MB
How to change rear strut mount on FORD Kuga Mk1 Off-Road – replacement guide

Free download PDF
2.64 MB
How to change front strut mount on FORD KUGA I – replacement guide

Free download PDF
2.79 MB

How to change front brake pads on FORD Kuga Mk2 (DM2) – replacement guide

Free download PDF
2.35 MB
How to change rear brake pads on FORD Kuga Mk2 (DM2) – replacement guide

Free download PDF
1.72 MB
How to change front brake pads on FORD Kuga Mk1 (C394) – replacement guide

Free download PDF
1.46 MB
How to change brake pads on a car – replacement tutorial

Universal

Free download PDF
2.84 MB
How to change rear brake pads on Ford Focus MK2 – replacement guide

Free download PDF
1.81 MB
How to change front brake pads on Ford Focus MK2 – replacement guide

Free download PDF
2.37 MB

Your profile is your personal assistant.

It can track car expenses, keep a car log and replacement schedule, and save favourite materials, notes and documents

Install the AUTODOC CLUB app!

Your personal car expenses manager, maintenance tips, reminders about upcoming appointments and service intervals, DIY repair instructions – all this on your phone.

Scan

To download the app:

- scan the QR code
- download from App Store
- download from Google Play

Important differences between car tools | AUTODOC tips

7K views

Published on: 16/12/2021
What to do if your car's air conditioning isn't working properly | AUTODOC tips

6K views

Published on: 05/08/2021
DIY car soundproofing | AUTODOC tips

75K views

Published on: 15/04/2021
How to repair a bumper yourself | AUTODOC tips

9K views

Published on: 01/06/2023