TF Ford Kuga 2013 Body Repair Summary
Introduction
This document provides vehicle body specialists with an overview of the Supplemental Restraint System (SRS) and key information regarding the vehicle's body construction. Vehicle body dimension information is also included.
This body repair summary is intended as an overview of the SRS and body construction and is not comprehensive. For complete information, consult the Workshop Manual, available from an Authorised Ford Dealer.
The TF generation Ford Kuga is a 5-door crossover vehicle seating 5 people, available in three specification levels: Ambiente, Trend, and Titanium. It features a fuel-efficient 1.6L EcoBoost turbo-charged petrol engine or a 2.0L turbo-charged diesel. Front-wheel drive (FWD) is available on the Ambiente model with a 6-speed manual transmission. Automatic transmissions are standard on Ambiente, Trend, and Titanium AWD variants. The Ford Kuga is equipped with comprehensive safety features.
ABS braking and Dynamic Stability Control (DSC) are standard across the range, as are side curtain airbags. The Ford Kuga's design offers a high vehicle ride height and an elevated seat position.
The body construction incorporates crumple zones designed to buckle at strategic weak points, absorbing crash loads and maintaining passenger cell integrity. Additional safety features include collapsible steering columns, breakaway pedals, and specially designed door trims for side impact absorption.
Disclaimer
The information contained in this publication was correct at the time of going to print.
Ford Motor Company of Australia Limited ("Ford") reserves the right to change specifications, designs, or equipment at any time without notice and without incurring any obligations. This publication, or part thereof, may not be reproduced nor translated without Ford's approval. To the maximum extent permitted by law, Ford is not liable for any errors or omissions in this document.
Copyright - Ford Motor Company of Australia Limited. Reproduction in whole or part is prohibited without written approval. Copyright © 2013
Health and Safety
Appropriate repair methods and correct execution of repairs are crucial for vehicle operating safety and personal safety. All relevant Health and Safety at Work regulations must be complied with during any repairs.
Body areas are subject to high forces during realignment work. If any component detaches suddenly, there is a significant risk of injury. Therefore, pulling chains and shackles must be secured with arrester cables.
Please refer to the TF Ford Kuga Workshop Manual (available from your Authorised Ford Dealer) for detailed instructions and precautions regarding the repair of the vehicle's Supplementary Restraint System.
Special Instructions for Airbag Systems
After disconnecting the power supply and before performing further work, allow a wait time of 15 minutes. Work on airbag systems may only be performed by persons holding a relevant certificate of competency.
- ⚠️ Always stand to the side of the airbag when removing or installing it.
- ⚠️ Always store an airbag or an airbag/steering wheel with the airbag side pointing upwards and in a safe place.
- ⚠️ Only install the airbag again when the vehicle is fully repaired and the complete electrical system has been tested.
- ⚠️ Take into account the location of side airbags.
Points to Note for Welding and Airbag Systems
- Disconnect the battery negative clamp and cover the battery terminal.
- Disconnect the electrical connector at the airbag control module.
- If welding is to be performed directly near a control module, it must be removed beforehand.
- Never connect the negative cable of the welder near an airbag or a control module.
- Connect the negative cable of the welder close to the location of the weld.
Supplemental Restraint System (SRS)
Component Location
Diagram showing the location of SRS components within the vehicle:
| Item | Description |
|---|---|
| 1 | Front impact sensor |
| 2 | Knee air bag |
| 3 | Instrument cluster with airbag telltale and belt warning display |
| 4 | Driver Air bag |
| 5 | Acceleration sensor |
| 6 | Safety belt retractor |
| 7 | Safety belt retractor |
| 8 | Safety belt switch |
| 9 | Side air curtain |
| 10 | Side air bag |
| 11 | Seat occupant sensor (passenger side only) |
| 12 | RCM (restraints control module) |
| 13 | Pressure sensor |
| 14 | Front passenger airbag |
General Overview
The Restraint Control Module (RCM) performs a self-diagnosis upon ignition switch-on. It checks all safety restraint system components, except for the front safety belt buckle switches and the passenger side seat occupancy sensor. If a fault is detected, the airbag telltale is activated.
Pressure sensors, designed for rapid reaction, are located in the front doors. Due to the vehicle's higher ride height, impact forces may occur above the rocker panel, with kinetic energy initially directed into the doors. Side impact sensors then detect movement.
In a side impact, the door outer skin is pressed inward, creating excess pressure within the door. If the pressure change exceeds a defined threshold, the sensor transmits a signal to the airbag control module. This threshold is set above values that could result from accidental door opening or minor impacts, preventing undesirable triggering. The triggering signal must also be confirmed by the accelerometer in the side impact sensor or by the RCM.
The use of pressure sensors has resulted in a time saving of 2 milliseconds.
Diagrams show an instrument cluster display (A) with various indicators including airbag and seatbelt warnings, and a seatbelt warning icon (B).
An image displays a pressure sensor and an accelerometer.
SRS Component Replacement in the Event of Deployment
CAUTION
Safety with SRS components is paramount.
Please refer to the TF Ford Kuga Workshop Manual (available from your Authorised Ford Dealer) for detailed instructions and precautions regarding the repair of the vehicle's Supplementary Restraint System.
When any deployable device (driver airbag, passenger airbag, side airbag, safety belt pretensioner, etc.) or combination of devices has deployed, or if the Restraint Control Module (RCM) has stored Diagnostic Trouble Codes (DTCs), the repair of the Supplemental Restraint System (SRS) must include the removal of all deployed devices and the installation of new deployable devices.
For assistance with DTCs, contact your Authorised Ford Dealer.
If any damage to impact sensor mounting points or hardware has occurred, repair or install new mounting points and hardware as needed.
During the repair process, inspect the entire vehicle for damage, including the following components:
- Steering column and clock spring.
- Instrument panel knee bolsters and mounting points.
- Instrument panel braces and brackets.
- Instrument panel and mounting points.
- Seats and seat mounting points.
- Safety belts, safety belt buckles and safety belt retractors, SRS wiring, wiring harnesses, and connectors.
Components to Replace After Front Airbag(s) and Seat Belt Tensioners Deployed:
- RCM unit.
- Deployed airbag module(s).
- Seat belt pretensioners.
- Seat belt outer lap tensioners.
- Front impact severity sensor.
Components to Replace After Side Airbag(s) Deployed:
- RCM unit.
- Deployed side airbag module(s).
- B-pillar side impact sensor(s).
- Seat trim(s).
Airbag Reconnect Checklist
The following checklist should be completed following diagnosis or repair of any airbag system concern:
- All restraint system diagnostic tools removed?
- All in-seat harness connectors connected?
- All airbag modules connected?
- Safety belt pretensioner connectors connected?
- RCM connected?
- All sensors (front and side impact sensors) connected?
- Battery connected?
Body Construction
The body consists of the following materials and components:
- High-Strength Low Alloy (HSLA), ultra high-strength steel (UHSS), and mild steels.
- Roof outer panel constructed of mild steel.
- Steel hood.
- Steel luggage compartment lid.
- Body side outer panels constructed of mild steel.
- Dual-phase steel (DP) in select body structure components.
- Bolted, removable front fenders, hinged doors, and hood.
- Dent-resistant steel fenders.
- Ultra high-strength steel (UHSS) front and rear bumper beam.
- Underbody components constructed of mild, dual-phase, and high-strength steels.
- Mastic pads used on the floor pan for sound deadening.
For recommended metal repair guidelines and recommendations, refer to the following illustrations. For additional information, refer to the TF Ford Kuga Workshop Manual.
Steel Type Legend
The following table and diagram illustrate the different steel types used and their corresponding colors:
| Item | Steel Type | Color |
|---|---|---|
| 1 | Mild Steel | Yellow |
| 2 | Bake Hardened Steel (BH) | Light Blue |
| 3 | Solid Solution Strength | Pink |
| 4 | High Strength Low Alloy (HSLA) | Dark Blue |
| 5 | Dual Phase (DP) 500, 600 Class Steel | Green |
| 6 | Dual Phase (DP) 700, 800, 900, 1000 Class Steel | Fuchsia |
| 7 | Laminate Steel | Teal |
| 8 | Ultra High Strength Steel (UHSS) Martensitic, Boron | Red |
| 9 | Transformation Induced Plasticity Steel (TRIP) | Gold |
| 10 | Aluminum | Purple |
Diagram showing a color-coded legend for steel types.
Component Details and Steel Types
Front Structure Components
Diagram showing front structure components. Note: LH (left-hand) side shown, RH (right-hand) side is similar.
| Item | Description | Steel Type |
|---|---|---|
| 1 | Bumper bracket | High-Strength Low Alloy (HSLA) steel |
| 2 | Frame rail and apron assembly | High-Strength Low Alloy (HSLA) steel |
| 3 | Dash panel | Mild steel |
| 4 | Plenum | Mild steel |
| 5 | Fender support | High-Strength Low Alloy (HSLA) steel |
| 6 | Fender apron reinforcement | Mild steel |
| 7 | Fender | Bake Hardened Steel (BH) |
| 8 | Fender apron bracket | High-Strength Low Alloy (HSLA) steel |
Floor and Body Side Components
Diagram showing floor and body side components. Note: LH side shown, RH side is similar.
| Item | Description | Steel Type |
|---|---|---|
| 1 | A-pillar | High-Strength Low Alloy (HSLA) steel |
| 2 | A-pillar inner reinforcement | High-Strength Low Alloy (HSLA) steel |
| 3 | Front floor pan | Mild steel |
| 4 | Floor pan reinforcement | Mild steel |
| 5 | Front floor crossmember (forward) | Dual Phase Steel (DP) 600 steel |
| 6 | Front floor crossmember (rear) | Dual Phase Steel (DP) 600 steel |
| 7 | Rear floor pan | Mild steel |
| 8 | Windshield pillar inner | High-Strength Low Alloy (HSLA) steel |
| 9 | Windshield pillar outer | Boron steel |
| 10 | Rear frame rail | Dual Phase Steel (DP) 500 steel |
Floor and Body Side Components (Continued)
Diagram showing further floor and body side components. Note: LH side shown, RH side is similar.
| Item | Description | Steel Type |
|---|---|---|
| 11 | Rear bumper bracket | Dual Phase Steel (DP) 500 steel |
| 12 | B-pillar inner | High-Strength Low Alloy (HSLA) steel |
| 13 | B-pillar outer | Boron steel |
| 14 | Roof reinforcement | Dual Phase Steel (DP) 780 steel |
| 15 | Liftgate hinge reinforcement | Mild steel |
| 16 | Upper body support to wheel house | High-Strength Low Alloy (HSLA) steel |
| 17 | Inner body side panel | Mild steel |
| 18 | Outer wheel house | Mild steel |
| 19 | Outer body uni-side | Mild steel |
| 20 | Lower body support to wheel house | Dual Phase Steel (DP) 600 steel |
| 21 | Lower body panel reinforcement | Mild steel |
| 22 | Rocker panel reinforcement | High-Strength Low Alloy (HSLA) steel |
| 23 | Floor inner side member | Dual Phase Steel (DP) 600 steel |
| 24 | Floor side member filler | Mild steel |
Rear Components
Diagram showing rear components. Note: LH side shown, RH side is similar.
| Item | Description | Steel Type |
|---|---|---|
| 1 | Rear corner lower panel | Mild steel |
| 2 | Rear corner upper panel | Mild steel |
| 3 | Roof rear header panel | Mild steel |
| 4 | Drain trough panel | Mild steel |
| 5 | Rear opening reinforcement | Mild steel |
| 6 | Rear lower panel reinforcement | Mild steel |
| 7 | Rear lower back panel | Mild steel |
| 8 | Rear bumper anchor plate | High-Strength Low Alloy (HSLA) steel |
Roof Panel(s)
Diagram showing roof panels.
| Item | Description | Steel Type |
|---|---|---|
| 1 | Roof panel without roof opening panel | Mild steel |
| 2 | Roof panel with roof opening panel | Mild steel |
| 3 | Roof panel reinforcement | Dual Phase Steel (DP) 780 steel |
| 4 | Windshield header assembly | High-Strength Low Alloy (HSLA) 350 steel |
| 5 | Roof bow (less moonroof) | Mild steel |
| 6 | Roof bow | Mild steel |
| 7 | Rear header assembly | Mild steel |
Front Door
Diagram showing front door components. Note: LH side shown, RH side is similar.
| Item | Description | Steel Type |
|---|---|---|
| 1 | Front door shell assembly | Mild steel |
| 2 | Front door anti-flutter beam | Mild steel |
| 3 | Front door intrusion beam | Boron steel |
| 4 | Front door outer panel reinforcement | Mild steel |
| 5 | Front door outer panel | Bake Hardened Steel (BH) 250 steel |
Rear Door
Diagram showing rear door components. Note: LH side shown, RH side is similar.
| Item | Description | Steel Type |
|---|---|---|
| 1 | Rear door shell assembly | Mild steel |
| 2 | Rear door anti-flutter beam | Mild steel |
| 3 | Rear door intrusion beam | Boron steel |
| 4 | Rear door outer panel reinforcement | Mild steel |
| 5 | Rear door outer panel | Bake Hardened Steel (BH) 250 steel |
Vehicle Dimensions
Under Body Measurements
Diagram showing underbody measurements. Note: All measurements are on center unless otherwise indicated.
- Overall width at rear axle: 1750 mm
- Overall width at front axle: 1380 mm
- Wheelbase: 2690 mm (calculated from front to rear axle measurements)
- Track width (front): 1615 mm
- Track width (rear): 1380 mm
- Side measurement from front wheel center to rear wheel center (approx): 2690 mm
- Various other measurements indicated on the diagram, including distances between points on the chassis frame. Specific measurements shown: 965 mm, 1418 mm, 1120 mm, 1380 mm, 1615 mm, 1380 mm, 1750 mm, 965 mm.
Under Hood Dimensions
Diagram showing under hood dimensions. Note: All measurements are on center unless otherwise indicated.
- Front crossmember width: 1177 mm
- Width between front suspension mounting points (approx): 1253 mm
- Height of front crossmember (approx): 1175 mm
Front Door Opening Dimensions
Diagram showing front door opening dimensions. Note: All measurements are on center unless otherwise indicated.
- Height at front of opening: 1070 mm
- Height at rear of opening: 1020 mm
- Width at top of opening: 1035 mm
- Width at bottom of opening: 950 mm
Rear Door Opening Dimensions
Diagram showing rear door opening dimensions. Note: All measurements are on center unless otherwise indicated.
- Height at front of opening: 822 mm
- Height at rear of opening: 643 mm
- Width at top of opening: 917 mm
- Width at bottom of opening: 1030 mm
Liftgate Opening Dimensions
Diagram showing liftgate opening dimensions. Note: All measurements are on center unless otherwise indicated.
- Width at top of opening: 1035 mm
- Diagonal measurement (top left to bottom right corner of opening): 1018 mm
- Diagonal measurement (top right to bottom left corner of opening): 1018 mm
- Vertical measurement (top center to bottom center): 1011 mm
- Lower width measurement: 995 mm
- Additional measurements shown: 1011 mm, 1018 mm, 995 mm.
Datum Height Dimensions
Diagram showing datum height dimensions. Note: All other measurements are on center.
- Datum height at front of vehicle (approx): 420 mm
- Datum height at front of rear wheel arch: 180 mm
- Datum height at rear of front wheel arch: 201 mm
- Datum height at rear of vehicle (approx): 425 mm
