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Body System - Uni-Body, Subframe & Mounting System: Removal & Installation Ford Kuga II

Frames, Subframes & Crossmembers 9 illustrations ~1156 words

Installation

  1. Use the General Equipment: Transmission Jack
  2. Torque: 62 lb.in (7 Nm)
  3. Finger tight at this stage. Use the General Equipment: Transmission Jack
  4. NOTE: While tightening the subframe bolts, make sure the front subframe does not move. Use Special Service Tool: 502-002 (T94P-2100-AH) Alignment Pins, Subframe .
  5. Torque: 85 lb.ft (115 Nm) Torque: Stage 1: 103 lb.ft (140 Nm) Stage 2: 180° Torque: 46 lb.ft (62 Nm) Torque: 35 lb.ft (47 Nm)
  6. Torque: 92 lb.ft (125 Nm)
  7. Torque: 18 lb.ft (25 Nm)
  8. On both sides. Torque: 61 lb.ft (83 Nm)
  9. On both sides. Torque: 35 lb.ft (48 Nm)
  10. NOTE: The stabilizer bar links are designed with low friction ball joints that have a low breakaway torque. NOTE: Use the hex-holding feature to prevent the ball stud from turning while removing or installing the stabilizer bar link nut. On both sides. Torque: 46 lb.ft (63 Nm)
  11. If equipped. On both sides. Torque: 18 lb.ft (25 Nm)
  12. If equipped.
  13. Refer to: «WHEEL AND TIRE»(ref-658846-S39478507132014092900000) .
  14. Torque: 21 lb.ft (28 Nm)
  15. Refer to: «BATTERY DISCONNECT AND CONNECT»(ref-658873-S03187421432014092900000) .
  16. Refer to: «FRONT TOE ADJUSTMENT»(ref-658847-S39501925392014092900000) .

Removal

Front bushings

Note. There are 2 Rear Drive Unit (RDU) front bushings in the rear subframe, this procedure shows how to remove one bushing. The procedure for the remaining RDU bushing is identical.

  1. Refer to: «AXLE ASSEMBLY»(ref-658879-S42611081212014092900000) .
  2. NOTE: Make sure the arrow on the RDU Bushing Remover/Installers is pointed toward the rear subframe when removing the bushing. Use Special Service Tool: 204-616 Remover/Installer, Rear Drive Unit Bushing (70 mm) , 204-618 Remover/Installer, Rear Drive Unit Bushing (60 mm) , 303-420 (T92P-6701-BH) Installer, Crankshaft Front Oil Seal . Rear bushings NOTE: There are 2 Rear Drive Unit (RDU) rear bushings in the rear subframe, this procedure shows how to remove one bushing. The procedure for the remaining RDU bushing is identical.
  3. Refer to: «AXLE ASSEMBLY»(ref-658879-S42611081212014092900000) .
  4. NOTE: The RDU Bushing Remover/Installer 204-618/1 must be used to remove the bushing to make sure that it passes through the receiver cup. NOTE: Make sure the RDU Bushing Remover/Installer 204-616/2 is positioned with the larger opening toward the bushing to act as the receiver cup. NOTE: Make sure the arrow on the RDU Bushing Remover/Installers is pointed toward the rear subframe when removing the bushing. Use Special Service Tool: 204-616 Remover/Installer, Rear Drive Unit Bushing (70 mm) , 204-618 Remover/Installer, Rear Drive Unit Bushing (60 mm) .

Front bushings

Note. There are 2 RDU front bushings in the rear subframe, this procedure shows how to remove one bushing. The procedure for the remaining RDU bushing is identical.

Scheme 1

Scheme 1: Installation
Scheme 1: Installation

Scheme 2

Scheme 2
Scheme 2
  1. NOTE: Make sure the alignment marks on the RDU Bushing Remover/Installers are aligned with the anti-rotation tabs on the RDU bushing. Use Special Service Tool: 204-618 Remover/Installer, Rear Drive Unit Bushing (60 mm).
  2. NOTE: Make sure the arrow on the RDU Bushing Remover/Installers is visible on the bottom and facing away from the subframe. The arrow must remain straight so that the bushings are correctly indexed into the subframe. NOTE: When installing the RDU bushing, RDU Bushing Remover/Installer 204-618/2 will fall away as the RDU bushing is installed into the subframe. The RDU Bushing Remover/Installers do not control the depth of the bushing. The RDU bushing is fully seated when the Replacer, Front Crankshaft Seal 303-420 contacts the RDU bushing housing. Do not continue to tighten the RDU Bushing Remover/Installers. Use Special Service Tool: 204-616 Remover/Installer, Rear Drive Unit Bushing (70 mm) , 204-618 Remover/Installer, Rear Drive Unit Bushing (60 mm) , 303-420 (T92P-6701-BH) Installer, Crankshaft Front Oil Seal .
  3. Refer to: «AXLE ASSEMBLY»(ref-658879-S42611081212014092900000) . Rear bushings
  4. NOTE: There are 2 RDU rear bushings in the rear subframe, this procedure shows how to remove one bushing. The procedure for the remaining RDU bushing is identical. NOTE: Make sure the alignment marks on the RDU Bushing Remover/Installers are aligned with the anti-rotation tabs on the RDU bushing. Use Special Service Tool: 204-618 Remover/Installer, Rear Drive Unit Bushing (60 mm).
  5. NOTE: Make sure the alignment marks are properly aligned on both RDU Bushing Remover/Installers and the anti-rotation tabs are properly seated in the RDU Bushing Remover/Installers. Use Special Service Tool: 204-616 Remover/Installer, Rear Drive Unit Bushing (70 mm).
  6. NOTE: Make sure the arrow on the RDU Bushing Remover/Installers is visible on the bottom and facing away from the subframe. The arrow must remain straight so that the bushings are correctly indexed into the subframe. NOTE: When installing the RDU bushing, RDU Bushing Remover/Installer 204-616/2 will fall away as the RDU bushing is installed into the subframe. The RDU Bushing Remover/Installers do not control the depth of the bushing. The RDU bushing is fully seated when the RDU Bushing Remover/Installers 204-618/1 contacts the RDU bushing housing. Do not continue to tighten the RDU Bushing Remover/Installers. Use Special Service Tool: 204-616 Remover/Installer, Rear Drive Unit Bushing (70 mm) , 204-618 Remover/Installer, Rear Drive Unit Bushing (60 mm) .
  7. Refer to: «AXLE ASSEMBLY»(ref-658879-S42611081212014092900000) .

Note. Suspension fasteners are critical parts that affect the performance of vital components and systems. Failure of these fasteners may result in major service expense. Use the same or equivalent parts if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Tighten fasteners as specified.

All vehicles

Scheme 3

Scheme 3: Removal
Scheme 3: Removal

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7
  1. Refer to: «WHEEL AND TIRE»(ref-658846-S39478507132014092900000) .
  2. On both sides. Refer to: «REAR STABILIZER BAR LINK»(ref-658848-S11934191302014092900000) .
  3. On both sides. Refer to: «SPRING»(ref-658848-S38939138262014092900000) .
  4. On both sides.
  5. On both sides.
  6. All wheel drive (AWD) vehicles
  7. Refer to: «REAR DRIVESHAFT»(ref-658878-S09057374352014092900000) .
  8. On both sides. Refer to: «REAR HALFSHAFT»(ref-658850-S03770732722014092900000) .
  9. NOTE: Located in RR wheel opening.
  10. All vehicles
  11. NOTE: AWD shown in illustration, FWD similar. If equipped.
  12. Use the General Equipment: Transmission Jack
  13. Use the General Equipment: Transmission Jack

All vehicles

Scheme 8

Scheme 8: Installation
Scheme 8: Installation

Scheme 9

Scheme 9
Scheme 9
  1. Use the General Equipment: Transmission Jack
  2. Torque: 85 lb.ft (115 Nm)
  3. NOTE: AWD shown in illustration, FWD similar. If equipped. All wheel drive (AWD) vehicles
  4. NOTE: Located in RR wheel opening.
  5. On both sides. Refer to: «REAR HALFSHAFT»(ref-658850-S03770732722014092900000) .
  6. Refer to: «REAR DRIVESHAFT»(ref-658878-S09057374352014092900000) . All vehicles
  7. On both sides. Finger tighten only.
  8. On both sides. Finger tighten only.
  9. On both sides. Refer to: «SPRING»(ref-658848-S38939138262014092900000) .
  10. NOTE: Use the General Equipment: Vehicle/Axle Stands
  11. NOTE: Tighten the suspension bushing fasteners with the suspension loaded or with the weight of the vehicle resting on the wheels and tires, or incorrect clamp load and bushing damage may occur. On both sides. Torque: 85 lb.ft (115 Nm)
  12. NOTE: Tighten the suspension bushing fasteners with the suspension loaded or with the weight of the vehicle resting on the wheels and tires, or incorrect clamp load and bushing damage may occur. On both sides. Torque: 85 lb.ft (115 Nm)
  13. On both sides. Refer to: «REAR STABILIZER BAR LINK»(ref-658848-S11934191302014092900000) .
  14. Refer to: «WHEEL AND TIRE»(ref-658846-S39478507132014092900000) .
  15. Check and, if necessary, adjust rear toe. Refer to: «REAR TOE ADJUSTMENT»(ref-658847-S09424700492014092900000) .

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