GROUP 06: Brake System
SECTION 206-00: Brake System — General Information
SECTION 206-03: Front Disc Brake
SECTION 206-04: Rear Disc Brake
SECTION 206-05: Parking Brake and Actuation
SECTION 206-06: Hydraulic Brake Actuation
SECTION 206-07: Power Brake Actuation
SECTION 206-09A: Anti-Lock Control — Rear
SECTION 206-09B: Anti-Lock Control — 4-Wheel
SECTION 206-00:
Brake System — General Information
SPECIFICATIONS
DESCRIPTION AND OPERATION
Brake System
DIAGNOSIS AND TESTING
Brake System
Inspection and Verification
Non-Pressure Leaks
Road Test
Symptom Chart
Pinpoint Tests
Component Tests
Brake Booster
Check Valve — Vacuum Booster Only
GENERAL PROCEDURES
Bleeding—Components
Bleeding—System
Hydraulic Leak Check
SECTION 206-00: Brake System — General
Information
SPECIFICATIONS
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
General Specifications
Item
Specification
Lining Wear Limit (Above Backing Plate or Rivets) mm (inch)
1.50 (0.06)
Lubricant
High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB ESA-M6C25-A
Front Disc Brake — F-250, F-350 mm (inch)
Rotor Thickness
38 (1.5)
Rotor Minimum Thicknessa
36 (1.417)
Rotor Maximum Runout
SRW 4x2
DRW 4x2
SRW/DRW 4x4
0.05 (0.0020)
0.07 (0.0028)
0.04 (0.0015)
Front Disc Brake — F-450, F-550 mm (inch)
Rotor Thickness
38 (1.5)
Rotor Minimum Thicknessa
36 (1.417)
Rotor Maximum Runout
0.04 (0.0015)
Rear Disc Brake — F-250, F-350 mm (inch)
Rotor Thickness
Rotor Minimum Thickness
30 (1.181)
a
28 (1.102)
Rotor Maximum Runout
0.04 (0.0015)
Rear Disc Brake — F-450, F-550 mm (inch)
Rotor Thickness
Rotor Minimum Thickness
38 (1.5)
a
36 (1.417)
Rotor Maximum Runout
Minimum rotor thickness is molded into the disc brake rotor.
a
Torque Specifications
Description
Caliper Bleeder Screw
Nm Lb/Ft
17-24 13-18
0.04 (0.0015)
Master Cylinder Outlet Tube Fittings
25
19
SECTION 206-00: Brake System — General
Information
DESCRIPTION AND OPERATION
Brake System
Component Locations
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Item
Part
Number
Description
1
2C219
Anti-Lock Brake Module (With 4-Wheel AntiLock Brakes [4WABS] Only)
2
2B373
Anti-Lock Brake Control Module (With Rear
Anti-Lock Brakes [RABS] Only)
3
—
Hydro-Boost and Brake Master Cylinder Assy
4
—
Hydro-Max and Brake Master Cylinder Assy
(Motorhome Only)
5
—
Vacuum Booster and Brake Master Cylinder
Assy (Except Motorhome)
6
—
Rear Disc Brake Assy
7
2209
Drum-in-Hat Parking Brake Assy
8
2C598
Transmission Mounted Parking Brake Assy
(Motorhome Only)
9
2780
Parking Brake Control
10
—
Front Disc Brake Assy, 4x4
11
—
Front Disc Brake Assy, 4x2
Except for the Motorhome chassis, the power brake booster (2005) may be the vacuum or the
Hydro-Boost type. The Motorhome chassis is equipped with either the Hydro-Boost or the
Hydro-Max type. Refer to Section 206-07.
The braking system is a front to rear split hydraulic system; refer to Section 206-06.
The front wheel brakes utilize a dual piston brake caliper and disc brake system; refer to Section
206-03.
The rear brakes utilize a dual piston brake caliper and disc brake system; refer to Section 206-04.
The parking brake system, except for Motorhome, is a mechanical system that activates a shoeand-drum system within the rear disc brake rotor (2C026); refer to Section 206-05.
The Motorhome chassis is equipped with a driveline parking brake; refer to Section 206-05.
The anti-lock brake system may be either rear wheel (RABS) or four wheel (4WABS). Refer to
Section 206-09A for RABS or to Section 206-09B for 4WABS.
SECTION 206-00: Brake System — General
Information
DIAGNOSIS AND TESTING
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Brake System
Refer to Wiring Diagrams Cell 60 (F-53 Motorhome Chassis, F-Super Duty 250-550),
Instrument Cluster for schematic and connector information.
Refer to Wiring Diagrams Cell 97 (F-53 Motorhome Chassis, F-Super Duty 250-550), Daytime
Running Lamps for schematic and connector information.
Special Tool(s)
73 Digital Multimeter
105-R0051 or Equivalent
Inspection and Verification
WARNING: Use of any other than the approved dot 3 brake fluid will cause
permanent damage to brake components and will render the brakes inoperative.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact
with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes
with running water for 15 minutes. Get medical attention if irritation persists. If taken
internally, drink water and induce vomiting. Get medical attention immediately.
CAUTION: Do not spill brake fluid onto painted surfaces. If spilled, wipe up
immediately.
NOTE: Always check the fluid level in the brake master cylinder reservoir (2K478) before
performing the test procedures. If the fluid level is not at the correct level, add High Performance
DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification
ESA-M6C25-A.
NOTE: Prior to performing any diagnosis, make sure the brake warning indicator is functional;
refer to Section 413-01.
The first indication that something may be wrong in the brake system is a change in the feeling
through the brake pedal (2455). The brake warning indicator in the instrument cluster and the
brake fluid level in the brake master cylinder reservoir are also indicators of system concerns.
If a wheel is locked and the vehicle must be moved, open a bleeder screw at the locked wheel
(1007) to let out enough fluid to relieve the pressure. Close the bleeder screw. This bleeding
operation may release the brakes but will not correct the cause of trouble. If this does not relieve
the locked wheel condition, repair the locked components before proceeding.
Inspect all hoses and connections. All unused vacuum connectors should be capped. Make sure
hoses and their connections are properly secured and in good condition with no holes, soft or
collapsed areas.
Non-Pressure Leaks
The only part of the brake system that could have a brake fluid loss that does not appear when
the system is under pressure is the brake master cylinder reservoir area. Brake fluid loss can be
caused by a missing or poorly-fitted brake master cylinder filler cap (2162), a punctured or
otherwise damaged brake master cylinder reservoir, a missing or damaged brake master cylinder
filler cap gasket, or by missing, damaged or poorly-fitted sealing grommets between the brake
master cylinder (2140) and the brake master cylinder reservoir.
The brake master cylinder reservoir grommets are not separately serviceable and must be
replaced as part of a new brake master cylinder reservoir.
NOTE: The wet appearance on the outer cover of rubber brake hoses is called "sweating." This
is a normal condition for neoprene rayon braid hose. The sweating condition is not evidence of a
brake fluid leak and will not result in a loss of pressure in the system.
Replace a flexible brake hose if it shows signs of softening, cracking or other damage.
When installing a new brake hose, position the hose to avoid contact with other vehicle
components.
Road Test
Perform a road test to compare actual vehicle braking performance with the performance
standards expected by the driver. The ability of the test driver to make valid comparisons and
detect performance deficiencies will depend on experience.
The driver should have a thorough knowledge of brake system operation and accepted general
performance guidelines in order to make good comparisons and detect performance problems.
Select a road that is reasonably smooth and level. Gravel or bumpy roads are not suitable
because the surface does not allow the tires to grip the road equally. Avoid crowned roads.
A key factor in evaluating brake concerns is the deceleration rate. This varies from vehicle to
vehicle and with changes in operating conditions. It is evident how well the brakes are working
after just a few applications.
Avoid locking the brakes. Locked brakes are not an indication of braking efficiency.
Visual Inspection Chart
Mechanical
Electrical
Brake master cylinder
Parking brake switch
Brake caliper piston
Damaged or corroded wiring harness
Disc brake rotors
Brake master cylinder fluid level switch
Brake pads
Power brake booster
Brake pedal linkage
Vacuum or hydraulic booster hose
Tires
Debris
For low or spongy brake pedal concerns:
check and, if necessary, refill the brake master cylinder reservoir
bleed the brake system and retest the brake pedal feel.
if the brake pedal is still low or feels spongy, check the brake pedal mounting for looseness
and correct installation. Check the power brake booster and the brake master cylinder for
loose mounting. Correct as necessary and retest the system for normal operation.
For a slow or incomplete brake pedal return concern:
inspect for binding, damage, correct installation or interference at the brake pedal.
check the power brake booster for binding, damage and correct installation.
Symptom Chart
SYMPTOM CHART
Condition
Possible Sources
Brakes Pull or Drift
Tire air pressure.
Action
GO to Pinpoint Test A.
Wheel alignment.
Brake pads.
Brake components.
Suspension
component.
Red Brake Warning
Indicator Always
On
Parking brake not
released.
RELEASE the parking brake.
Low brake fluid
level.
FILL the brake master
cylinder reservoir.
Instrument cluster.
GO to Pinpoint Test B.
Circuit.
Parking brake
switch.
Brake fluid level
switch.
Vibration When
Brakes are Applied
Disc brakes.
GO to Pinpoint Test C.
Brake Pedal Goes
Down Fast
Brake fluid level.
FILL the brake master
cylinder reservoir.
BLEED the system.
REFER to Bleeding—
System in this section.
Air in system.
BLEED the system. REFER
to Bleeding—System in
this section.
Brake master
cylinder.
CARRY OUT the Brake
Master Cylinder
component test in this
section.
The Pedal Eases Down
Slowly
Brakes Lock Up
During Light
Brake Pedal Force
Air in system.
BLEED the system. REFER
to Bleeding—System in
this section.
Brake master
cylinder.
CARRY OUT the Brake
Master Cylinder
component test in this
section.
Disc brake
component.
GO to Pinpoint Test D.
Parking brake
component.
Anti-lock brake
control system.
Excessive/Erratic
Brake Pedal Travel
Leak in hydraulic
system.
GO to Pinpoint Test E.
Air in system.
Disc brake caliper.
Brake booster-tobrake master
cylinder push
rod adjustment.
Brake master
cylinder.
Brakes Drag
Parking brake
component.
REPAIR or REPLACE
components as necessary.
REFER to Section 20605.
Disc brake caliper.
REPAIR or REPLACE as
necessary. REFER to
Section 206-03 and
Section 206-04.
Brake booster-tobrake master
cylinder push
rod adjustment.
ADJUST the push rod.
REFER to Section 20607.
Brake master
cylinder.
CARRY OUT the Brake
Master Cylinder
component test in this
section.
Excessive Brake Pedal
Effort
Power brake
booster.
CARRY OUT the Brake
Booster component test in
this section.
Power brake booster
check valve
(2365).
CARRY OUT the Check
Valve component test in
this section.
Vacuum or
hydraulic
booster hose.
REROUTE, REPAIR or
REPLACE as necessary.
Red Brake Warning
Indicator
Inoperative
Circuit.
REFER to Section 413-01.
Brake Noise
Disc brake
component.
Bulb.
MACHINE or REPLACE as
necessary. REFER to
Section 206-03 or to
Section 206-04.
Pinpoint Tests
PINPOINT TEST A: BRAKES PULL OR DRIFT
CONDITIONS
DETAILS/RESULTS/ACTIONS
A1 CHECK THE TIRE PRESSURE
Check for excessive wear and measure the air
pressure in all four tires.
Are the tires good and the tire pressure
within specifications?
Yes
GO to A2.
No
ADJUST the tire pressure. ROTATE the tires
front to rear. REPLACE excessively worn tires.
TEST the system for normal operation.
A2 CHECK THE CALIPER PISTON AND PINS
Check the disc brake caliper pistons and pins
for binding or sticking.
Do the disc brake caliper pistons or pins
bind or stick?
Yes
REPAIR or REPLACE components as necessary.
TEST the system for normal operation.
No
GO to A3.
A3 INSPECT THE BRAKE PADS
Inspect the brake pads for contamination and
wear concerns.
Are the brake pads OK?
Yes
GO to A4.
No
REPLACE the brake pads; REFER to Section
206-03 (front) or Section 206-04 (rear).
A4 INSPECT THE DISC BRAKE ROTORS AND THE HUBS
Inspect the disc brake hubs and rotors for
excessive runout or damage.
Does excessive runout or damage exist?
Yes
REPAIR or REPLACE the disc brake hub or rotor
as necessary. TEST the system for normal
operation.
No
GO to A5.
A5 CHECK THE ALIGNMENT
Check for correct camber, caster and toe-in
settings; refer to Section 204-00.
Is the alignment set to specification?
Yes
REPLACE the disc brake caliper at the affected
wheel. TEST the system for normal operation.
No
RESET the alignment and road test the vehicle.
PINPOINT TEST B: RED BRAKE WARNING INDICATOR ALWAYS ON
NOTE: Prior to troubleshooting the vehicle for this concern, verify that the rubber bumper on
the parking brake pedal arm contacts the parking brake switch when the pedal is in the fully
released position.
CONDITIONS
DETAILS/RESULTS/ACTIONS
B1 CHECK PARKING BRAKE SWITCH
Parking Brake Switch
Does the red brake warning light go out?
Yes
REPLACE the parking brake switch. TEST the
system for normal operation.
No
GO to B2.
B2 CHECK BRAKE FLUID LEVEL SWITCH
Brake Fluid Level Switch
Does the red brake warning light go out?
Yes
REPLACE the brake master cylinder reservoir.
TEST the system for normal operation.
No
GO to B3.
B3 CHECK INSTRUMENT CLUSTER
Instrument Cluster C250
Does the brake warning light go out?
Yes
GO to B4.
No
REPAIR or REPLACE the instrument cluster.
TEST the system for normal operation.
B4 CHECK FOR GROUNDED CIRCUIT
GEM C239
Measure the resistance to ground at GEM
C239-7, C239-12, C239-21 and C239-24; Circuits
162 (LG/R), 977 (P/W), 512 (T/LG) and 531
(DG/Y).
Is the resistance less than 10,000 ohms at
any pin?
Yes
REPAIR the ground condition on the affected
circuit. TEST for normal operation.
No
REPLACE the GEM. REFER to Section 419-10.
PINPOINT TEST C: VIBRATION WHEN BRAKES ARE APPLIED
CONDITIONS
DETAILS/RESULTS/ACTIONS
C1 ROAD TEST THE VEHICLE
Drive the vehicle so as to duplicate the customer concern.
Apply the brakes at low, medium and high speeds.
Can the vibration be isolated to the front or rear of the vehicle?
Yes
NOTE the location and GO to C2 .
No
GO to C3.
C2 CHECK ROTOR RUNOUT
NOTE: Check the front or rear of the vehicle, as noted in C1.
NOTE: Ford recommends on-vehicle rotor machining. Follow the lathe manufacturer's
instructions.
Check the rotor runout and parallelism at both sides of the vehicle.
Is the rotor runout OK?
Yes
GO to C3.
No
MACHINE both of the disc brake rotors. TEST the system for normal
operation.
C3 CHECK FRONT ROTOR RUNOUT
NOTE: This step is performed if the location of the brake vibration could not be determined
in C1 or C2.
NOTE: Ford recommends on-vehicle rotor machining. Follow the lathe manufacturer's
instructions.
Check the rotor runout and parallelism at the front of the vehicle.
Are the rotor runout and parallelism OK?
Yes
GO to C4.
No
MACHINE both of the front disc brake rotors. INSTALL new brake pads
on both LH and RH sides. TEST the system for normal operation.
C4 CHECK THE REAR ROTORS
NOTE: Ford recommends on-vehicle rotor machining. Follow the lathe manufacturer's
instructions.
Check the rotor runout at the rear of the vehicle.
Is the rotor runout OK?
Yes
Beginning at the front of the vehicle, REPLACE the disc brake calipers.
TEST the system for normal operation.
No
MACHINE both of the rear disc brake rotors. TEST the system for normal
operation.
PINPOINT TEST D: BRAKES LOCK UP DURING LIGHT BRAKE PEDAL FORCE
CONDITIONS
DETAILS/RESULTS/ACTIONS
D1 CHECK FOR BINDING OR STICKING BRAKE COMPONENTS
Check brake components for binding, damage and correct installation at
each wheel.
Do any of the components bind or stick?
Yes
REPAIR or REPLACE components as necessary. TEST the system for
normal operation.
No
GO to D2.
D2 CHECK PARKING BRAKE COMPONENTS
Check parking brake components for damage, seized condition, and
proper adjustment; refer to Section 206-05.
Are the parking brake components OK?
Yes
GO to D3.
No
REPAIR or REPLACE components as necessary. REFER to Section 20605. TEST the system for normal operation.
D3 INSPECT BRAKE PADS
Inspect brake pads for contamination, excessive wear or damage. Refer
to Section 206-03 for front disc brakes. Refer to Section 206-04 for rear
disc brakes.
Are the brake pads OK?
Yes
GO to D4.
No
REPLACE the brake pads as necessary. TEST the system for normal
operation.
D4 CHECK FOR LOOSE BRAKE COMPONENT MOUNTINGS
Check for loose or damaged caliper mounting bolts.
Are the component mountings OK?
Yes
CHECK the anti-lock brake system. REFER to Section 206-09A for RABS
or to Section 206-09B for 4WABS.
No
REPAIR as necessary. TEST the system for normal operation.
PINPOINT TEST E: EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL
CONDITIONS
DETAILS/RESULTS/ACTIONS
E1 CHECK FOR SPONGY PEDAL
Operate the brake pedal and note pedal feel.
Does the pedal feel spongy?
Yes
BLEED the brake system. REFER to Bleeding—System in this section.
TEST the system for normal operation.
No
GO to E2.
E2 CHECK BRAKE PEDAL
Inspect the brake pedal and bracket for binding, obstruction or damage.
Are the brake pedal and the bracket OK?
Yes
GO to E3.
No
REPAIR or REPLACE as necessary. TEST the system for normal
operation.
E3 CHECK BRAKE COMPONENTS
Inspect the disc brake calipers and brake pads for binding, damage,
correct installation and contamination.
Are the disc brake calipers and brake pads OK?
Yes
CHECK the power brake booster, and brake master cylinder for loose
mounting and correct installation. CORRECT as necessary. TEST the
system for normal operation.
No
REPAIR or REPLACE as necessary. TEST the system for normal
operation.
Component Tests
WARNING: Use of other than the approved dot 3 brake fluid will cause permanent
damage to the brake components and will render the brakes inoperative.
NOTE: If a vehicle with a locked wheel must be moved, loosen the bleeder screw to relieve
pressure.
Always check brake fluid level and, if necessary, fill with Ford High Performance DOT 3 Brake
Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A.
Brake Booster
With the transmission (7003) in NEUTRAL and the engine (6007) stopped, apply the brakes
several times to exhaust the vacuum in the vacuum boost system or the pressure in the
Hydro-Boost system.
Hold the brake pedal in the applied position.
Start the engine.
If the power brake system is functioning properly, the brake pedal can be felt to move
downward after the engine starts.
With a vacuum type power brake booster, if engine vacuum is available to the power brake
booster and no power assist is felt, replace the power brake booster and retest the system.
If power steering pump pressure is available to the Hydro-Boost power brake booster and no
power assist is felt, replace the Hydro-Boost power brake booster and retest the system.
If power steering pump pressure is not available at the Hydro-Boost power brake booster, check
the power steering pump pressure and flow; refer to Section 211-00.
On a Hydro-Max booster system, if power is available at the electric pump and no power assist is
felt, replace the Hydro-Max booster assembly and retest the system.
If power is not available at the electric pump, correct the electrical concern and retest the system.
Accumulator, Hydro-Boost Only
Start and run the engine.
Stop the engine.
Apply the brakes. The accumulator in the Hydro-Boost power brake booster should retain
enough pressure for at least two power assisted brake operations. If no power assist is
felt, replace the Hydro-Boost power brake booster and retest the system.
Check Valve — Vacuum Booster Only
The function of the power brake booster check valve is to allow manifold vacuum to enter the
power brake booster and prevent the escape of vacuum in case manifold vacuum is lost during
sustained full throttle operation.
To test the function of the power brake booster check valve :
Start and run the engine for at least 10 seconds.
Operate the brake pedal to check for power assist.
Disconnect the vacuum booster hose (2A047) from the power brake booster. Do not remove
the power brake booster check valve from the power brake booster.
There should be enough vacuum retained in the power brake booster for at least one more
power-assisted brake operation.
Replace the power brake booster check valve if it fails the above test.
Brake Master Cylinder
Disconnect the brake lines at the brake master cylinder.
Plug the outlet ports of the brake master cylinder.
Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has
an internal leak and must be replaced.
Compensator Port Check
The purpose of the compensator ports in the brake master cylinder is to supply any additional
brake fluid required by the system due to brake pad wear and to allow brake fluid returning from
the brake lines to the brake master cylinder to enter the brake master cylinder reservoir.
The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir.
Turbulence seen in the brake master cylinder reservoir upon release of the brake pedal is normal
and shows that the compensating ports are not plugged.
SECTION 206-00: Brake System — General
Information
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Bleeding—Components
Special Tool(s)
New Generation Star (NGS)
Tester
418-F048 (007-00500) or
Equivalent
NGS Flash Cable
418-F120 (007-00531) or
Equivalent
Master Cylinder Priming — In-Vehicle or Bench
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact
with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes
with running water for 15 minutes. Get medical attention if irritation persists. If taken
internally, drink water and induce vomiting. Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the
bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake
fluid. Never reuse the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is
spilled onto a painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or replacement,
air can enter the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been properly connected. The hydraulic system can be bled
manually or with pressure bleeding equipment.
NOTE: When the brake master cylinder has been replaced or the system has been emptied, or
partially emptied, it should be primed to prevent air from entering the system.
For in-vehicle priming, disconnect the brake lines.
For bench priming, mount the brake master cylinder in a vise.
Install short brake tubes with the ends submerged in the brake master cylinder reservoir, and
fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid
C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A.
Have an assistant pump the brake pedal, or slowly depress the primary piston until clear fluid
flows from both brake tubes, without air bubbles.
If the brake master cylinder is being primed at the bench, install it in the vehicle; refer to
Section 206-06.
Remove the short brake tubes, and install the brake outlet tubes.
Bleed each brake tube at the brake master cylinder as follows:
Have an assistant pump the brake pedal, and then hold firm pressure on the brake
pedal.
Loosen the rearmost brake tube fittings until a stream of brake fluid comes out. While
the assistant maintains pressure on the brake pedal, tighten the brake tube fitting.
Repeat this operation until clear, bubble-free fluid comes out.
Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation
at the front brake tube.
Four Wheel Anti-Lock Brake System (4WABS) Hydraulic Control Unit (HCU)
NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS)
hydraulic control unit (HCU) has been replaced or if the HCU lines have been opened.
Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master
cylinder reservoir with the specified brake fluid.
Connect a clear waste line to the RH rear bleeder screw and the other end in a container
partially filled with recommended brake fluid.
With the RH rear bleeder screw open, cycle the brake pedal until no more air is seen in the
waste line.
Tighten the RH rear bleeder screw, and disconnect the waste line.
Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder
screw, and the LH front disc brake caliper bleeder screw, in that order.
Connect the NGS DCL cable adapter into the vehicle data link connector (DLC) under the
dash, and follow the NGS instructions.
Repeat the system bleed procedure as outlined in Steps 1 through 5.
Caliper
NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper
was disconnected.
Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain
tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a
container partially filled with clean brake fluid.
Have an assistant pump the brake pedal (BP) (2B222) and then hold firm pressure on the
brake pedal.
Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While
the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder
screw.
Repeat until clear, bubble-free fluid comes out.
Refill the brake master cylinder reservoir as necessary.
Tighten the disc brake caliper bleeder screw. Refer to Specifications.
SECTION 206-00: Brake System — General
Information
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Bleeding—System
Manual
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact
with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes
with running water for 15 minutes. Get medical attention if irritation persists. If taken
internally, drink water and induce vomiting. Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the
bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake
fluid. Never reuse the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is
spilled onto a painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or replacement,
air may get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been properly connected. The hydraulic system can be bled
manually or with pressure bleeding equipment.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake
master cylinder reservoir with the specified brake fluid.
2. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the
RH rear bleeder screw and submerge the free end of the tube in a container partially filled
with clean brake fluid.
3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw.
• Repeat until clear, bubble-free fluid comes out.
• Refill the brake master cylinder reservoir as necessary.
5. Tighten the RH rear bleeder screw.
6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw.
7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber
drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of
the tube in a container partially filled with clean brake fluid.
8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
9. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes
out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc
brake caliper bleeder screw.
• Repeat until clear, bubble-free fluid comes out.
• Refill the brake master cylinder reservoir as necessary.
10. Tighten the RH front disc brake caliper bleeder screw; refer to Specifications in this
section.
11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw.
Pressure
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake
master cylinder reservoir with the specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various
manufacturers of pressure bleeding equipment. Follow the instructions of the
manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder
tank hose to the fitting on the adapter.
3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified
brake fluid to complete the bleeding operation.
Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the
RH rear bleeder screw, and submerge the free end of the tube in a container partially
filled with clean brake fluid.
4. Open the valve on the bleeder tank.
5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows,
then tighten the RH rear bleeder screw and remove the rubber hose.
6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw
to the RH front disc brake caliper bleeder screw ending with the LH front disc brake
caliper bleeder screw.
7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the
adapter.
SECTION 206-00: Brake System — General
Information
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Hydraulic Leak Check
1. NOTE: Brake fluid is water soluble and it is possible that all evidence of fluid leakage
has been washed off if the vehicle has been operated in the rain or snow.
Make sure the brake master cylinder reservoir is full.
2. Apply the brakes several times and make sure the pedal feel is not spongy. If necessary,
bleed the system; refer to Bleeding—System in this section.
3. Verify that the reservoir level is dropping.
4. If the reservoir level is dropping, inspect the brake components, fittings and lines to
locate the source of the leak.
SECTION 206-03:
Front Disc Brake
SPECIFICATIONS
DESCRIPTION AND OPERATION
Front Disc Brake
DIAGNOSIS AND TESTING
Front Disc Brake
REMOVAL AND INSTALLATION
Pads
Caliper
Brake Caliper Anchor Plate
Disc—F-250, F-350 4x4 and F-450, F-550
Disc—F-250, F-350 4x2
Disc—Motorhome Chassis
Shield—F-250, F-350 4x2
DISASSEMBLY AND ASSEMBLY
Caliper
SECTION 206-03: Front Disc Brake
SPECIFICATIONS
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 08/13/2003
General Specifications
Item
Specification
Brake Pads
Brake pad minimum thickness
3.0 mm (0.118
inch)
Brake pad maximum thickness variation (pad-to-pad)
2.0 mm (0.079)
Brake pad maximum taper wear (in any direction)
3.0 mm (0.118
inch)
Brake Disc
Front brake disc minimum thickness
36.0 mm (1.41
inch)
Minimum thickness to machine front brake disc
36.6 mm (1.44
inch)
Lubricants
High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 (Canada CPM1)
ESA-M6C25-A
Premium Long-Life Grease XG-1-C
ESA-M1C75-B
Brake Parts Cleaner PM-4
—
Torque Specifications
Description
Nm lb-ft lb-in
Disc Brake Caliper Pin Bolts
56
42
—
Front Brake Hose Bolt
35
26
—
Front Disc Brake Caliper Anchor Plate Bolt (F250, F350)
225 166
—
Front Disc Brake Caliper Anchor Plate Bolt (F450, F550, Motorhome Chassis) 400 295
—
Front Wheel Hub Extender Nuts
176 130
—
Front Disc Brake Rotor Shield Screws
11
—
98
Spindle Nut
—
Refer to Disc — F250, F350 4x2 or Disc — Motorhome Chassis in this section.
—
—
a
a
SECTION 206-03: Front Disc Brake
DESCRIPTION AND OPERATION
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
Front Disc Brake
Front Disc Brake Components — F-250, F-350 4x2
Item Part Number
Description
1
385116-S2
Flow Bolt
2
388949-S
Brass Washer
3
2078
Front Brake Hose
4
—
Bleeder Screw and Bleeder Screw Cap Assy
5
2N386
Caliper Bolt
6
2B296
Guide Pin
7
2A492
Guide Pin Boot
8
2001
Pads
9
2L200
Stainless Steel Slippers
10
2B120
Disc Brake Caliper
11
2B164
Anti-Rattle Spring
12
1102
Front Disc Brake Hub and Rotor
13
2B292
Front Disc Brake Caliper Anchor Plate
Front Disc Brake Components — F-250, F-350 4x4 and F-450, F-550, Motorhome
Chassis
Item Part Number
Description
1
2B292
Front Disc Brake Caliper Anchor Plate
2
2L200
Stainless Steel Slippers
3
2001
Pads
4
2B120
Disc Brake Caliper
5
2A492
Guide Pin Boot
6
2B296
Guide Pin
7
2N386
Caliper Bolt
8
—
Bleeder Screw and Bleeder Screw Cap Assy
9
2078
Front Brake Hose
10
388949-S
Brass Washer
11
385116-S2
Flow Bolt
12
1125
Front Disc Brake Rotor
The front disc brake caliper (2B120):
•
bolts to the front disc brake caliper anchor plate (2B292), which bolts to the front front
wheel spindle (3105)
•
•
is a dual piston, pin slider design
has a fluid inlet at the center of the caliper housing
The front disc brake rotors (1125):
•
•
•
•
are of a ventilated full-cast design, with non-directional cooling fins
are mounted to the wheel hub (1104) (F250, F-350 4x4 and F-450, F-550 vehicles)
are mounted to the front wheel spindle (F-250, F-350 4x2, and motorhome chassis
vehicles)
are serviced with the disc brake caliper and front disc brake caliper anchor plate removed
The front disc brake rotor shield (2K005):
•
•
•
is mounted between the wheel hub and the front wheel knuckle (F-250, F-350 4x4 and F450, F-550 vehicles)
is bolted to the front wheel spindle (F-250, F-350 4x2 vehicles)
protects the front wheel bearings and inboard surface of the front disc brake rotor
The pads:
•
•
are housed in the front disc brake caliper anchor plate
are of a non-asbestos, semi-metallic composition
SECTION 206-03: Front Disc Brake
DIAGNOSIS AND TESTING
Front Disc Brake
Refer to Section 206-00.
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
SECTION 206-03: Front Disc Brake
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
Pads
WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is
hazardous to health if inhaled.
WARNING: Brake and clutch assemblies should be cleaned using a vacuum cleaner
recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag
must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's
contents.
WARNING: If a vacuum suitable for asbestos is not available, cleaning should be
done wet. If dust generation is still possible, technicians should wear government-approved
toxic dust purifying respirators.
WARNING: Occupational health and safety act (OSHA) requires areas where
asbestos dust generation is possible to be isolated and posted with warning signs. Only
technicians performing brake or clutch repair should be present in the area.
Remove the brake master cylinder filler cap (2162). Check brake fluid level in brake master
cylinder reservoir (2K478). Remove fluid until brake master cylinder reservoir is half
full.
Raise and support the vehicle; refer to Section 100-02.
Remove the wheel and tire assembly; refer to Section 204-04.
CAUTION: Replace the pad if worn to or past the specified thickness above the
metal backing plate or rivets. Replace the pads in complete axle sets.
Inspect the pads for wear and contamination.
CAUTION: When removing the disc brake caliper (2B120), never allow it to hang
from the brake hose. Provide a suitable support.
Remove the disc brake caliper.
Remove two front disc brake caliper pin bolts.
Lift the disc brake caliper from the front disc brake caliper anchor plate (2B292).
Measure the front disc brake rotor thickness.
Replace the front disc brake rotor (1125) if not within specification.
Inspect the disc brake caliper for leaks.
If leaks are found, disassembly is required. Refer to Caliper in the Disassembly and
Assembly portion of this section.
Remove the pads and rail clips.
Remove the pads.
Remove the front disc brake caliper anchor plate stainless steel rail clips.
Installation
CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact
the pad lining material. Do not install contaminated pads.
Install the pads.
Install the front disc brake caliper anchor plate stainless steel rail clips.
Install the pads.
Compress the caliper pistons (2196).
CAUTION: Use care not to damage the bleeder screw or front disc brake rotor
shield (2K005).
Install the disc brake caliper.
Install the disc brake caliper.
Install the disc brake caliper pin bolts.
Install the wheel and tire assembly; refer to Section 204-04.
Lower the vehicle.
Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid
C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A.
Install the brake master cylinder filler cap.
Inspect brake operation.
SECTION 206-03: Front Disc Brake
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
Caliper
Material
Item
High Performance DOT 3
Motor Vehicle Brake Fluid
PM-1 (Canada CPM-1)
Specification
ESA-M6C25A
Removal
WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is
hazardous to health if inhaled.
WARNING: Brake and clutch assemblies should be cleaned using a vacuum cleaner
recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag
must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's
contents.
WARNING: If a vacuum suitable for asbestos is not available, cleaning should be
done wet. If dust generation is still possible, technicians should wear government-approved
toxic dust purifying respirators.
WARNING: Occupational health and safety act (OSHA) requires areas where
asbestos dust generation is possible to be isolated and posted with warning signs. Only
technicians performing brake or clutch repair should be present in the area.
Raise and support the vehicle. For additional information, refer to Section 100-02.
Remove the wheel and tire assembly. For additional information, refer to Section 204-04.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact
with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush
eyes with running water for 15 minutes. Get medical attention if irritation persists.
If taken internally, drink water and induce vomiting. Get medical attention
immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake
fluid is spilled onto a painted or plastic surface, wash it with water immediately.
Disconnect the brake hose.
Remove the brake hose bolt.
Disconnect the brake hose.
Remove and discard the copper washers. Plug the brake hose.
Remove the disc brake caliper.
Remove the disc brake caliper pin bolts.
Lift the disc brake caliper from the disc brake caliper anchor plate.
Inspect the disc brake caliper for leaks.
If leaks are found, disassembly is required. For additional information, refer to
Caliper in this section.
Installation
Install the disc brake caliper.
Install the disc brake caliper.
Install the disc brake caliper pin bolts.
Install the brake hose.
Use new copper washers. Connect the brake hose.
Install the brake hose bolt.
Bleed the brake system. For additional information, refer to Section 206-00.
Install the wheel and tire assembly. For additional information, refer to Section 204-04.
Fill the brake master cylinder reservoir with clean DOT 3 motor vehicle brake fluid. Install
the brake master cylinder filler cap.
Inspect the brake system operation.
SECTION 206-03: Front Disc Brake
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
Brake Caliper Anchor Plate
Removal
Remove the pads; refer to Pads in this section.
Remove the front disc brake caliper anchor plate (2B292).
Remove the two front disc brake caliper anchor plate bolts.
Remove the front disc brake caliper anchor plate.
Installation
Follow the removal procedure in reverse order.
SECTION 206-03: Front Disc Brake
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 03/20/2003
Disc—F-250, F-350 4x4 and F-450, F-550
Removal
CAUTION: When installing a new disc brake rotoe, measure the hub flange to verify
correct part installation. Early build vehicles have a 10 mm thick flange; late build vehicles
have a 13 mm thick flange. The disc brake rotors are not interchangeable between early
and late build vehicles. If an incorrect part is installed during the repair, symptoms such as
brake drag, extensive lining wear. brake shudder and the associated brake noise may
occur.
Remove the front disc brake caliper anchor plate (2B292); refer to Brake Caliper Anchor
Plate in this section.
NOTE: Perform this step for F-250 and F-350 4x4 SRW vehicles.
Remove the rotor.
NOTE: Perform this step for DRW vehicles.
NOTE: If excessive force must be used during brake rotor removal, the brake rotors
should be checked for lateral runout prior to installation; refer to Section 206-00.
Remove the eight hub extender nuts, the hub plate and the rotor.
Remove the eight hub plate nuts.
Remove the hub plate.
Remove the rotor.
Installation
Position the front disc brake rotor (1125) to the wheel hub (1104). Make sure the wheel hub
and the front disc brake rotor braking and mounting surfaces are clean.
Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent to clean the front disc
brake rotor.
NOTE: Perform this step for DRW vehicles only.
Install the front wheel hub extender and nuts.
Install the front disc brake caliper anchor plate; refer to Brake Caliper Anchor Plate in this
section.
If a new disc brake rotor was installed, rotate the wheel by hand to check te drag force of the
front brakes. The wheel should turn easily. If it does not, the wrong disc brake rotor may
have been installed. Remove the wheel and check for correct parts information.
SECTION 206-03: Front Disc Brake
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
Disc—F-250, F-350 4x2
Material
Item
Premium Long-Life Grease
XG-1-C
Specification
ESA-M1C175-B
Brake Parts Cleaner
PM-4
—
Removal
Remove the disc brake caliper anchor plate. For additional information, refer to Brake
Caliper Anchor Plate in this section.
Remove the disc brake rotor as follows:
Remove the hub grease cap.
Remove the cotter pin.
Remove the nut retainer.
Remove the spindle nut.
Remove the outer wheel bearing retainer washer.
Remove the outer wheel bearing.
Remove the disc brake hub and rotor.
If necessary, resurface the disc brake hub and rotor. Ford recommends on-vehicle rotor
machining.
Remove the wheel hub grease seal.
Remove the inner wheel bearing.
Installation
Thoroughly clean and inspect the front wheel bearings and the disc brake hub and rotor.
Use brake parts cleaner to clean the front disc brake rotor.
Lubricate the wheel bearings.
Use long-life grease to lubricate the wheel bearings.
Install a new wheel hub grease seal.
Install the inner wheel bearing.
Install a new wheel hub grease seal.
Install the disc brake hub and rotor.
Position the disc brake hub and rotor.
Install the outer wheel bearing.
Install the wheel outer bearing retainer washer.
Install the spindle nut.
While rotating the disc brake hub and rotor, tighten the spindle nut.
Loosen the spindle nut two turns.
Tighten the spindle nut while rotating the disc brake hub and rotor.
Loosen the spindle nut.
Tighten the spindle nut while rotating the disc brake hub and rotor.
Install the following components:
Install the nut retainer.
Install the cotter pin.
Install the hub grease cap.
Install the disc brake caliper anchor plate. For additional information, refer to Brake Caliper
Anchor Plate in this section.
SECTION 206-03: Front Disc Brake
REMOVAL AND INSTALLATION
Disc—Motorhome Chassis
Material
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 08/13/2003
Item
Premium Long Life Grease
XG-1-C
Specification
ESA-M1C75-B
Brake Parts Cleaner
PM-4
—
Removal
Remove the disc brake caliper anchor plate. For additional information, refer to Brake
Caliper Anchor Plate in this section.
Remove the disc brake hub and rotor as follows:
Remove the hub grease cap screws.
Remove the hub grease cap.
Remove the cotter pin.
Remove the spindle nut.
Remove the outer wheel bearing retainer washer.
Remove the outer wheel bearing.
Remove the hub grease cap gasket.
Remove the disc brake hub and rotor.
If necessary, resurface the disc brake hub and rotor. Ford recommends on-vehicle rotor
machining. Follow the lathe manufacturer's instructions.
Remove the wheel hub grease seal.
Remove the inner wheel bearing.
Installation
Thoroughly clean and inspect the wheel bearings and the disc brake hub and rotor.
Use brake parts cleaner to clean the disc brake hub and rotor.
Lubricate the wheel bearings.
Use long-life grease to lubricate the bearings.
Install a new wheel hub grease seal.
Install the inner wheel bearing.
Install a new wheel hub grease seal.
Install the disc brake hub and rotor.
Position the disc brake hub and rotor.
Install the outer wheel bearing.
Install the outer wheel bearing retainer washer.
Install the spindle nut.
While rotating the disc brake hub and rotor, tighten the spindle nut.
Loosen the spindle nut two turns.
Tighten the spindle nut while rotating the disc brake hub and rotor.
Loosen the spindle nut.
Tighten the spindle nut while rotating the disc brake hub and rotor.
Install the following components:
Install the cotter pin.
Install the hub grease cap gasket.
Install the hub grease cap.
Install the hub grease cap screws.
Install the disc brake caliper anchor plate; refer to Brake Caliper Anchor Plate in this section.
SECTION 206-03: Front Disc Brake
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
Shield—F-250, F-350 4x2
Removal
Remove the front disc brake rotor (1125); refer to Disc—F-250, F-350 4x4 and F-450, F-550,
Disc—F-250, F-350 4x2, Disc—Motorhome Chassis in this section.
Remove the front disc brake rotor shield (2K005).
Remove the front disc brake rotor shield screws, and remove the front disc brake
rotor shield.
Installation
Follow the removal procedure in reverse order.
SECTION 206-03: Front Disc Brake
DISASSEMBLY AND ASSEMBLY
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
Caliper
Material
Item
High Performance DOT 3
Motor Vehicle Brake Fluid
PM-1 (Canada CPM-1)
Specification
ESA-M6C25A
Disassembly
Remove the disc brake caliper. For additional information, refer to Caliper in this section.
Drain the remaining brake fluid from the disc brake caliper.
Apply low air pressure to the fluid port in the disc brake caliper.
Place a block of wood between the caliper bridge and the caliper pistons.
Apply low air pressure to the fluid port in the disc brake calipers and force out the
caliper pistons to the block of wood.
Remove the block of wood and the caliper pistons.
Remove the piston seals and boots.
Remove the piston boot retainer.
Remove and discard the piston boots and seals.
NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores.
If the caliper bores are excessively scored or corroded, replace the disc brake caliper.
Assembly
CAUTION: Never reuse piston seals and dust boots.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
Lubricate the piston boot, caliper piston, piston seal and caliper bores with clean DOT 3
motor vehicle brake fluid.
Install the caliper pistons.
Install the piston seal.
Install the piston boot on the piston.
CAUTION: Be careful not to damage or dislodge the piston seal.
Insert the caliper piston.
CAUTION: Be careful not to cock the caliper piston.
Position the boot in the bore, and press the caliper piston into the bore.
Install the piston boot retainer.
Install the disc brake caliper. For additional information, refer to Caliper in this section.
SECTION 206-04:
Rear Disc Brake
SPECIFICATIONS
DESCRIPTION AND OPERATION
Rear Disc Brake
DIAGNOSIS AND TESTING
Rear Disc Brake
REMOVAL AND INSTALLATION
Caliper
Pads
Disc
Brake Caliper Anchor Plate
Adapter
Shield
DISASSEMBLY AND ASSEMBLY
Caliper
SECTION 206-04: Rear Disc Brake
SPECIFICATIONS
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
General Specifications
Item
Lining Wear Limit (Above Backing Plate or Rivets) mm (Inch)
Specification
1.0 (0.039)
Rear Disc Brake — F-250, F-350 mm (Inch)
Rotor Thickness
Rotor Minimum Thickness
30.0 (1.181)
a
28.0 (1.102)
Rotor Maximum Runout
0.04 (0.0015)
Rear Disc Brake — F-450, F-550, Motorhome mm (Inch)
Rotor Thickness
Rotor Minimum Thickness
38 (1.5)
a
36 (1.417)
Rotor Maximum Runout
0.04 (0.0015)
Lubricants
High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB ESA-M6C25-A
Minimum rotor thickness is molded into the disc brake rotor.
a
Torque Specifications
Description
LbNm Ft
Disc brake caliper pin bolts — F-250/F-350 with Ford and Dana axle
36
27
Disc brake caliper pin bolts — F-450/F-550/Motorhome with Dana axle
55
41
Caliper banjo bolt
50
37
Bleeder screw — F-250/F-350 with Ford axle
11
8
Bleeder screw — F-350 with Dana axle
11
8
Bleeder screw — F-450/F-550/Motorhome with Dana axle
15
12
Rear wheel disc brake adapter bolts — F-250/F-350 with Ford axle
203 150
Rear wheel disc brake adapter bolts — F-350/F-450/F-550/Motorhome with Dana
axle
135 100
Rotor shield bolts — F-250/F-350 with Ford axle
11
8
Rotor shield bolts — F-350/F-450/F-550/Motorhome with Dana axle
15
12
Rotor-to-hub bolts
127
94
Disc brake caliper anchor bolts
Stone shield nuts
Refer to the procedure in this section.
a
—
62
46
a
SECTION 206-04: Rear Disc Brake
DESCRIPTION AND OPERATION
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
Rear Disc Brake
Item
Part
Number
Description
1
2552
Rear Disc Brake Caliper
2
—
Rear Disc Brake Rotor and Hub Assy
3
2B582
Rear Disc Brake Caliper Anchor Plate
4
2018
Brake Pads
5
2209
Rear Wheel Disc Brake Adapter
6
2C028
Rear Wheel Disc Brake Shield (Except
Motorhome)
The rear disc brake has the following characteristics:
•
•
•
•
•
A two-piston rear disc brake caliper (2552)
A vented-cast, drum in hat-type rear disc brake rotor (2C026)
A rear disc brake caliper anchor holds the brake pads
A rear wheel disc brake adapter holds the rear disc brake caliper anchor and the rear
wheel disc brake shield (2C028)
A rear wheel disc brake shield protects the rear disc brake rotor from road debris
SECTION 206-04: Rear Disc Brake
DIAGNOSIS AND TESTING
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
Rear Disc Brake
Refer to Section 206-00.
SECTION 206-04: Rear Disc Brake
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
Caliper
Removal and Installation
WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is
hazardous to health if inhaled.
Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for
use with asbestos fibers such as brake/clutch/service vacuum. The bag must be labeled per
OSHA instructions, sealed, and the trash hauler notified as to the bag's contents.
If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust
generation is still possible, technicians should wear government-approved toxic dust
purifying respirators.
Occupational safety and health act (OSHA) requires areas where asbestos dust generation
is possible to be isolated and posted with warning signs. Only technicians performing brake
or clutch repair should be present in the area.
WARNING: Brake fluid contains polyglycolethers and polyglycols. Avoid contact
with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes
with running water for 15 minutes. Get medical attention if irritation persists. If taken
internally, drink water and induce vomiting. Get medical attention immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is
spilled onto a painted or plastic surface, immediately wash it with water.
All vehicles
1. Raise and support the vehicle. For additional information, refer to Section 100-02.
2. Remove the wheel and tire assembly. For additional information, refer to Section 204-04.
Forward-of-axle brake calipers
3. Remove the nuts and the stone shield.
All vehicles
4. Remove the caliper pin bolts.
5. Remove the banjo bolt. Remove and discard the copper washers.
• Prior to installing the banjo bolt, install new copper washers.
6. Remove the rear disc brake caliper (2552).
7. To install, reverse the removal procedure.
8. Bleed the brake system. For additional information, refer to Section 206-00.
SECTION 206-04: Rear Disc Brake
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
Pads
Removal and Installation
All vehicles
Remove the brake master cylinder filler cap. Check brake fluid level in brake master cylinder
reservoir. Remove fluid until brake master cylinder reservoir is half full.
Remove the wheel and tire assembly. For additional information, refer to Section 204-04.
Inspect the brake pads for wear or contamination. If worn, damaged, or past specification,
install new brake pad.
Forward-of-axle brake calipers
Remove the nuts and the stone shield.
All vehicles
Remove the caliper pin bolts.
CAUTION: Never allow the rear disc brake caliper (2552) to hang from the brake
hose. Provide suitable support.
Remove the rear disc brake caliper.
Remove the brake pads and rail clips.
Measure the rear brake disc thickness.
Install a new rear brake disc if not within specification.
Inspect the disc brake caliper for leaks.
If leaks are found, disassembly is required. For additional information, refer to
Caliper in the Disassembly and Assembly portion of this section.
To install, reverse the removal procedure.
SECTION 206-04: Rear Disc Brake
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 03/31/2003
Disc
Removal and Installation
All except Ford single rear wheel axle
NOTE: The brake disc is part of the wheel hub on all axles except the Ford 10.50-inch axle
for single rear wheel applications. Removal of the hub on a Dana axle is covered in
Section 205-02B. The hub on a Ford axle for dual rear wheel applications is covered in
Section 205-02D.
Remove the hub.
Remove the rotor-to-hub bolts and separate the hub and rear disc brake rotor.
Ford single rear wheel axle
Remove and support the caliper and anchor plate assembly.
Remove the anchor plate bolts.
All vehicles
Remove the disc.
To install, reverse the removal procedure.
SECTION 206-04: Rear Disc Brake
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
Brake Caliper Anchor Plate
Removal
Remove the brake pads. For additional information, refer to Pads in this section.
NOTE: Forward-of-axle rear disc brake caliper anchor (2B582) plates are mounted using
stud bolts.
Remove the bolts and the rear disc brake caliper anchor plate.
Installation
F-250/350
Position the rear disc brake caliper anchor plate. Install the bolts.
F-450/550, Motorhome, with rear-of-axle brake calipers
Position the rear disc brake caliper anchor plate. Install the bolts.
F-450/550, Motorhome, with forward-of-axle brake calipers
Position the rear disc brake caliper anchor plate. Install the bolts.
Tighten the bolts in the sequence shown in three stages.
Stage 1: Tighten bolt 1 to 400 Nm (295 lb-ft).
Stage 2: Using a suitable crowfoot socket, tighten bolt 2 to 136 Nm (100 lb-ft).
Stage 3: Mark the rear disc brake caliper anchor plate and bolt 2. Tighten bolt 2 an
additional 1/8 to 1/4 turn.
All vehicles
Install the brake pads. For additional information, refer to Caliper in this section.
SECTION 206-04: Rear Disc Brake
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
Adapter
Removal
Remove the rear disc brake caliper anchor plate (2B582); refer to Brake Caliper Anchor Plate
in this section.
Remove the hub and rotor; refer to Section 205-02A.
Remove the rear brake shoes and linings (2200); refer to Section 206-05.
Remove the adapter nuts.
Slide the adapter far enough to disconnect the parking brake rear cable and conduit (2A635).
Remove the rear wheel disc brake adapter and rotor shield assembly.
Remove the bolts and the rear wheel disc brake shield (2C028).
Installation
Follow the removal procedure in reverse order.
For Ford axle, F-250 and F-350, tighten to specification.
For Dana axle, F-350, F-450, F-550 and Motorhome, tighten to specification.
SECTION 206-04: Rear Disc Brake
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
Shield
Removal and Installation
For additional information, refer to Adapter in this section.
SECTION 206-04: Rear Disc Brake
DISASSEMBLY AND ASSEMBLY
1999 F-Super Duty 250-550 Workshop Manual
Procedure revision date: 01/26/2000
Caliper
Disassembly
Remove the rear disc brake caliper. For additional information, refer to Caliper in this
section.
Drain remaining brake fluid from the rear disc brake caliper.
Secure the rear disc brake caliper.
Remove the caliper pistons.
Place a block of wood between the caliper bridge and the caliper pistons.
Apply low air pressure to the fluid port in the rear disc brake caliper.
Force out the caliper pistons to the block of wood.
Remove the block of wood and the caliper pistons.
Remove and discard the piston seals and boots.
NOTE: Do not hone the cylinder bores. Pistons are not available for honed cylinder bores.
If the rear disc brake caliper is leaking, install new piston seals. If the cylinder bores are
excessively scored or corroded, install a new rear disc brake caliper.
Item
Part Number
Description
1
2207
Dust boot
2
2B115
Piston seal
3
2552
Rear disc brake caliper
4
2208
Bleeder screw
5
2196
Caliper piston
Assembly
CAUTION: Never reuse piston seals and dust boots.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
Lubricate the following with High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A:
dust boots.
caliper pistons.
piston seals.
cylinder bores.
Install the caliper pistons.
Install the piston seals.
Install the dust boots.
CAUTION: Be careful not to damage or dislodge the piston seal.
Insert the caliper pistons.
Press the caliper pistons into the cylinder bore being careful not to cock the caliper
pistons.
Install the rear disc brake caliper. For additional information, refer to Caliper in this section.
SECTION 206-05:
Parking Brake and Actuation
SPECIFICATIONS
DESCRIPTION AND OPERATION
Parking Brake
All Vehicles Except Motorhome Chassis
Motorhome Chassis
Brake Warning System
DIAGNOSIS AND TESTING
Parking Brake
Inspection and Verification
Symptom Chart
Pinpoint Tests
GENERAL PROCEDURES
Parking Brake Shoe and Lining Adjustment
Cable Adjustment—Motorhome Chassis
Parking Brake Cable Tension Release—Except Motorhome Chassis
Parking Brake Cable Tension Release—Motorhome Chassis
REMOVAL AND INSTALLATION
Control—Except Motorhome Chassis
Control—Motorhome Chassis
Shoes—Rear Wheel
Bulb—Brake System Warning Indicator
Parking Brake, Transmission Mounted
SECTION 206-05: Parking Brake and
Actuation
SPECIFICATIONS
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
General Specifications
Item
Specification
Parking Brake Drum Maximum Inside Diameter
F-250, F-350
206.25 mm (8.12 In.)
F-450, F-550
242.25 mm (9.54 In.)
Lubricants
Penetrating and Lock Lubricant E8AZ-19A501-B
—
Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or XT-2-DDX
Torque Specifications
Description
Parking Brake Control Retaining Nuts
Parking Brake Release Handle Nuts
Nm
lb-ft
25
19
8-11
6-8
Parking Brake Rear Cable and Conduit Retaining Bolts 37-50 28-37
Parking Brake, Transmission Mounted Retaining Bolts
Parking Brake, Transmission Mounted Filler Plug
55
41
35-40 26-30
MERCON®
SECTION 206-05: Parking Brake and
Actuation
DESCRIPTION AND OPERATION
Parking Brake
All Vehicles Except Motorhome Chassis
Parking Brake System Actuation Components
Item
Part
Number
Description
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
1
2780
Parking Brake Control
2
2783
Parking Brake Release Handle
3
2853
Front Parking Brake Cable and Conduit
4
2A635
Parking Brake Rear Cable and Conduit — LH
(F-Super Duty 250-550)
5
2A635
Parking Brake Rear Cable and Conduit — RH
(F-Super Duty 250-550)
6
2A793
Parking Brake Intermediate Cable (F-Super
Duty 250-550)
7
2A635
Parking Brake Rear Cable and Conduit — LH
(Excursion)
8
2A635
Parking Brake Rear Cable and Conduit — RH
(Excursion)
9
2A793
Parking Brake Intermediate Cable (Excursion)
The parking brake system is cable-actuated and controlled by an independent foot-operated
parking brake control (2780).
The parking brake system is actuated when the parking brake control is depressed. The parking
brake control applies tension to the front parking brake cable and conduit (2853), the parking
brake intermediate cable (2A793), and the parking brake cable equalizer (part of 2A793). The
parking brake cable equalizer is coupled to the RH parking brake rear cable and conduit
(2A635), and the LH parking brake rear cable and conduit(2A809). The respective rear parking
brake assemblies are then applied.
Parking Brake Rear Wheel Components
Item Part Number
Description
1
—
Brake shoe retracting spring — outboard
(part of parking brake spring kit (2069))
2
2A637
Parking brake lever
3
2N712
Parking brake shoe and linings
4
—
Brake shoe hold-down spring
(part of parking brake spring kit (2069))
5
2041
Brake adjuster screw
6
—
Brake shoe adjusting screw spring
(part of parking brake spring kit (2069))
7
—
Brake shoe retracting spring — inboard
(part of parking brake spring kit (2069))
The rear wheel disc brake assembly contains a cable-actuated parking brake assembly.
Motorhome Chassis
Parking Brake Components
Item Part Number
Description
1
2780
Parking brake control
2
2598
Parking brake assy (transmission mounted)
3
2853
Front parking brake cable and conduit
4
2A709
Parking brake cable retainer
5
6A023
Transmission support crossmember
6
2A651
Parking brake lever return spring
7
7A039
Extension housing
The parking brake system is actuated when the parking brake control is depressed. The parking
brake control applies tension to the front parking brake cable and conduit, activating the parking
brake assembly.
Brake Warning System
The brake warning indicator:
is located in the instrument cluster.
illuminates to signal the driver that the parking brake is applied or to signal a low brake fluid
condition.
remains lit to indicate a brake system concern has occurred.
SECTION 206-05: Parking Brake and
Actuation
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Parking Brake Shoe and Lining Adjustment
Raise and support the vehicle. For additional information, refer to Section 100-02.
Remove the wheel and tire assembly. For additional information, refer to Section 204-04.
Remove the brake adjusting hole cover from the backing plate.
Turn the brake adjuster screw (2041) to expand the parking brake shoe and linings until they
drag against the drum-in-hat rotor.
Back off the brake adjuster screw until no drag is evident.
SECTION 206-05: Parking Brake and
Actuation
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Cable Adjustment—Motorhome Chassis
Raise and support the vehicle.
Disconnect the adjusting clevis.
Remove the clevis pin locking pin.
Remove the clevis pin, and disconnect the adjusting clevis from the parking brake
lever.
Set the adjusting clevis.
Loosen the jam nut several turns.
Position the parking brake lever in the applied position.
Tighten or loosen the adjusting clevis until the adjusting clevis hole lines up with the
parking brake lever hole, and then loosen the adjusting clevis 13 mm (0.5 inch).
Install the pins, and tighten the jam nut.
Install the clevis pin through the adjusting clevis and the parking brake lever.
Install the locking pin in the clevis pin.
Tighten the jam nut.
Lower the vehicle.
Test the parking brake operation.
SECTION 206-05: Parking Brake and
Actuation
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Parking Brake Cable Tension Release—Except Motorhome Chassis
NOTE: Make sure the parking brake control is fully released.
Relieve the tension on the parking brake system.
Pull the front parking brake cable and conduit.
Insert a suitable retainer in the parking brake control.
SECTION 206-05: Parking Brake and
Actuation
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Parking Brake Cable Tension Release—Motorhome Chassis
NOTE: Make sure the parking brake control is fully released.
Disconnect the front parking brake cable and conduit from the parking brake lever.
Disconnect the parking brake lever return spring from the clevis pin.
Remove the locking pin from the clevis pin, and remove the clevis pin.
SECTION 206-05: Parking Brake and
Actuation
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Control—Except Motorhome Chassis
Removal
Disconnect the battery ground cable (14301); refer to Section 414-01.
Remove the powertrain control module (PCM) (12A650); refer to Section 303-14A for
gasoline engines or Section 303-14B for diesel engines.
Disconnect the electrical connector from the parking brake switch.
Relieve the tension on the parking brake system.
Pull the front parking brake cable and conduit (2853).
Insert a suitable retainer in the parking brake control (2780).
Disconnect the parking brake release handle cable from the parking brake control.
Unclip and remove the scuff panel.
Remove the cowl trim panel.
Remove the pushpin.
Remove the cowl trim panel.
Remove the parking brake control retaining nuts.
Lower the parking brake control.
Disconnect the hood release cable from the parking brake control.
Disconnect the front parking brake cable and conduit from the parking brake control.
Remove the parking brake control.
Installation
Follow the removal procedure in reverse order.
SECTION 206-05: Parking Brake and
Actuation
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Control—Motorhome Chassis
Removal
Disconnect the battery ground cable (14301); refer to Section 414-01.
Disconnect the front parking brake cable and conduit (2853) from the parking brake lever.
Disconnect the parking brake lever return spring from the clevis pin.
Remove the locking pin from the clevis pin, and remove the clevis pin.
Remove the parking brake control retaining nuts.
Lower the parking brake control (2780).
Disconnect the front parking brake cable and conduit from the parking brake control.
Installation
Follow the removal procedure in reverse order.
SECTION 206-05: Parking Brake and
Actuation
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Shoes—Rear Wheel
Special Tool(s)
Brake Adjusting Gauge
206-D002 (D81L-1103-A) or
Equivalent
Removal
WARNING: Asbestos fiber dust can be present on brake and clutch assemblies and is
hazardous if inhaled. Brake and clutch assemblies must be cleaned using a vacuum cleaner
recommended for use with asbestos fibers such as a brake/clutch/service vacuum. The bag
must be labeled per OSHA instruction, sealed, and the trash hauler notified as to the bag's
contents. If a vacuum suitable for asbestos is not available, cleaning must be done wet. If
dust generation is still possible, technicians must wear government-approved toxic dust
purifying respirators.
WARNING: Occupational health and safety act (OSHA) requires areas where
asbestos dust generation is possible to be isolated and posted with warning signs. Only
technicians performing brake or clutch repair are to be present in the area.
Remove the rear disc brake rotor. For additional information, refer to Section 206-04.
Disconnect the rear parking brake cable at the parking brake intermediate cable (2A793).
Disconnect the parking brake cable at the parking brake lever.
Remove the outboard brake shoe retracting spring.
Remove the brake shoe adjusting screw spring.
Remove the brake shoe hold-down springs.
Remove the brake adjuster screw (2041).
Remove the parking brake shoe and linings (2N712) along with the inboard brake shoe
retracting spring.
Inspect the components for excessive wear or damage and replace as required.
Installation
NOTE: Make sure the inboard brake shoe retracting spring is attached to the parking brake
shoe.
Install the LH parking brake shoe and brake shoe hold-down spring, along with the
inboard brake shoe retracting spring.
Connect the inboard brake shoe retracting spring to the RH parking brake shoe, and install
the RH parking brake shoe and the brake shoe hold-down spring.
Install the brake adjuster screw.
Install the brake shoe adjusting screw spring.
NOTE: The outboard brake shoe retracting spring mounts above the inboard brake shoe
retracting spring.
Install the outboard brake shoe retracting spring.
Connect the parking brake cable at the parking brake lever.
Connect the rear parking brake cable at the parking brake intermediate cable.
Install the rear disc brake rotor. For additional information, refer to Section 206-04.
Use the Brake Adjusting Gauge to set the rear brake shoe and lining diameter to 0.76
mm (0.030 in.) less than the inside diameter of the drum portion of the rear disc
brake rotor.
Burnish the parking brake shoe and linings.
Accelerate the vehicle to 40 km/h (25 mph).
Shift the transmission to NEUTRAL.
Slowly apply the parking brake control (2780) to approximately one-half to threequarters of its travel.
Allow the vehicle to come to a complete stop.
Release the parking brake.
SECTION 206-05: Parking Brake and
Actuation
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Bulb—Brake System Warning Indicator
For additional information, refer to Section 413-01.
SECTION 206-05: Parking Brake and
Actuation
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Parking Brake, Transmission Mounted
Removal
NOTE: The parking brake control (2780) must be fully released.
Put the transmission in gear, and release the parking brake control.
Raise and support the vehicle.
Disconnect and lubricate.
Disconnect the parking brake lever return spring from the parking brake lever
(2A637).
Apply penetrating oil, such as Penetrating and Lock Lubricant E8AZ-19A501-B or
equivalent, at the adjusting clevis, jam nut and the threads of the front parking
brake cable and conduit (2853).
Disconnect the front parking brake cable and conduit.
Loosen the jam nut.
Remove the clevis locking pin.
Remove the clevis pin.
Remove the adjusting clevis from the parking brake lever.
Compress the retainer, and remove the front parking brake cable and conduit from the cable
bracket.
Remove the driveshaft (4602); refer to Section 205-01.
Remove the parking brake assembly.
Keep the parking brake vent upward to prevent contamination of the parking brake
shoe and linings (2N712).
Remove the six bolts, the parking brake assembly and the gasket from the
transmission extension housing (7A039).
Discard the bolts and the gasket.
Installation
Mount the parking brake assembly.
Position the parking brake and a new gasket on the transmission extension housing.
Install and tighten six new transmission-to-parking brake bolts.
CAUTION: If installing a new parking brake assembly, fill with Motorcraft
MERCON® Multi-Purpose ATF XT-2-QDX or XT-2-DDX or MERCON®
equivalent after mounting to the transmission extension housing.
Check and, if necessary, fill the parking brake assembly with Motorcraft MERCON®
Multi-Purpose ATF XT-2-QDX or XT-2-DDX or MERCON® equivalent to the bottom
of the filler plug hole.
If necessary, replace and tighten the filler plug.
Install the driveshaft; refer to Section 205-01.
Position the front parking brake cable and conduit, and press the retainer into the cable
bracket until it snaps into place.
Set the adjusting clevis.
Loosen the jam nut several turns.
Position the parking brake lever in the applied position.
Tighten or loosen the adjusting clevis until the adjusting clevis hole lines up with the
parking brake lever hole, and then loosen the adjusting clevis 13 mm (0.5 inch).
Install the pins, and tighten the jam nut.
Install the clevis pin through the adjusting clevis and the parking brake lever.
Install the locking pin in the clevis pin.
Tighten the jam nut.
Install the parking brake lever return spring.
Lower the vehicle.
Test the parking brake operation.
SECTION 206-06:
Hydraulic Brake Actuation
SPECIFICATIONS
DESCRIPTION AND OPERATION
Hydraulic Brake Actuation
Brake Fluid
Brake Master Cylinder
Brake Master Cylinder Reservoir
Brake Tubes and Hoses
DIAGNOSIS AND TESTING
Hydraulic Brake Actuation
REMOVAL AND INSTALLATION
Pedal and Bracket
Master Cylinder—Except Hydro-Max
Master Cylinder—Hydro-Max
Reservoir
DISASSEMBLY AND ASSEMBLY
Master Cylinder
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
SECTION 206-06: Hydraulic Brake
Actuation
SPECIFICATIONS
General Specifications
Item
Specification
High-Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB ESA-M6C25-A
Torque Specifications
Description
Nm lb-ft
Brake Master Cylinder Nuts (Except Hydro-Max) 27
20
Brake Master Cylinder Nuts (Hydro-Max)
37
28
Brake Pedal Bracket Nuts
25
19
Brake Pedal Bracket Bolt
25
19
17
13
Brake Pressure Switch
a
Brake Master Cylinder Hydraulic Tubes
25 19
All hydraulic tubes must be tightened to the specific torque value and be free of fluid leakage.
a
SECTION 206-06: Hydraulic Brake
Actuation
DESCRIPTION AND OPERATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Hydraulic Brake Actuation
CAUTION: Blistering or swelling of rubber brake components may indicate
contamination of the brake fluid by a petroleum based substance. Contaminated rubber
components in the hydraulic brake system must be replaced and the entire hydraulic brake
system must be flushed with clean brake fluid to prevent recontamination.
This vehicle is equipped with a brake pedal actuated dual brake system. The system consists of
the following:
power brake booster
brake master cylinder
front disc brake calipers
rear disc brake calipers
brake tubes and hoses
anti-lock brake system (ABS) components (if so equipped)
The dual brake system is split front and rear with the front wheel brakes comprising one circuit
and the rear wheel brakes, the other circuit.
Brake Fluid
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact
with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush with
running water for 15 minutes. Get medical attention if irritation persists. If taken
internally, drink water and induce vomiting. Get medical attention immediately.
Clean, fresh Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or
equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A is the only brake fluid that
should be used in Ford vehicles.
Do not reuse brake fluid drained or bled from the system.
Do not use brake fluid that has been stored in an open container.
Do not mix different types of brake fluid.
Brake Master Cylinder
The brake master cylinder is a dual piston type. The brake master cylinder operates as follows:
When the brake pedal is depressed, pressure is applied by mechanical linkage to the primary
and secondary piston.
Brake master cylinder pistons apply hydraulic pressure to the two hydraulic circuits.
The brake master cylinder consists of:
brake master cylinder reservoir
brake master cylinder body
Brake Master Cylinder Reservoir
NOTE: Whenever the brake master cylinder reservoir is removed from the brake master
cylinder, new grommets must be installed.
The brake master cylinder reservoir:
is mounted to the brake master cylinder.
holds fluid supply for each brake master cylinder hydraulic piston.
provides visual fluid level markings.
contains the brake master cylinder fluid level sensor.
Brake Tubes and Hoses
CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion
which could result in brake tube failure.
Steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be
properly double flared to provide strong leakproof connections. When bending the tubing to fit
the underbody or rear axle contours, be careful not to kink or crack the tube, allow the tube to
contact any other component, or come within 50.8 mm (2 in.) of the exhaust system.
If a section of brake tube is damaged, the entire section must be replaced with a tube of the same
type, size, shape and length.
When replacing hydraulic brake tubing, hoses or connectors, tighten all connections securely.
After replacement, bleed the brake system; for additional information, refer to Section 206-00.
SECTION 206-06: Hydraulic Brake
Actuation
DIAGNOSIS AND TESTING
Hydraulic Brake Actuation
For additional information, refer to Section 206-00.
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
SECTION 206-06: Hydraulic Brake
Actuation
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Pedal and Bracket
Removal
Disconnect the battery ground cable (14301); for additional information, refer to Section
414-01.
Remove the fuse panel cover.
Remove the stoplight switch retaining pin.
Slide the stoplight switch (13480) and booster push rod from the brake pedal pin.
Remove the brake pedal bracket retaining nuts.
Remove the brake pedal and bracket.
Installation
Follow the removal procedure in reverse order.
SECTION 206-06: Hydraulic Brake
Actuation
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Master Cylinder—Except Hydro-Max
Removal
Disconnect the battery ground cable; for additional information, refer to Section 414-01.
Remove the air cleaner housing; for additional information, refer to Section 303-12.
Disconnect the fluid level sensor connector.
Disconnect the brake pressure switch connector, if so equipped.
Disconnect the brake tubes.
On vehicles with Hydro-Boost, remove the bolts retaining the power steering tubes to the
bracket.
Remove the brake master cylinder nuts.
On vehicles with Hydro-Boost, remove the power steering tube retaining bracket.
Remove the brake master cylinder (2140).
Installation
Follow the removal procedure in reverse order.
Bleed the brake system; for additional information, refer to Section 206-00.
SECTION 206-06: Hydraulic Brake
Actuation
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Master Cylinder—Hydro-Max
Removal
CAUTION: Do not depress the brake pedal while the hydraulic fluid supply line is
disconnected. The inlet pressure port check ball may be dislodged which will result in a
non-functional backup system.
Disconnect the battery ground cable; for additional information, refer to Section 414-01.
Remove the support bracket bolt and nut.
Disconnect the brake tubes.
Remove the ground wire nut and the ground wire.
Remove the four master cylinder nuts.
Installation
Follow the removal procedure in reverse order.
Bleed the brake system; for additional information, refer to Section 206-00.
SECTION 206-06: Hydraulic Brake
Actuation
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Reservoir
Removal
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact
with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes
with running water for 15 minutes. Get medical attention if irritation persists. If taken
internally, drink water and induce vomiting. Get medical attention immediately.
Disconnect the brake master cylinder fluid level switch.
Use a suitable suction device to drain the brake master cylinder reservoir (2K478).
Carefully pry up on the brake master cylinder reservoir to remove.
Installation
NOTE: Whenever replacing the brake master cylinder reservoir, replace the grommets.
Install the brake master cylinder reservoir.
Lubricate the two grommets with High Performance DOT 3 Motor Vehicle Brake
Fluid C6AZ-19542-AB or equivalent fluid meeting Ford specification ESAM6C25-A, and insert the grommets into the brake master cylinder (2140).
Press the brake master cylinder reservoir into the grommets until it is fully seated.
Connect the brake master cylinder fluid level switch.
Fill the brake master cylinder reservoir with clean High Performance DOT 3 Motor
Vehicle Brake Fluid C6AZ-19542-AB or equivalent fluid meeting Ford
specification ESA-M6C25-A.
SECTION 206-06: Hydraulic Brake
Actuation
DISASSEMBLY AND ASSEMBLY
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Master Cylinder
Disassembly
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact
with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes
with running water for 15 minutes. Get medical attention if irritation persists. If taken
internally, drink water and induce vomiting. Get medical attention immediately.
Remove the brake master cylinder (2140); for additional information, refer to Master
Cylinder—Except Hydro-Max or Master Cylinder—Hydro-Max in this section.
Clean the outside of the brake master cylinder.
Remove the brake master cylinder filler cap (2162) and drain the remaining brake fluid.
If so equipped, remove the brake pressure switch.
Remove the primary piston assembly.
Depress the primary piston and remove the snap ring.
Remove and discard the primary piston assembly.
Remove the secondary piston assembly.
Plug the rear outlet port and, if necessary, plug the brake pressure switch port.
Apply compressed air into the front outlet port and remove the secondary piston
assembly and discard.
NOTE: If the brake master cylinder bore is damaged, the brake master cylinder must be
replaced.
Clean the brake master cylinder bore using isopropyl alcohol and inspect for damage.
Assembly
Use clean High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or
equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A to lubricate the new
piston assembly seals.
Carefully install the secondary piston assembly.
Carefully install the primary piston assembly.
Install the snap ring.
Depress the primary piston.
Install the snap ring.
If so equipped, install the brake pressure switch.
Install the brake master cylinder; for additional information, refer to Master Cylinder—
Except Hydro-Max or Master Cylinder—Hydro-Max in this section.
SECTION 206-07:
Power Brake Actuation
SPECIFICATIONS
DESCRIPTION AND OPERATION
Brake Booster—Hydro-Boost
Brake Booster—Vacuum
Brake Booster—Hydro-Max
DIAGNOSIS AND TESTING
Power Brake System
GENERAL PROCEDURES
Push Rod Adjustment
Hydro-Boost Bleeding
REMOVAL AND INSTALLATION
Brake Booster—Hydro-Boost
Brake Booster—Vacuum
Brake Booster—Hydro-Max
SECTION 206-07: Power Brake Actuation 1999 F-Super Duty 250-550 Workshop Manual
SPECIFICATIONS
Procedure revision date: 01/26/2000
General Specifications
Item
Specification
Type
Dual Diaphragm
Power Brake Booster Push Rod Length mm (in)
24.89-25.27 (0.980-0.995)
Lubricant
Motorcraft MERCON® ATF XT-2-QDX or -DDX
MERCON®
Torque Specifications
Description
Nm Lb-Ft Lb-In
Booster Nuts
24
18
—
Master Cylinder Nuts
24
18
—
Power Steering Pressure Hose Fitting 35
26
—
Electric Motor Relay Bolt
5
—
45
Ground Wire Nut
20
15
—
Hydro-Max Booster Nuts
40
30
—
Hydraulic Fluid Supply Line Nut
28
21
—
Hydro-Max Master Cylinder Nuts
37
28
—
Support Bracket Bolt
40
30
—
Support Bracket Nut
40
30
—
Power Steering Line Clamp Bolts
17
13
—
SECTION 206-07: Power Brake
Actuation
DESCRIPTION AND OPERATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Brake Booster—Hydro-Boost
The Hydro-Boost brake booster is a hydraulically operated brake booster powered by the power
steering pump. The power steering pump provides the fluid pressure to operate both the power
brake booster and the power steering gear.
A Hydro-Boost reserve system (accumulator) stores sufficient fluid under pressure to provide at
least two power-assisted brake applications in the event the power steering pump fluid flow is
interrupted.
For low assist concerns on vehicles equipped with the Hydro-Boost system, refer to Section 21100 to check the power steering pump pressure and flow.
The brakes can also be applied manually if the reserve system is depleted.
Model identification is stamped into the power brake booster housing near the power steering
pressure hose.
Any leakage goes directly back to the power steering pump reservoir.
SECTION 206-07: Power Brake
Actuation
DESCRIPTION AND OPERATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Brake Booster—Vacuum
The vacuum type power brake booster (2005):
is a dual diaphragm, vacuum assisted power brake booster.
reduces brake pedal force and travel distance.
is located on the LH side of the bulkhead in the engine compartment, between the brake
pedal (2455) and the brake master cylinder (2140).
is divided into separate chambers by the diaphragms.
will not operate if vacuum is restricted or if any of the vacuum related power brake
components fail.
is installed as an assembly.
If the power assist fails, the brake system will continue to operate with increased brake pedal
effort.
Hose and Check Valve
The power brake booster check valve (2365):
is located on the front of the power brake booster.
is installed separately (install a new grommet when installing a new check valve).
is positioned between the power brake booster and the power brake booster hose.
closes when the engine is turned off.
in the closed position, traps engine vacuum in the power brake booster
retains vacuum to provide several power assisted brake applications with the engine off.
Item
Part Number
Description
1
2140
Brake master cylinder
2
2005
Power brake booster
3
2365
Power brake booster check valve
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
SECTION 206-07: Power Brake
Actuation
DESCRIPTION AND OPERATION
Brake Booster—Hydro-Max
The Hydro-Max power brake system is composed of a hydraulic-powered booster, a mini master
cylinder, a reserve system electric motor pump, a relay, an electric monitor and an integral
pressure differential switch.
Item
Part Number
Description
1
2C185
Flow Switch Contact Assy
2
—
Outlet Return Port (Part of 2005)
3
2005
Hydro-Max Booster
4
2A016
Electric Pump and Motor Assy
SECTION 206-07: Power Brake Actuation 1999 F-Super Duty 250-550 Workshop Manual
DIAGNOSIS AND TESTING
Procedure revision date: 01/26/2000
Power Brake System
Refer to Section 206-00.
SECTION 206-07: Power Brake Actuation 1999 F-Super Duty 250-550 Workshop Manual
GENERAL PROCEDURES
Procedure revision date: 01/26/2000
Push Rod Adjustment
Remove the brake master cylinder (2140). For additional information, refer to Section 20606.
CAUTION: Do not apply the brake pedal with the master cylinder removed from
the booster.
Adjust the power brake booster to brake master cylinder push rod, vacuum applied.
Measure the power brake booster to brake master cylinder push rod.
If necessary, adjust the screw within specification.
Install the brake master cylinder. For additional information, refer to Section 206-06.
SECTION 206-07: Power Brake
Actuation
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/15/2002
Hydro-Boost Bleeding
NOTE: The Hydro-Boost power brake booster (2B560) is generally self-bleeding, and the
following procedure will normally bleed the air from the power brake booster. Normal
operation of the vehicle will further remove any additional trapped air.
Fill the power steering oil reservoir (3A697) with MERCON® Multi-Purpose ATF XT2-QDX or MERCON® equivalent.
Remove the powertrain control module (PCM) fuse to prevent the engine from starting.
Crank the engine for several seconds.
Check the fluid level in the power steering oil reservoir and add if necessary. Install the
powertrain control module (PCM) fuse.
Start the engine.
With the engine running, turn the steering wheel (3600) from stop-to-stop twice. Turn the
engine off.
Depress the brake pedal (2455) several times to discharge the accumulator.
Repeat Steps 5 and 6.
If foaming occurs, stop the engine and allow the foam to dissipate.
Repeat Steps 5 and 6 as required, until all the air is removed from the system (when the
foaming stops).
SECTION 206-07: Power Brake
Actuation
REMOVAL AND INSTALLATION
Brake Booster—Hydro-Boost
Removal
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
WARNING: The power brake booster should not be carried by the accumulator, nor
should it ever be dropped on the accumulator. Check the snap ring on the accumulator for
proper seating before the power brake booster is used. The accumulator contains highpressure nitrogen gas and can be dangerous if mishandled.
WARNING: If the accumulator is to be disposed of, it must not be exposed to
excessive heat. Before discarding the accumulator, drill a 1.6-mm (1/16-inch) diameter hole
in the end of the accumulator can to relieve the gas pressure. Always wear safety glasses
when performing this operation.
With the engine off, depress the brake pedal (2455) several times to discharge the
accumulator.
Disconnect the battery ground cable (14301). On vehicles equipped with dual batteries; for
additional information, refer to Section 414-01.
Remove the left side battery (10655); for additional information, refer to Section 414-01.
Remove the air cleaner housing; for additional information, refer to Section 303-12
Remove the brake pressure switch electrical connector.
Disconnect the power steering pressure hoses.
Disconnect the power steering return line hose (3A005).
Remove the three power steering line clamp bolts.
Remove the brake master cylinder nuts.
Remove the power steering hose mounting bracket and the brake master cylinder (2140), and
position aside.
Remove the fuse panel cover.
Remove the self-locking pin.
Remove the stoplight switch (13480) and the brake booster push rod from the brake pedal
pin.
Remove the power brake booster nuts, and remove the power brake booster.
Installation
Follow the removal procedure in reverse order.
Install new Teflon® seals on the power steering pressure fittings.
Bleed hydro-boost; for additional information, refer to Hydro-Boost Bleeding in this
section.
SECTION 206-07: Power Brake
Actuation
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Brake Booster—Vacuum
Removal and Installation
Disconnect the battery ground cable (14301). For additional information, refer to Section
414-01.
Remove the air cleaner housing. For additional information, refer to Section 303-12.
Remove the brake master cylinder nuts.
Position the brake master cylinder (2140) aside.
Disconnect the booster vacuum hose.
Disconnect the power distribution box auxiliary relay and set aside.
Remove the instrument panel steering column opening cover.
Remove the brake pedal position (BPP) switch self-locking pin.
Remove the brake pedal position (BPP) switch (13480) and the brake booster push rod from
the brake pedal pin.
Remove the power brake booster nuts.
Remove the power brake booster (2005).
To install, reverse the removal procedure.
SECTION 206-07: Power Brake
Actuation
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Brake Booster—Hydro-Max
Removal
CAUTION: Do not depress the brake pedal while the hydraulic fluid supply line is
disconnected. The inlet pressure port check ball may be dislodged which will result in a
non-functional backup system.
Disconnect the battery.
Remove the support bracket bolt and nut.
Remove the ground wire nut and the ground wire.
Remove the four master cylinder nuts.
Position the master cylinder aside.
Remove the electric motor relay bolt.
Disconnect the flow switch electrical connector.
Remove the steering column cover.
Remove the brake pedal position (BPP) switch self-locking pin.
Remove the brake pedal position (BPP) switch (13480) and the brake booster push rod from
the brake pedal.
Disconnect the electric pump and motor assembly electric connector.
Disconnect the hydraulic fluid return hose.
Remove the hydraulic fluid supply line nut.
Remove the Hydro-Max booster nuts, and remove the Hydro-Max booster.
Installation
NOTE: Start the hydraulic fluid supply line before tightening the Hydro-Max nuts and bolts.
Follow the removal procedure in reverse order.
SECTION 206-09A:
Anti-Lock Control — Rear
SPECIFICATIONS
DESCRIPTION AND OPERATION
Anti-Lock Control
DIAGNOSIS AND TESTING
Anti-Lock Control
Inspection and Verification
ABS Control Module Parameter Identification (PID) Index
ABS Control Module Active Command Index
ABS Control Module Diagnostic Trouble Code (DTC) Index
Symptom Chart
Pinpoint Tests
Component Test — Intermittent Failures
REMOVAL AND INSTALLATION
Hydraulic Control Unit—Electronic (EHCU)
Module—Anti-Lock Brake Control
Sensor—Rear
Sensor Indicator—Rear
Switch—Pressure
Switch—Brake Pedal Position
SECTION 206-09A: Anti-Lock Control —
Rear
SPECIFICATIONS
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
General Specifications
Item
Specification
SAE 75W-140 High Performance Rear Axle Lubricant WSL-M2C192-A
F1TZ-19580-B
Torque Specifications
Description
Anti-Lock Brake Control Module Screw
Nm
4
lb-ft lb-in
—
35
Electronic Hydraulic Control Unit (EHCU) Bracket to Frame Bolts 20-30 15-22
—
Electronic Hydraulic Control Unit (EHCU) Bolts
23-34 17-24
—
7/16-24 Hydraulic Brake Line
20-30 15-22
—
Rear Anti-Lock Sensor Bolt
34-40 25-29
—
Wheel Cylinder Bleeder Screw
7-9
—
63-80
SECTION 206-09A: Anti-Lock Control —
Rear
DESCRIPTION AND OPERATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Anti-Lock Control
Anti-Lock Control Component Location
Item
Part
Number
Description
1
2C219
Electronic Hydraulic Control Unit (EHCU)
(Includes 2C065)
2
2C065
Anti-Lock Brake Control Module
3
—
Yellow ABS Warning Indicator
4
2C190
Rear Anti-Lock Brake Sensor
5
2C189
Rear Anti-Lock Brake Sensor Indicator
The electronic hydraulic control unit (EHCU) consists of the anti-lock brake control module and
the hydraulic control unit (HCU).
The anti-lock brake control module can be replaced separately. If the EHCU is inoperative, the
EHCU must be replaced as an assembly.
The rear anti-lock brake system (RABS) prevents rear wheel lockup by automatically modulating
the brake pressure during an emergency stop. By not locking the wheels, the driver can stop the
vehicle in the shortest possible distance under most conditions.
The brake pedal force required to engage the RABS function may vary with the road surface
condition. A dry surface requires greater force than a slippery surface.
During the RABS operation, the driver may feel a pulsation in the brake pedal (2455),
accompanied by a slight up and down movement in the pedal height. In addition, a mechanical
noise from the engine compartment may be heard. The pedal effort and pedal feel during normal
braking are similar to that of a conventional power brake system.
When the brakes are applied, brake fluid is forced from the brake master cylinder outlet ports to
the HCU inlet ports. The fluid pressure is transmitted through three normally open solenoid
valves inside the HCU, through the outlet ports of the HCU to the rear brakes. One circuit of the
brake master cylinder (2140) feeds the front brakes, while the other circuit feeds the rear brakes.
If the anti-lock brake control module senses that a rear wheel (1007) is about to lock, based on
wheel speed sensor data, the solenoid valve will pulse closed preventing more fluid from
entering the circuit. The anti-lock brake control module then reads the sensor signal from the rear
wheels again. If the wheels are still decelerating, the normally closed solenoid valve for that
circuit is opened. A controlled amount of pressure between the normally open valve and the
brake is relieved into the HCU accumulator. Once the affected wheels return to vehicle speed,
the HCU returns the solenoid valves to their normal condition allowing fluid flow to the affected
brake.
The anti-lock brake control module monitors the electromechanical components of the system.
Malfunction of the anti-lock brake system will cause the anti-lock brake control module to shut
off or inhibit the system. However, normal power-assisted braking remains. Malfunctions are
indicated by the yellow ABS warning indicator in the instrument cluster (10849).
The RABS system is self-monitoring. When the ignition switch is placed in the RUN position,
the anti-lock brake control module performs a preliminary self-check on the anti-lock electrical
system indicated by a five-second illumination of the yellow ABS warning indicator in the
instrument cluster.
A self-test of the solenoid valve coils and the pump motor is performed when the vehicle is
started. During starting, the brake pedal must be released to run the self-test. If the brake pedal is
depressed or a failed brake switch occurs, the self-test is run at 6 km/h (4 mph) regardless of
brake pedal position.
SECTION 206-09A: Anti-Lock Control —
Rear
DIAGNOSIS AND TESTING
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Anti-Lock Control
Refer to Wiring Diagrams Cell 42 (F-53 Motorhome Chassis, F-Super Duty 250-550), Anti-Lock
Brake System (ABS) for schematic and connector information.
Special Tool(s)
73 Digital Multimeter or
equivalent
105-R0051
88 Digital Multimeter or
equivalent
105-R0053
ABS Adapter Cable or
equivalent
418-F038 (007-00108)
EEC-IV 60-Pin Breakout Box
or equivalent
418-005 (014-00322)
New Generation STAR (NGS)
Tester or equivalent
418-F048 (007-00500)
Inspection and Verification
Anti-Lock Quick Check Sheet Using EEC-IV 60-Pin Breakout Box
Ignition
Mode
Measure
Between Pin
Numbers
Battery Power
OFF or
ON
3 and Chassis
Ground
DC Volts
10 V min
GO to
Symptom
Chart.
Ignition Feed
OFF
14 and Chassis
Ground
DC Volts
0V
ON
14 and Chassis
Ground
DC Volts
10 V min
GO to
Pinpoint
Test F.
GO to
Pinpoint
Test F.
OFF
9 and 21
kohms
0.8-2.5
kohms
GO to
Pinpoint
Test B.
Anti-Lock Brake Sensor
Continuity to Ground
Rear
OFF
9 and Chassis
Ground
Continuity
No continuity
GO to
Pinpoint
Test B.
Anti-Lock Brake Sensor
Voltage: Rotate wheel @
one revolution per
second
Rear
OFF
9 and 21
AC mVolts
100-3500
mV
GO to
Pinpoint
Test C.
Item to Be Tested
Rear Anti-Lock Brake
Sensor Resistance
Tester
Scale/Range Specification
Pinpoint
Test
Verify the customer concern by operating the vehicle and applying the brakes under different
conditions to duplicate the condition.
Inspect to determine if one of the following mechanical or electrical concerns apply:
Visual Inspection Chart
Mechanical
Parking brake cable binding
Electrical
Damaged fuse(s)
Improperly inflated tires
Power distribution box fuse maxi 14 (60A)
Mismatched wheels or tires on
vehicle
Fuse junction panel
Fuse 15 (5A)
Fuse 29 (5A)
Fuse 25 (5A)
Damaged connectors or connections
Circuitry open/shorted
Shorting cap in evac and fill connector loose or
missing
If the inspection reveals an obvious concern(s) that can be readily identified, repair as
required.
If the concern remains after the inspection connect the New Generation STAR (NGS) Tester
to the data link connector (DLC) located beneath the instrument panel and select the
vehicle to be tested from the NGS menu. If the NGS does not communicate with the
vehicle:
check that the program card is properly installed.
check the connections to the vehicle.
check the ignition switch position.
If the NGS still does not communicate with the vehicle, refer to the New Generation STAR
Tester manual.
Perform the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section
418-00.
NO RESP/NOT EQUIP for anti-lock brake control module, go to Pinpoint Test E.
SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes
(DTCs), erase the continuous DTCs and perform self-test diagnostics for the antilock brake control module.
If the DTCs retrieved are related to the concern, go to ABS Control Module Diagnostic
Trouble Code (DTC) Index to continue diagnostics.
If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue
diagnostics.
ABS Control Module Parameter Identification (PID) Index
ABS Control Module Parameter Identification (PID) Index
PID
Description
Expected Values
4WDABS
4 Wheel Drive Input Switch
2WD-4WD
ABSLAMP
ABS Warning Lamp State
ON, OFF
ABSR_I
Rear ABS Inlet Valve
ON, OFF
ABSR_O
Rear ABS Outlet Valve
ON, OFF
BOO_ABS
Brake Switch Input
ON, OFF
BRKLAMP
Brake Warning Lamp State
ON, OFF
CCNTABS Continuous DTCs In ABS Module
# Of DTCs
R_WSPD
Rear Wheel Speed Sensor
0-255 KPH
PWR_RLY
Power Relay Feedback Input
ON, OFF
ABS Control Module Active Command Index
ABS Control Module Active Command Index
Active Command
Display
Action
ABS OUTPUT CONTROL ABS POWER ON, OFF
PMP MOTOR ON, OFF
R INLET
ON, OFF
R OUTLET ON, OFF
BRKWARN ON, OFF
ABS Control Module Diagnostic Trouble Code (DTC) Index
ABS Control Module Diagnostic Trouble Code (DTC) Index
DTC
Description
Action
B1342
Anti-lock Brake Control Module
Failure
INSTALL a new anti-lock brake control
module. REFER to Module—Anti-Lock
Brake Control.
C1241
Shorted Reset Switch Circuit Failure
(Hydraulic Pressure Differential
Switch)
INSTALL a new anti-lock brake control
module. REFER to Module—Anti-Lock
Brake Control.
C1226
Brake Lamp Warning Output Short to
Ground
REFER to Section 413-01. Use GEM
DTC C1125.
C1202/C1204
Open/Shorted Dump Valve Coil
Circuit Failure
GO to Pinpoint Test A.
C1206/C1208
Open/Shorted Isolation Valve Coil
Circuit Failure
GO to Pinpoint Test A.
C1230
Rear Wheel Sensor Open
GO to Pinpoint Test B.
C1229
Erratic Wheel Speed Sensor
GO to Pinpoint Test C.
C1169
Excessive Dump Time
GO to Pinpoint Test F.
B2141
Vehicle Speed Calibration Data Not
Programmed Into Module
REFER to Section 418-01.
C1185
Power Relay Output Circuit Failure
GO to Pinpoint Test G.
C1115
Power Relay Output Short Circuit to
Battery
GO to Pinpoint Test G.
B1485
Brake Pedal Position (BPP) Switch
Circuit Malfunction
GO to Pinpoint Test H.
Symptom Chart
Failure of a mechanical brake component may not cause the yellow ABS warning indicator to
illuminate or a DTC to be stored. The Symptom Chart is a starting point for diagnosis of these
concerns.
Symptom Chart
Condition
ABS Misfire,
ABS Too
Sensitive,
ABS Fires
On Normal
Stop
Possible Sources
Action
Rear anti-lock brake
sensor indicator
is damaged.
REMOVE rear sensor from the
differential housing; INSPECT
rear anti-lock brake sensor
indicator for damaged teeth.
Sensor output is out
of sync.
GO to Pinpoint Test C.
Intermittent open or
shorted sensor
circuit.
GO to Component Test —
Intermittent Failures to test
circuits: 523 (R/PK) and 519
(LG/BK).
Chafed wire
insulation or
pinched wire due
INSPECT wiring harness from
front sensor knuckle to the
frame and from the rear axle to
to improper
routing causing
intermittent
short.
Wheels Lock Up
the frame for worn or chafed
wire insulation.
Linings are grabby.
ELIMINATE base brake system as
cause of problem.
Loose sensor(s).
TIGHTEN sensor bolt to
specifications. REFER to
Specifications.
Hydraulic outlet
(dump) valve.
GO to Pinpoint Test F.
Leaky inlet
(isolation) valve
during ABS
(soft).
ELIMINATE base brake system as
cause of problem. REFER to
Section 206-00.
Binding parking
brake.
Leaking rear axle
seal.
Hard or Soft
Brake Pedal
Stuck inlet
(isolation) valve
(hard brake
pedal) or leaky
outlet (dump)
valve (soft brake
pedal).
GO to Pinpoint Test D.
Hydraulic leak in
brake line or
hose, fitting,
master cylinder,
wheel cylinder,
or caliper (soft
brake pedal).
ELIMINATE base brake system as
cause of problem. REFER to
Section 206-00.
Air in brake system
(soft brake
pedal).
Little or no vacuum
boost (hard
brake pedal).
Stuck or inoperative
caliper (hard
brake pedal).
Pinched or crimped
brake line or
hose (hard brake
pedal).
Lack of
Deceleration
During
Medium/Har
d Brake
Application
Stuck shut inlet
(isolation) valve
or leaky outlet
(dump) valve
(rear axle only).
GO to Pinpoint Test D.
Hydraulic leak in
brake line or
hose, fitting,
master cylinder,
wheel cylinder,
or caliper.
ELIMINATE base brake system as
cause of problem. REFER to
Section 206-00.
Air in brake system.
Little or no vacuum
boost.
Stuck or inoperative
caliper.
Ineffective brake
shoe or pad
linings.
Vehicle Pulls
During
Braking
Frozen or binding
caliper (one side
of vehicle).
ELIMINATE base brake system as
cause of problem. REFER to
Section 206-00.
Uneven brake pad or
shoe wear.
Pinched or crimped
brake line or
hose.
Fully or partially
blocked front
inlet (isolation)
valve.
REPLACE the electronic hydraulic
control unit (EHCU). REFER
to Hydraulic Control Unit—
Electronic (EHCU).
ABS Warning
Lamp On
With System
Pass
ABS warning lamp
circuit.
Soft or
Excessive
Pedal Travel
Electronic hydraulic
control unit
(EHCU).
GO to Pinpoint Test D.
No
Fuse(s).
GO to Pinpoint Test E.
Communicati
on With the
Anti-Lock
Brake
Control
Module
Anti-lock brake
control module.
CHECK circuit 603 (DG) for open
or short to B+. REPAIR circuit
603 (DG) if necessary. If OK,
REPLACE the anti-lock brake
control module. REFER to
Module—Anti-Lock Brake
Control. TEST the system for
normal operation.
Circuitry.
Module.
Pinpoint Tests
PINPOINT TEST A: DTCS C1202, C1204, C1206, C1208 — ISOLATION VALVE,
DUMP VALVE
CONDITIONS
DETAILS/RESULTS/ACTIONS
A1 CHECK FOR FAULT REPEATABILITY
Anti-Lock Brake Control Module C1041
NGS
Clear DTCs
Perform ABS Control Module On-Demand
Self-Test.
Retrieve DTCs
Inspect the connector wiring and terminals
for opens, corrosion looseness and backed-out
pins.
Are the wiring and connector OK? Is a
single valve DTC set?
Yes
GO to G2. REPLACE the anti-lock brake control
module. REFER to Module—Anti-Lock Brake
Control. GO to A2 .
No
REPAIR as required. TEST the system for
normal operation.
No
If multiple valve DTCs are set, GO to A2 .
If no DTCs are set, TEST the system for normal
operation.
A2 CHECK EHCU 2-PIN POWER CIRCUIT 532 (O/Y)
CAUTION: A blown fuse may be an indication of some other wiring or component
concern within the circuit.
EHCU C1041
Measure the voltage between EHCU C10412, circuit 532 (O/Y), and ground.
Is the voltage greater than 10 volts?
Yes
REPLACE the anti-lock brake control module.
REFER to Module—Anti-Lock Brake Control.
GO to A3 . TEST the system for normal
operation.
No
RECONNECT EHCU C1041. GO to A3 .
A3 CHECK POWER DISTRIBUTION BOX FUSE 14 (60A)
Power Distribution Box Fuse 14 (60A)
Is the fuse OK?
Yes
REPAIR circuit 532 (O/Y). TEST the system for
normal operation.
No
REPLACE the fuse. TEST the system for normal
operation. If the fuse fails again, CHECK for
short to ground. REPAIR as necessary. TEST the
system for normal operation.
PINPOINT TEST B: DTC:1230 — REAR ANTI-LOCK BRAKE SENSOR
(ELECTRICAL/STATIC)
CONDITIONS
DETAILS/RESULTS/ACTIONS
B1 CHECK FOR FAULT REPEATABILITY
NGS
Clear Continuous DTCs
Drive the vehicle a minimum speed of 6 km/h
(10 mph).
Retrieve and document continuous DTCs.
Is DTC C1230 retrieved?
Yes
GO to B2.
No
If no DTC is retrieved, GO to B6 .
If a different DTC is retrieved, GO to ABS
Control Module Diagnostic Trouble Code (DTC)
Index.
B2 CHECK ANTI-LOCK BRAKE SENSOR COIL RESISTANCE AT EHCU
CONNECTOR
Install EEC-IV 60-Pin Breakout Box.
Measure the resistance between EEC-IV 60Pin Breakout Box pin 9, circuit 523 (R/PK), and
EEC-IV 60-Pin Breakout Box Pin 21, circuit 519
(LG/BK).
Is the resistance between 800 and 3500
ohms?
Yes
GO to B4.
No
GO to B3.
B3 DETERMINE LOCATION OF FAULT
Rear Anti-Lock Brake Sensor C404
Measure the resistance between the two
terminals of the rear anti-lock brake sensor C404.
Is the resistance between 800 and 3500
ohms?
Yes
REPAIR circuit 519 (LG/BK) and circuit 523
(R/PK). TEST the system for normal operation.
No
REPLACE the rear anti-lock brake sensor.
REFER to Sensor—Rear. TEST the system for
normal operation.
B4 CHECK REAR ANTI-LOCK BRAKE SENSOR CIRCUIT FOR SHORT TO
GROUND
Measure the resistance between EEC-IV 60Pin Breakout Box pin 9, circuit 523 (R/PK), and
ground; and between EEC-IV 60-Pin Breakout
Box pin 21, circuit 519 (LG/BK), and ground.
Is resistance greater than 10,000 ohms?
Yes
REPLACE the anti-lock control module. REFER
to Module—Anti-Lock Brake Control. TEST the
system for normal operation.
No
GO to B5.
B5 CHECK FOR ANTI-LOCK BRAKE SENSOR SHORT
Rear Anti-Lock Brake Sensor C404
Measure the resistance between rear anti-lock
brake sensor C404 terminals, and ground.
Is resistance greater than 10,000 ohms?
Yes
REPAIR circuit 519 (LG/BK) and circuit 523
(R/PK).
No
REPLACE the rear anti-lock brake sensor.
REFER to Sensor—Rear. TEST the system for
normal operation.
B6 TEST FOR INTERMITTENT ANTI-LOCK BRAKE SENSOR FAULT
Perform the Sensor Failure test for the rear
anti-lock brake sensor. Refer to Component Test
— Intermittent Failures.
Did the rear anti-lock brake sensor pass?
Yes
System is OK.
No
REPLACE the rear anti-lock brake sensor.
REFER to Sensor—Rear. TEST the system for
normal operation.
PINPOINT TEST C: DTCs: C1229, C1237 — REAR ANTI-LOCK BRAKE SENSOR
DIAGNOSIS (DYNAMIC)
CONDITIONS
C1 RETRIEVE DTCs
DETAILS/RESULTS/ACTIONS
NGS
Retrieve Continuous DTCs
Is DTC C1230 retrieved?
Yes
DIAGNOSE DTC C1230 first. IGNORE all other
DTCs retrieved.
No
GO to C2.
C2 CHECK REAR BRAKE ANTI-LOCK SENSOR SIGNAL
WARNING: The electrical power to the air suspension system must be shut off
prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished
by turning off the air suspension switch located in the RH kick panel area. Failure to do
so may result in unexpected inflation or deflation of the air springs which may result in
shifting of the vehicle during these operations.
Anti-Lock Brake Control Module C1040
Raise and support the vehicle on a hoist so
that all wheels are clear of the ground.
Turn the rear wheels at a minimum speed of 8
km/h (5 mph).
Measure the voltage between the anti-lock
brake control module C1040-21, circuit 519
(LG/BK), and anti-lock brake control module
C1040-9, circuit 523 (R/PK).
Is the voltage steady and greater than 650
mVACRMS?
Yes
REPLACE the anti-lock brake control module;
REFER to Module—Anti-Lock Brake Control.
TEST the system for normal operation.
No
GO to C3.
C3 CHECK REAR ANTI-LOCK BRAKE SENSOR INDICATOR
Raise the vehicle on a hoist.
CAUTION: Examine the anti-lock
brake sensor indicator carefully. Failure to
properly diagnose the anti-lock brake sensor
indicator at this time will lead to unnecessary
component replacement and wasted diagnostic
time.
Inspect the anti-lock brake sensor
indicator for damaged or missing teeth.
Rotate the anti-lock brake sensor indicator
to be sure all teeth are checked.
Is the anti-lock brake sensor indicator
damaged or does it have missing teeth?
Yes
REPLACE the anti-lock brake sensor indicator.
REFER to Sensor Indicator—Rear. TEST the
system for normal operation.
No
GO to C4.
C4 CHECK FOR LOOSE ANTI-LOCK BRAKE SENSOR MOUNTING
Wiggle the anti-lock brake sensor at the
differential case (4204).
Is any looseness detected?
Yes
CLEAN the anti-lock brake sensor mounting
surface. VERIFY that the anti-lock brake sensor
is seated properly. TIGHTEN anti-lock brake
sensor bolt to specifications. TEST the system for
normal operation.
No
GO to C5.
C5 CHECK FOR ANTI-LOCK BRAKE SENSOR SHORT
Rear Anti-Lock Brake Sensor C404
Measure the resistance between rear anti-lock
brake sensor C404 terminals, and ground.
Is resistance greater than 10,000 ohms?
Yes
GO to C6.
No
REPLACE the anti-lock brake sensor. REFER to
Sensor—Rear. TEST the system for normal
operation.
C6 CHECK CIRCUITS
Install EEC-IV 60-Pin Breakout Box.
Measure the resistance between EEC-IV 60Pin Breakout Box pin 9, circuit 523 (R/PK), and
EEC-IV 60-Pin Breakout Box pin 21, circuit 519
(LG/BK).
Is resistance greater than 10,000 ohms?
Yes
GO to C7.
No
REPAIR circuit 519 (LG/BK) and circuit 523
(R/PK). TEST the system for normal operation.
C7 CHECK FOR INTERMITTENT WIRING CONCERN
Perform the Sensor Failure test for the rear
anti-lock brake sensor. Refer to Component Test
— Intermittent Failures.
Did the rear anti-lock brake sensor pass?
Yes
GO to C8.
No
REPAIR as necessary. TEST the system for
normal operation.
C8 INSPECT THE REAR ANTI-LOCK BRAKE SENSOR FOR DAMAGE
Remove the rear anti-lock brake sensor. Refer
to Sensor—Rear.
Inspect the housing for stress cracks or
breaks.
Inspect the anti-lock brake sensor C404 for
evidence of water entry, pin corrosion, or
excessive debris.
Are any of the above conditions evident?
Yes
REPAIR as necessary. TEST the system for
normal operation.
No
REPLACE the anti-lock brake control module;
REFER to Module—Anti-Lock Brake Control.
TEST the system for normal operation.
PINPOINT TEST D: SOFT OR EXCESSIVE PEDAL TRAVEL
CONDITIONS
D1 CHECK BASE BRAKE COMPONENTS
DETAILS/RESULTS/ACTIONS
Visually inspect the brake lines from EHCU
to wheel cylinders.
Visually inspect the calipers and brake
components.
Are any of these components damaged?
Yes
REPLACE or REPAIR as necessary. TEST the
system for normal operation.
No
GO to D2.
D2 BASE BRAKE TEST DRIVE
Remove power distribution box fuse 14
(60A).
Drive the vehicle at approximately 12 kph (20
mph).
Perform a light to medium (normal) traffic
stop.
Does one wheel lock consistently?
Yes
GO to Symptom Chart.
No
GO to Inspection and Verification — System
Precheck.
PINPOINT TEST E: NO COMMUNICATION WITH THE ANTI-LOCK BRAKE
CONTROL MODULE
CONDITIONS
DETAILS/RESULTS/ACTIONS
E1 VERIFY THE CONNECTION BETWEEN NGS TESTER AND THE DLC II
CONNECTOR
Reconnect NGS Tester to the DLC connector.
Retrieve and document continuous DTCs.
Are DTCs obtained?
Yes
GO to ABS Control Module Diagnostic Trouble
Code (DTC) Index.
No
GO to E2.
E2 CHECK POWER TO THE ANTI-LOCK BRAKE CONTROL MODULE
Install EEC-IV 60-Pin Breakout Box.
Measure the voltage between EEC-IV 60-Pin
Breakout Box pin 14, circuit 533 (T/R), and
ground.
Is the voltage greater than 10 volts?
Yes
GO to E3.
No
CHECK fuse junction panel fuse 25 (5A) and/or
REPAIR circuit 533 (T/R). TEST the system for
normal operation.
E3 CHECK ANTI-LOCK BRAKE CONTROL MODULE GROUND
EHCU C1041
Disconnect the battery negative cable.
Measure the resistance between EHCU
C1041-1, circuit 530 (LG/Y), and ground.
Is the resistance less than 5 ohms?
Yes
REFER to Section 418-00.
No
REPAIR circuit 530 (LG/Y). TEST the system for
normal operation.
PINPOINT TEST F: DTC: C1169 — EXCESSIVE DUMP TIME
CONDITIONS
DETAILS/RESULTS/ACTIONS
F1 CHECK FOR FAULT REPEATABILITY
NGS
Clear Continuous
DTCs
Retrieve and document continuous DTCs.
•
Is DTC C1169 retrieved?
Yes
REPLACE the EHCU. REFER to Hydraulic Control Unit—Electronic
(EHCU). TEST the system for normal operation.
No
GO to F2.
F2 LOW SPEED ABS STOP
Drive the vehicle at approximately 6 km/h (10 mph).
NOTE: Wetting down the area where the stop is to be performed
will aid in this test.
NOTE: Momentary lock-up is permissible. An assistant should
be used to monitor the wheels during ABS stop.
Apply the brakes hard enough to lock all four wheels.
•
Does one wheel lock consistently?
Yes
GO to Symptom Chart.
No
System is OK. TEST the system for normal operation.
PINPOINT TEST G: DTC 1115/1185 — POWER RELAY OUTPUT CIRCUIT
FAILURE
CONDITIONS
DETAILS/RESULTS/ACTIONS
G1 CHECK CONNECTOR C1041 (2 WIRE)
Anti-Lock Brake Control
Module C1041
Inspect the connector wiring and terminals for opens,
corrosion looseness and backed-out pins.
•
Are the wiring and connector OK?
Yes
GO to G2.
No
REPAIR as required. TEST the system for normal operation.
G2 CHECK GROUND CIRCUIT FOR AN OPEN
Measure the resistance between control module C1041,
circuit 530 (LG/Y) and ground.
•
Is the resistance less than 5 ohms?
Yes
GO to G3.
No
REPAIR the circuit. TEST the system for normal operation.
G3 CHECK BATTERY CIRCUIT FOR OPEN
Measure the voltage between control module C1041, circuit
532 (O/Y) and ground.
•
Is the voltage greater than 10 volts?
Yes
REPLACE the control module.
No
REPAIR the circuit. TEST the system for normal operation.
PINPOINT TEST H: DTC B1485 — BRAKE PEDAL POSITION (BPP) SWITCH
CIRCUIT MALFUNCTION
CONDITIONS
DETAILS/RESULTS/ACTIONS
H1 CHECK POWER FEED TO BPP SWITCH
Brake Pedal Position
Switch C279
Measure the voltage between connector terminal 3, circuit 22
(LB/BK) and ground.
•
Is the voltage greater than 10 volts?
Yes
GO to H2.
No
REPAIR open in circuit 22 (LB/BK). CLEAR DTCs. TEST the
system for normal operation.
H2 CHECK BPP SWITCH CONTINUITY — BRAKE NOT APPLIED
Measure the resistance across BPP switch terminal 1, circuit 676
(PK/OG) and terminal 2, circuit 810 (RD/LG).
•
Is the resistance less than 5 ohms?
Yes
GO to H3.
No
REPLACE the BPP switch. REFER to Section 417-01. TEST the
system for normal operation.
H3 CHECK BPP SWITCH CONTINUITY — BRAKE APPLIED
Press the brake pedal and hold.
Measure the resistance across BPP switch terminal 2, circuit 810
(RD/LG) and terminal 3, circuit 22 (LB/BK).
•
Is the resistance less than 5 ohms?
Yes
GO to H4.
No
REPLACE the BPP switch. REFER to Section 417-01. TEST the
system for normal operation.
H4 CHECK CONTINUITY OF CIRCUIT 810 (RD/LG)
Anti-Lock Brake
Control Module C104a
Measure the resistance between BPP switch connector terminal
3 and module connector terminal 15, circuit 810 (RD/LG).
•
Is the resistance less than 5 ohms?
Yes
GO to H5.
No
REPAIR the open in circuit 810 (RD/LG). TEST the system for
normal operation.
H5 CHECK CIRCUIT 810 (RD/LG) FOR A SHORT TO BATTERY
Measure the voltage between BPP switch connector terminal 2,
circuit 810 (RD/LG) and ground.
•
Is the voltage greater than 10 volts?
Yes
REPAIR the short to ground on circuit 810 (RD/LG).
No
REPLACE the anti-lock brake control module. REFER to Module—
Anti-Lock Brake Control in this section. TEST the system for
normal operation.
Component Test — Intermittent Failures
Power/Ground to Anti-Lock Brake Control Module
If the fuse had failed:
•
•
•
•
•
Check the weather packing of the power connector to the anti-lock brake control module
C1041.
Remove power distribution box fuse 14 (60A).
Measure the resistance between the outside pin of power distribution box fuse 14 (60A),
circuit 532 (O/Y), and ground.
Spray with water and wiggle the wiring between the power distribution box and the antilock brake control module.
If any continuity is measured, repair/replace the wiring.
Check for opens in wiring:
•
•
•
•
•
Disconnect the anti-lock brake control module C1041.
While measuring the voltage between anti-lock brake control module C1041-2, circuit
532 (O/Y), and negative battery post, wiggle the wiring harness.
If the voltage momentary drops below 10 volts, while the harness is wiggled, repair or
replace the wiring.
While measuring the resistance between the anti-lock brake control module C1041-1,
circuit 530 (LG/Y), and ground, wiggle the wiring harness.
If the resistance momentarily goes above 5 ohms, while the harness is wiggled, repair or
replace the wiring.
Indicator Failure
Does not illuminate (prove out):
•
•
•
Connect EEC-IV 60-Pin Breakout Box to the EHCU with ABS Adapter Cable.
Connect EEC-IV 60-Pin Breakout Box pin 1 (yellow indicator) to the B+ pin.
Wiggle the wire harness at the several points between the anti-lock brake control module
and the instrument cluster.
•
Repair/replace the wire harness at the location that the indicator flickered off for an open
circuit.
Does illuminate (proves out):
•
•
Wiggle the wire harness at the several points between the anti-lock brake control module
and the instrument cluster.
Repair/replace the wire harness at the location that the indicator flickered on for a short to
ground.
Sensor Failure
•
Connect EEC-IV 60-Pin Breakout Box to the EHCU with ABS Adapter Cable.
•
Disconnect the rear anti-lock brake sensor.
•
Check the harness for short to ground.
• NOTE: Use 88 Digital Multimeter with the minimum resistance hold feature
enabled for this test.
Monitor the resistance between EEC-IV 60-Pin Breakout Box pins and ground as
follows:
•
Sensor
Breakout Box Pins
Circuits
Rear anti-lock brake sensor
9 and 21
523 (R/PK) and 519 (LG/BK)
•
Drive over rough roads at various speeds.
•
If there is continuity between either circuit and ground, repair the circuit for a
short to ground.
Check harness for open circuit.
• NOTE: Connect jumper securely to the rear sensor connector.
Connect a jumper between the two pins on the rear sensor connector.
•
NOTE: Use 88 Digital Multimeter with the maximum resistance hold feature
enabled for this test.
Monitor the resistance between EEC-IV 60-Pin Breakout Box pins as follows:
Sensor
Breakout Box Pins
Circuits
Rear anti-lock brake sensor
9 and 21
523 (R/PK) and 519 (LG/BK)
•
•
Drive over rough roads at various speeds.
•
If there is open circuit detected between pins, repair the circuit(s) for an open
circuit.
Check suspect sensor electrical connector.
• NOTE: Use 88 Digital Multimeter with the maximum resistance hold feature
enabled for this test.
Monitor the resistance between suspect anti-lock brake sensor terminals while
wiggling the electrical connector:
Sensor
Resistance
Rear
4x2 or 4x4 2,500 ohms
•
If the resistance is above specifications, replace the anti-lock brake sensor.
•
NOTE: Use 88 Digital Multimeter with the minimum resistance hold feature
enabled for this test.
Monitor the resistance between rear anti-lock brake sensor terminals while
wiggling the electrical connector:
Sensor
Resistance
Rear
4x2 or 4x4 800 ohms
•
If the resistance is below specifications, replace the rear anti-lock brake sensor.
•
NOTE: Use 88 Digital Multimeter with the minimum resistance hold feature
enabled for this test.
Monitor the resistance between an anti-lock brake sensor terminal and ground on
the highest resistance scale of the meter, while wiggling the electrical connector.
•
If the meter shows anything but open circuit, replace the rear anti-lock brake
sensor.
SECTION 206-09A: Anti-Lock Control —
Rear
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Hydraulic Control Unit—Electronic (EHCU)
Removal
CAUTION: Prior to removal of module, it is necessary to upload module
configuration information to the scan tool. This information needs to be downloaded into
the new module once installed. For additional information, refer to Section 418-01.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed
to these charges, damage may result.
On diesel equipped vehicles, remove the battery tray. For additional information, refer to
Section 414-01.
On gas equipped vehicles, disconnect the battery tray ground cable.
On gas equipped vehicles, remove the engine air cleaner assembly. For additional
information, refer to Section 303-12.
On gas equipped vehicles, remove the EVAP canister. For additional information, refer to
Section 303-13.
Remove the brackets.
Remove rubber dust cover.
Remove pushpin.
Disconnect the anti-lock brake control module electrical connectors.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact
with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush
eyes with running water for 15 minutes. Get medical attention if irritation persists.
If taken internally, drink water and induce vomiting. Get medical attention
immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake
fluid is spilled onto a painted or plastic surface, immediately wash it with water.
NOTE: Plug each port to prevent brake fluid from spilling.
Disconnect the hydraulic brake lines.
Remove the electronic hydraulic control unit (EHCU).
Remove the EHCU bracket
Remove the EHCU.
Installation
CAUTION: Once the new module is installed, it is necessary to download the module
configuration information from the scan tool into the new module. For additional
information, refer to Section 418-01.
NOTE: When the battery (10655) is disconnected and reconnected, some abnormal drive
symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may
need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Bleed the HCU. For additional information, refer to Section 206-00.
SECTION 206-09A: Anti-Lock Control —
Rear
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Module—Anti-Lock Brake Control
Removal
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed
to these charges, damage may result.
On diesel equipped vehicles, remove the battery tray; refer to Section 414-01.
On gas equipped vehicles, disconnect the battery ground cable.
On gas equipped vehicles, remove the engine air cleaner; refer to Section 303-12.
On gas equipped vehicles, remove the EVAP canister; refer to Section 303-13.
Remove rubber dust cover.
Remove pushpin.
Disconnect the three anti-lock brake control module electrical connectors.
Remove the anti-lock brake control module.
Remove the screw.
Lift and remove the anti-lock brake control module.
Installation
NOTE: When the battery (10655) is disconnected and reconnected, some abnormal drive
symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may
need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
SECTION 206-09A: Anti-Lock Control —
Rear
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Sensor—Rear
Removal
Disconnect the battery ground cable.
Raise and support the vehicle; refer to Section 100-02.
CAUTION: Clean off dirt and debris that may have collected around the rear
brake anti-lock sensor before removal to prevent fluid contamination.
Remove the rear brake anti-lock sensor (2C190).
Disconnect the electrical connector.
Remove the bolt.
Remove the rear brake anti-lock sensor.
Installation
CAUTION: Use care not to get dirt in the rear axle housing (4010).
Clean and inspect the rear brake anti-lock sensor.
Clean the axle mounting surface.
Inspect and clean the magnetized rear brake anti-lock sensor pole piece.
Inspect the rear anti-lock brake control O-ring (2M060) for damage. Replace if
necessary.
Lightly lubricate the rear anti-lock brake control O-ring with SAE 75W-140 High
Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford
specification WSL-M2C192-A.
Install the rear brake anti-lock sensor.
NOTE: Do not apply force to the plastic rear brake anti-lock sensor connector.
Position the rear brake anti-lock sensor and install the rear brake anti-lock sensor
bolt.
Connect the electrical connector.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms
may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be
driven 16 km (10 mi) or more to relearn the strategy.
Connect the battery ground cable.
SECTION 206-09A: Anti-Lock Control —
Rear
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Sensor Indicator—Rear
Removal and Installation
NOTE: The rear anti-lock brake sensor indicator is attached to the differential case. It is
necessary to remove the ring gear in order to remove the rear anti-lock sensor indicator.
Refer to the appropriate section in Group 205 for the procedure.
SECTION 206-09A: Anti-Lock Control —
1999 F-Super Duty 250-550 Workshop
Rear
REMOVAL AND INSTALLATION
Manual
Procedure revision date: 01/26/2000
Switch—Pressure
Removal and Installation
For additional information, refer to Section 206-06.
SECTION 206-09A: Anti-Lock Control —
Rear
REMOVAL AND INSTALLATION
Switch—Brake Pedal Position
Removal and Installation
For additional information, refer to Section 417-01.
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
SECTION 206-09B:
Anti-Lock Control — 4-Wheel
SPECIFICATIONS
DESCRIPTION AND OPERATION
Anti-Lock Control
DIAGNOSIS AND TESTING
Anti-Lock Control
Inspection and Verification
Anti-Lock Brake Control Module Parameter Identification (PID) Index
Anti-Lock Brake Control Module Active Command Index
Anti-Lock Brake Control Module Diagnostic Trouble Code (DTC) Index
Symptom Chart
Pinpoint Tests
Component Test — Intermittent Failures
REMOVAL AND INSTALLATION
Hydraulic Control Unit—Electronic (EHCU)
Module—Anti-Lock Brake Control
Sensor—Rear
Sensor—Front, 4x2
Sensor—Front, 4x4
Sensor Indicator—Front, 4x2
Sensor Indicator—Front, 4x4
Sensor Indicator—Rear
Switch—Pressure
Switch—Brake Pedal Position
SECTION 206-09B: Anti-Lock Control — 4Wheel
SPECIFICATIONS
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
General Specifications
Item
Specification
SAE 75W-140 High Performance Rear Axle Lubricant WSL-M2C192-A
F1TZ-19580-B
Torque Specifications
Description
Anti-Lock Brake Control Module Screws
Nm
4-5
lb-ft lb-in
—
33-46
Electronic Hydraulic Control Unit (EHCU) Bracket Bolts to Frame 26-34 19-25
—
Front Anti-Lock Brake Sensor Bolt
15-20 11-14
—
Front Anti-Lock Brake Sensor Bolt (Motorhome)
11-13 8-10
—
Front Anti-Lock Brake Sensor Wire Harness Bolt
7-9
—
63-80
Front Disc Brake Caliper Bleeder Screw
17-24 13-17
—
1/2-20 and 9/16-18 Hydraulic Brake Line
22-28 16-21
—
7/16-24 Hydraulic Brake Line
15-20 12-14
—
Rear Anti-Lock Brake Sensor Bolt
34-40 25-29
—
Wheel Cylinder Bleeder Screw
7-9
—
63-80
SECTION 206-09B: Anti-Lock Control — 4Wheel
DESCRIPTION AND OPERATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Anti-Lock Control
Anti-Lock Control Component Location
Item
1
Part
Number
2C219
Description
Electronic Hydraulic Control Unit (EHCU)
(Includes 2C065)
2
2C065
Anti-Lock Brake Control Module
3
—
Yellow ABS Warning Indicator
4
2C190
Rear Anti-Lock Brake Sensor
5
2C189
Rear Anti-Lock Brake Sensor Indicator
6
2C182
Front Anti-Lock Brake Sensor Indicator
7
2C204
Front Anti-Lock Brake Sensor
The anti-lock brake control module can be replaced if it is inoperative. If the hydraulic control
unit (HCU) is inoperative, the EHCU must be replaced as an assembly.
The 4-wheel anti-lock brake system (4WABS) prevents wheel lockup by automatically
modulating the brake pressure during an emergency stop. By not locking the wheels, the driver
can improve steering control during hard braking and stop the vehicle in the shortest possible
distance under most conditions.
The 4WABS controls both front and rear brakes separately. The brake pedal force required to
engage the 4WABS function may vary with the road surface condition. A dry surface requires
greater force than a slippery surface.
During the 4WABS operation, the driver may feel a pulsation in the brake pedal (2455),
accompanied by a slight up and down movement in the pedal height. In addition, a mechanical
noise from the engine compartment may be heard. The pedal effort and pedal feel during normal
braking are similar to that of a conventional power brake system.
When the brakes are applied, brake fluid is forced from the brake master cylinder outlet ports to
the HCU inlet ports. The fluid pressure is transmitted through three normally open solenoid
valves inside the HCU, through the outlet ports of the HCU to the brakes. One circuit of the
brake master cylinder (2140) feeds the front brakes while the other circuit feeds the rear brakes.
If the anti-lock brake control module senses that a wheel (1007) is about to lock, based on wheel
speed sensor data, the solenoid valve will pulse closed, preventing more fluid from entering that
circuit. The anti-lock brake control module then reads the sensor signal from the affected wheel
again. If the wheel is still decelerating, the normally closed solenoid valve for that circuit is
opened. A controlled amount of hydraulic pressure between the normally open valve and the
brake is relieved into the HCU accumulator. Once the affected wheel returns to vehicle speed,
the anti-lock brake control module returns the solenoid valves to their normal condition, allowing
fluid flow to the affected brake.
The anti-lock brake control module monitors the electromechanical components of the system.
Malfunction of the anti-lock brake system will cause the anti-lock brake control module to shut
off or inhibit the system. However, normal power-assisted braking remains. Malfunctions are
indicated by the yellow ABS warning indicator in the instrument cluster (10849).
The 4WABS system is self-monitoring. When the ignition switch is placed in the RUN position,
the anti-lock brake control module performs a preliminary self-check on the anti-lock electrical
system indicated by a three-second illumination of the yellow ABS warning indicator in the
instrument cluster.
A self-test of the solenoid valve coils and the pump motor is performed when the vehicle is
started. During starting, the brake pedal must be released to run the self-test. If the brake pedal is
depressed or a failed brake switch occurs, the self-test is run at 6 km/h (4 mph) regardless of
brake pedal position.
SECTION 206-09B: Anti-Lock Control — 4Wheel
DIAGNOSIS AND TESTING
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 03/05/2003
Anti-Lock Control
Refer to Wiring Diagrams Cell 42 (F-53 Motorhome Chassis, F-Super Duty 250-550), Anti-Lock
Brake System (ABS) for schematic and connector information.
Special Tool(s)
73 Digital Multimeter
105-R0051 or equivalent
88 Digital Multimeter
105-R0053 or equivalent
ABS Adapter Cable
418-F038 (007-00108) or
equivalent
EEC-IV 60-Pin Breakout Box
418-005 (014-00322) or
equivalent
Worldwide Diagnostic System
(WDS)
418-F224,
New Generation STAR (NGS)
Tester
418-F052, or equivalent
diagnostic tool with
appropriate adapter cable
Inspection and Verification
Anti-Lock Quick Check Sheet Using EEC-IV 60-Pin Breakout Box
Ignition
Mode
Measure
Between Pin
Numbers
Tester
Scale/Range
Specification
Ignition Feed
OFF
14 and Chassis
DC Volts
0V
Ignition Feed
ON
14 and Chassis
DC Volts
10 V min
LF Anti-Lock Brake
Sensor Resistance (4x2
F250/350)
RF Anti-Lock Brake
Sensor Resistance (4x2
F250/350)
OFF
23 and 11
kohms
2,000-4,000
kohms
OFF
10 and 22
kohms
2,000-4,000
kohms
OFF
Resistance
23 and 11
ohms
650-800 ohms
OFF
10 and 22
ohms
650-800 ohms
OFF
9 and 21
ohms
800-1,400
ohms
Item to Be Tested
LF Anti-Lock Brake
Sensor (4x4 F250/550
and 4x2 F450/550)
RF Anti-Lock Brake
Sensor (4x4 F250/550
and 4x2 F450/550)
Rear Anti-Lock Brake
Sensor
Anti-Lock Brake Sensor Voltage: Rotate wheel @ one revolution per second
LF
OFF
23 and 11
AC mVolts 120-3,500 mV
RF
OFF
10 and 22
AC mVolts
120-3,500 mV
Rear (Both at same
time and direction)
OFF
9 and 21
AC mVolts
120-3,500 mV
Pinpoint
Test
Go To
Pinpoint
Test N.
Go To
Pinpoint
Test N.
Go To
Pinpoint
Test C.
Go To
Pinpoint
Test B.
Go To
Pinpoint
Test C.
Go To
Pinpoint
Test B.
Go To
Pinpoint
Test D.
Go To
Pinpoint
Test F.
Go To
Pinpoint
Test G.
Go To
Pinpoint
Test H.
Verify the customer concern by operating the vehicle and applying the brakes under different
conditions to duplicate the condition.
Inspect to determine if one of the following mechanical or electrical concerns apply:
Visual Inspection Chart
Mechanical
Electrical
Parking brake cable binding
Damaged Fuse(s)
Improperly inflated tires
Damaged connectors or connections
Mismatched wheels or tires on
vehicle
Circuitry open/shorted
Shorting cap in evac and fill connector loose or
missing
If the inspection reveals an obvious concern(s) that can be readily identified, repair as
required.
If the concern remains after the inspection, connect the diagnostic tool to the data link
connector (DLC) located beneath the instrument panel and select the vehicle to be tested
from the diagnostic tool menu. If the diagnostic tool does not communicate with the
vehicle:
check that the program card is properly installed.
check the connections to the vehicle.
check the ignition switch position.
If the diagnostic tool still does not communicate with the vehicle, refer to the diagnostic tool
manual.
Perform the DATA LINK DIAGNOSTIC TEST. If the diagnostic tool responds with:
CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to Section
418-00.
NO RESP/NOT EQUIP for anti-lock brake control module, Go To Pinpoint Test L.
SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes
(DTCs), erase the continuous DTCs, and perform self-test diagnostics for the antilock brake control module.
If the DTCs retrieved are related to the concern, go to Anti-Lock Brake Control Module
Diagnostic Trouble Code (DTC) Index to continue diagnostics.
If no DTCs related to the concern are retrieved, go to Symptom Chart to continue
diagnostics.
Anti-Lock Brake Control Module Parameter Identification (PID) Index
Anti-Lock Brake Control Module Parameter Identification (PID) Index
PID
Description
Expected Values
4WDABS
4 Wheel Drive Input Switch
2WD-4WD
ABSLAMP
ABS Warning Lamp State
ON, OFF
ABSLF_I
Left Front ABS Inlet Valve
ON, OFF
ABSLF_O
Left Front ABS Outlet Valve
ON, OFF
ABSR_I
Rear ABS Inlet Valve
ON, OFF
ABSR_O
Rear ABS Outlet Valve
ON, OFF
ABSRF_I
Right Front ABS Inlet Valve
ON, OFF
ABSRF_O
Right Front ABS Outlet Valve
ON, OFF
BOO_ABS
Brake Switch Input
ON, OFF
BRKLAMP
Brake Warning Lamp State
ON, OFF
CCNTABS
Continuous DTCs in ABS Module
# of DTCs
LF_WSPD
Left Front Wheel Speed Sensor
0-255 km/h
R_WSPD
Rear Wheel Speed Sensor
0-255 km/h
RF_WSPD
Right Front Wheel Speed Sensor
0-255 km/h
PWR_RLY
Power Relay Feedback Input
ON, OFF
Anti-Lock Brake Control Module Active Command Index
Anti-Lock Brake Control Module Active Command Index
Active Command
Display
Action
ABS Output Control
ABS POWER
ON, OFF
PMP MOTOR
ON, OFF
LF INLET
ON, OFF
LF OUTLET
ON, OFF
RF INLET
ON, OFF
RF OUTLET
ON, OFF
R INLET
ON, OFF
R OUTLET
ON, OFF
BRKWARN
ON, OFF
Anti-Lock Brake Control Module Diagnostic Trouble Code (DTC) Index
Anti-Lock Brake Control Module Diagnostic Trouble Code (DTC) Index
DTCS
Description
B1342
Anti-Lock Brake Control
Module Failure
B2141/B2477 NV Memory Configuration
Failure
DTC
Caused
By
Action
ABS
REPLACE anti-lock brake control
module. REFER to Module—AntiLock Brake Control.
ABS
Using the diagnostic tool, PROGRAM
anti-lock brake control module.
REFER to Section 418-01.
C1226
Brake Lamp Warning Output
Short to Ground
ABS
REFER to Section 413-01.
C1194/C1196
Dump Valve, Front Left
ABS
GO to Pinpoint Test A.
C1198/C1200 Isolation Valve, Front Left
ABS
GO to Pinpoint Test A.
C1202/C1204
Dump Valve, Rear
ABS
GO to Pinpoint Test A.
C1206/C1208
Isolation Valve, Rear
ABS
GO to Pinpoint Test A.
C1210/C1212
Dump Valve, Front Right
ABS
GO to Pinpoint Test A.
ABS
GO to Pinpoint Test A.
Front Left Anti-Lock Brake
Sensor (Electrical/Static)
ABS
GO to Pinpoint Test B.
C1158/C1233 Front Left Anti-Lock Brake
Sensor (Dynamic)
ABS
GO to Pinpoint Test C.
Front Right Anti-Lock Brake
Sensor (Electrical/Static)
ABS
GO to Pinpoint Test D.
C1148/C1234 Front Right Anti-Lock Brake
Sensor (Dynamic)
ABS
GO to Pinpoint Test E.
C1214/C1216 Isolation Valve, Front Right
C1155
C1145
C1230
Rear Anti-Lock Brake
Sensor (Electrical/Static)
ABS
GO to Pinpoint Test F.
C1229/C1237
Rear Anti-Lock Brake
Sensor (Dynamic)
ABS
GO to Pinpoint Test G.
C1095/C1096
Pump Motor
ABS
GO to Pinpoint Test J.
C1115
Shorted Internal Power Relay
ABS
GO to Pinpoint Test K.
C1185
Open Internal Power Relay
ABS
GO to Pinpoint Test K.
C1169
Excessive Dump Time
ABS
GO to Pinpoint Test M.
C1184
ABS System Timeout
ABS
GO to Pinpoint Test N.
C1222
Wheel Speed Error
(Dynamic)
ABS
GO to Pinpoint Test N.
B1485
Brake Pedal Position (BPP)
Switch Circuit Malfunction
ABS
GO to Pinpoint Test P.
Symptom Chart
Failure of a mechanical brake component may not cause the yellow ABS warning indicator to
illuminate or a DTC to be stored. The Symptom Chart is a starting point to begin diagnosis of
these concerns.
Symptom Chart
Condition
Possible Sources
Action
ABS Misfire,
ABS Too
Sensitive,
ABS Fires
On Normal
Stop
Rear anti-lock
brake sensor
indicator is
damaged.
REMOVE rear sensor from the
differential housing; INSPECT
rear anti-lock brake sensor.
Front anti-lock
brake sensor
indicator is
damaged.
INSPECT for damaged teeth.
INSPECT both front anti-lock
brake sensor indicators.
Sensor output is out
of sync.
If left front sensor output is out of
sync, GO to Pinpoint Test C. If
right front sensor output is out
of sync, GO to Pinpoint Test E.
If rear sensor output is out of
sync, GO to Pinpoint Test G.
Intermittent open or
shorted sensor
circuit.
GO to Intermittent Failures to test
circuits 514 (Y/R), 516 (Y/BK),
523 (R/PK), and 519 (LG/BK).
Chafed wire
insulation or
pinched wire
due to improper
routing causing
intermittent
INSPECT wiring harness from
front sensor knuckle to the
frame and from the rear axle to
the frame for worn or chafed
wire insulation.
short.
Parking brake
adjustment too
tight.
ELIMINATE base brake system as
cause of problem.
Brake linings are
grabby.
Wheels Lock Up
Loose sensor(s).
TIGHTEN sensor bolt to
specifications. REFER to
Specifications.
Hydraulic outlet
(dump) valve.
GO to Pinpoint Test K.
Leaky inlet
(isolation) valve
during ABS
(soft).
ELIMINATE base brake system as
cause of problem. REFER to
Section 206-00.
Damp or
contaminated
rear brake
linings, or
stuck/leaking
rear disc brake
caliper.
Binding parking
brake.
Leaking rear axle
seal.
Hard or Soft
Brake Pedal
Stuck inlet
(isolation) valve
(hard brake
pedal) or leaky
outlet (dump)
valve (soft
brake pedal).
GO to Pinpoint Test H.
Hydraulic leak in
brake line or
hose, fitting,
master cylinder,
or caliper (soft
brake pedal).
ELIMINATE base brake system as
cause of problem. REFER to
Section 206-00.
Air in brake system
(soft brake
pedal).
Little or no vacuum
boost (hard
brake pedal).
Stuck or inoperative
or caliper (hard
brake pedal).
Pinched or crimped
brake line or
hose (hard
brake pedal).
Lack of
Deceleration
During
Medium/Har
d Brake
Application
Stuck shut inlet
(isolation) valve
or leaky outlet
(dump) valve
(rear axle only).
GO to Pinpoint Test H.
Hydraulic leak in
brake line or
hose, fitting,
master cylinder,
or caliper.
ELIMINATE base brake system as
cause of problem. REFER to
Section 206-00.
Air in brake system.
Little or no vacuum
boost.
Stuck or inoperative
caliper.
Ineffective brake
linings.
Vehicle Pulls
During
Braking
Improperly adjusted
rear brake.
Frozen or binding
caliper (one side
of vehicle).
Uneven brake
ELIMINATE base brake system as
cause of problem. REFER to
Section 206-00.
lining wear.
Pinched or crimped
brake line or
hose.
Fully or partially
blocked front
inlet (isolation)
valve.
REPLACE the electronic hydraulic
control unit (EHCU). REFER to
Hydraulic Control Unit—
Electronic (EHCU).
Yellow ABS
Warning
Indicator On
With System
Pass
Yellow ABS
warning
indicator circuit.
CHECK circuit 603 (DG) for open
or short to B+. REPAIR circuit
603 (DG) if necessary. If OK,
REPLACE the anti-lock brake
control module. REFER to
Module—Anti-Lock Brake
Control. TEST the system for
normal operation.
Soft or Excessive
Pedal Travel
Electronic
Hydraulic
Control Unit
(EHCU).
GO to Pinpoint Test H.
No
Fuse(s).
GO to Pinpoint Test L.
Communicati
on With the
Anti-Lock
Brake
Control
Module
Anti-lock brake
control module.
Circuitry.
Module.
Pinpoint Tests
PINPOINT TEST A: DTCs C1194, C1196, C1198, C1200, C1202, C1204, C1206,
C1208, C1210, C1212, C1214, C1216 — ISOLATION VALVE, DUMP VALVE
CONDITIONS
A1 CHECK FOR FAULT REPEATABILITY
1.
Scan Tool
DETAILS/RESULTS/ACTIONS
2.
Clear DTCs
3.
3. Perform anti-lock control module OnDemand Self-Test.
4.
Retrieve DTCs
Is a single valve DTC set?
→ Yes
REPLACE the anti-lock brake control module
(2B373). REFER to Module—Anti-Lock Brake
Control.
→ No
If multiple valve DTCs are set, GO to A2 .
If no DTCs are set, TEST the system for
normal operation.
A2 CHECK EHCU 2-PIN POWER CIRCUIT 532 (O/Y)
CAUTION: A blown fuse may be an indication of some other wiring or component
concern within the circuit.
1.
2.
EHCU C1041 (Motorhome C130)
3.
3. Measure the voltage between EHCU C10412 (motorhome C130-2), circuit 532 (O/Y), and
ground.
Is the voltage greater than 10 volts?
→ Yes
REPLACE the anti-lock brake control module.
REFER to Module—Anti-Lock Brake Control.
TEST the system for normal operation.
→ No
RECONNECT EHCU C1041 (motorhome
C130). GO to A3 .
A3 CHECK POWER DISTRIBUTION BOX FUSE 14 (60A)
1.
Power Distribution Box Fuse 14 (60A)
(Motorhome Fuse F [60A])
Is the fuse OK?
→ Yes
REPAIR circuit 532 (O/Y). TEST the system
for normal operation.
→ No
REPLACE the fuse. TEST the system for
normal operation. If the fuse fails again,
CHECK for short to ground. REPAIR as
necessary. TEST the system for normal
operation.
PINPOINT TEST B: DTC C1155 — LEFT FRONT ANTI-LOCK BRAKE SENSOR
(ELECTRICAL/STATIC)
CONDITIONS
DETAILS/RESULTS/ACTIONS
B1 CHECK FOR FAULT REPEATABILITY
1.
Scan Tool
2.
Clear Continuous DTCs
3. Drive the vehicle at least 6 km/h (10 mph).
4.
4. Retrieve and document continuous DTCs.
Is DTC C1155 retrieved?
→ Yes
GO to B2.
→ No
If no DTC is retrieved, GO to B6 .
If a different DTC is retrieved, GO to AntiLock Brake Control Module Diagnostic
Trouble Code (DTC) Index.
B2 CHECK SENSOR COIL RESISTANCE AT EHCU CONNECTOR
1.
2. Install EEC-IV 60-Pin Breakout Box.
3.
3. Measure the resistance between EEC-IV 60Pin Breakout Box pin 11 and EEC-IV 60-Pin
Breakout Box pin 23.
Is the resistance between:
4x2 F250/350: 2,000-4,000 ohms
4x2 F450/550: 650-800 ohms
4x4 F250/550: 650-800 ohms?
→ Yes
GO to B4.
→ No
GO to B3.
B3 DETERMINE LOCATION OF FAULT
1.
Left Front Anti-Lock Brake Sensor C1064
(Motorhome C127)
2.
2. Measure the resistance between the two
terminals of the left front anti-lock brake sensor
C1064 (motorhome C127).
Is the resistance between:
4x2 F250/350: 2,000-4,000 ohms
4x2 F450/550: 650-800 ohms
4x4 F250/550: 650-800 ohms?
→ Yes
REPAIR circuit 522 (T/BK) and/or circuit 521
(T/O). TEST the system for normal operation.
→ No
REPLACE the left front anti-lock brake sensor.
REFER to Sensor—Front, 4x2 or Sensor—
Front, 4x4. TEST the system for normal
operation.
B4 CHECK LEFT FRONT ANTI-LOCK BRAKE SENSOR CIRCUIT FOR SHORT TO
GROUND
1.
1. Measure the resistance between EEC-IV 60Pin Breakout Box pin 11 and ground; and
between EEC-IV 60-Pin Breakout Box pin 23
and ground.
Are the resistances greater than 10,000
ohms?
→ Yes
REPLACE the anti-lock brake control module.
REFER to Module—Anti-Lock Brake Control.
TEST the system for normal operation.
→ No
GO to B5.
B5 CHECK FOR INTERNAL SENSOR SHORT
1.
Left Front Anti-Lock Brake Sensor C1046
(Motorhome C127)
2.
2. Measure the resistance between the left front
anti-lock brake sensor C1046 (motorhome
C127) terminals and ground.
Are the resistances greater than 10,000
ohms?
→ Yes
REPAIR circuit 522 (T/BK) and/or circuit 521
(T/O). TEST the system for normal operation.
→ No
REPLACE the left front anti-lock brake sensor.
REFER to Sensor—Front, 4x2 or Sensor—
Front, 4x4. TEST the system for normal
operation.
B6 TEST FOR INTERMITTENT SENSOR FAULT
1. Perform the Sensor Failure test for the left
front anti-lock brake sensor. Go to Component
Test — Intermittent Failures.
Did the left front anti-lock brake sensor
pass?
→ Yes
System is OK.
→ No
REPAIR as necessary. TEST the system for
normal operation.
PINPOINT TEST C: DTCs C1158, C1233 — LEFT FRONT ANTI-LOCK BRAKE
SENSOR (DYNAMIC)
CONDITIONS
DETAILS/RESULTS/ACTIONS
C1 RETRIEVE DTCs
1.
Scan Tool
2.
2. Retrieve and document continuous DTCs.
Is DTC C1155 retrieved?
→ Yes
DIAGNOSE DTC C1155 first. IGNORE all
other DTCs retrieved.
→ No
GO to C2.
C2 REPEATABILITY DRIVE TEST (MISMATCHED OUTPUT)
NOTE: If a hard turn is made, some variation between all three sensors is expected.
NOTE: Recording the speeds for later plotting will eliminate the necessity of monitoring the
diagnostic tool while driving.
1.
1. Monitor anti-lock brake control module PIDs
LF_WSPD, RF_WSPD, and R_WSPD.
2. Drive the vehicle at various speeds.
Does the left front anti-lock brake sensor
consistently match the other two?
→ Yes
GO to C7.
→ No
GO to C3.
C3 CHECK LEFT FRONT ANTI-LOCK BRAKE SENSOR INDICATOR
1. Raise the vehicle on a hoist.
2.
CAUTION: Examine the anti-lock
brake sensor indicator carefully. Failure to
properly diagnose sensor indicator at this
time will lead to unnecessary component
replacement and wasted diagnostic time.
Inspect the anti-lock brake sensor
indicator for damaged or missing teeth.
Rotate the anti-lock brake indicator to be
sure all teeth are checked.
Is the anti-lock brake sensor indicator
damaged or missing?
→ Yes
REPLACE the anti-lock brake sensor indicator.
REFER to Sensor Indicator—Front, 4x2 or
Sensor Indicator—Front, 4x4. TEST the system
for normal operation.
→ No
GO to C4.
C4 CHECK FOR LOOSE ANTI-LOCK BRAKE SENSOR MOUNTING
1. Wiggle the anti-lock brake sensor at wheel
end.
Is any looseness detected?
→ Yes
TIGHTEN anti-lock brake sensor bolt to
specification. TEST the system for normal
operation.
→ No
GO to C5.
C5 CHECK FOR INTERNAL ANTI-LOCK BRAKE SENSOR SHORT TO GROUND
1.
2.
Left Front Anti-Lock Brake Sensor C1064
(Motorhome C127)
3.
3. Measure the resistance between the left front
anti-lock brake sensor C1064 (motorhome
C127) terminals and ground.
Is the resistance greater than 10,000
ohms?
→ Yes
GO to C6.
→ No
REPLACE the anti-lock brake sensor. REFER
to Sensor—Front, 4x2 or Sensor—Front, 4x4.
TEST the system for normal operation.
C6 CHECK CIRCUIT 521 (T/O) AND CIRCUIT 522 (T/BK)
1. Install EEC-IV 60-Pin Breakout Box.
2.
2. Measure the resistance between EEC-IV 60Pin Breakout Box pin 11 and EEC-IV 60-Pin
Breakout Box pin 23.
Is the resistance less than 10,000 ohms?
→ Yes
REPAIR circuit 521 (T/O) and circuit 522
(T/BK). TEST the system for normal operation.
→ No
GO to C8.
C7 CHECK FOR INTERMITTENT WIRING CONCERN
1.
2. Perform the Sensor Failure test for the left
front anti-lock brake sensor; go to Component
Test — Intermittent Failures.
Did the left front anti-lock brake sensor
pass?
→ Yes
System is OK.
→ No
REPAIR as necessary. TEST the system for
normal operation.
C8 INSPECT THE LEFT FRONT ANTI-LOCK BRAKE SENSOR FOR DAMAGE
1. Remove the left front anti-lock brake sensor;
refer to Sensor—Front, 4x2 or Sensor—Front,
4x4.
2. Inspect the housing for stress cracks or
breaks.
3. Inspect the left front anti-lock brake sensor
C1064 (motorhome C127) cavity for evidence
of water entry, pin corrosion, or excessive
debris.
Are any of the above conditions evident?
→ Yes
REPAIR as necessary. TEST the system for
normal operation.
→ No
REPLACE the anti-lock brake control module.
REFER to Module—Anti-Lock Brake Control.
TEST the system for normal operation.
PINPOINT TEST D: DTC C1145 — RIGHT FRONT ANTI-LOCK BRAKE SENSOR
(ELECTRICAL/STATIC)
CONDITIONS
DETAILS/RESULTS/ACTIONS
D1 CHECK FOR FAULT REPEATABILITY
1.
Scan Tool
2.
Clear Continuous DTCs
3. Drive the vehicle at least 6 km/h (10 mph).
4.
4. Retrieve and document continuous DTCs.
Is DTC C1145 retrieved?
→ Yes
GO to D2.
→ No
If no DTC is retrieved, GO to D6 .
If a different DTC is retrieved, GO to AntiLock Brake Control Module Diagnostic
Trouble Code (DTC) Index.
D2 CHECK ANTI-LOCK BRAKE SENSOR COIL RESISTANCE AT EHCU
CONNECTOR
1.
2. Install EEC-IV 60-Pin Breakout Box.
3.
3. Measure the resistance between EEC-IV 60Pin Breakout Box pin 10 and EEC-IV 60-Pin
Breakout Box pin 22.
Is the resistance between:
4x2 F250/350: 2,000-4,000 ohms
4x2 F450/550: 650-800 ohms
4x4 F250/550: 650-800 ohms?
→ Yes
GO to D4.
→ No
GO to D3.
D3 DETERMINE LOCATION OF FAULT
1.
Right Front Anti-Lock Brake Sensor C1066
(Motorhome C154)
2.
2. Measure the resistance between the two
terminals of the right front anti-lock brake
sensor C1066 (motorhome C154).
Is the resistance between:
4x2 F250/350: 2,000-4,000 ohms
4x2 F450/550: 650-800 ohms
4x4 F250/550: 650-800 ohms?
→ Yes
REPAIR circuit 514 (Y/R) and circuit 516
(Y/BK).
→ No
REPLACE the right front anti-lock brake
sensor. REFER to Sensor—Front, 4x2 or
Sensor—Front, 4x4.
D4 CHECK RIGHT FRONT ANTI-LOCK BRAKE SENSOR CIRCUIT FOR SHORT TO
GROUND
1.
1. Measure the resistance between EEC-IV 60Pin Breakout Box pin 10 and ground; and
between EEC-IV 60-Pin Breakout Box pin 22
and ground.
Is the resistance greater than 10,000
ohms?
→ Yes
GO to D6.
→ No
GO to D5.
D5 CHECK FOR INTERNAL SENSOR SHORT
1.
Right Front Anti-Lock Brake Sensor C1066
(Motorhome C154)
2.
2. Measure the resistance between the right
front anti-lock brake sensor C1066 (motorhome
C154) terminals and ground.
Is the resistance greater than 10,000
ohms?
→ Yes
REPAIR circuit 514 (Y/R) and/or circuit 516
(Y/BK). TEST the system for normal
operation.
→ No
REPLACE the right front anti-lock brake
sensor. REFER to Sensor—Front, 4x2 or
Sensor—Front, 4x4. TEST the system for
normal operation.
D6 TEST FOR INTERMITTENT ANTI-LOCK BRAKE SENSOR FAULT
1. Perform the Sensor Failure test for the right
front anti-lock brake sensor. Go to Component
Test — Intermittent Failures.
Did the right front anti-lock brake sensor
pass?
→ Yes
System is OK.
→ No
REPAIR as necessary. TEST the system for
normal operation.
PINPOINT TEST E: DTCs C1148, C1234 — RIGHT FRONT ANTI-LOCK BRAKE
SENSOR (DYNAMIC)
CONDITIONS
DETAILS/RESULTS/ACTIONS
E1 RETRIEVE DTCS
1.
Scan Tool
2.
2. Retrieve and document continuous DTCs.
Is DTC C1145 retrieved?
→ Yes
DIAGNOSE DTC C1145 first. IGNORE all
other DTCs retrieved.
→ No
GO to E2.
E2 REPEATABILITY DRIVE TEST (MISMATCHED OUTPUT)
NOTE: If a hard turn is made, some variation between all three anti-lock brake sensors is
expected.
NOTE: Recording the speeds for later plotting will eliminate the necessity of monitoring the
diagnostic tool while driving.
1.
1. Monitor anti-lock brake control module PIDs
LF_WSPD, RF_WSPD, and R_WSPD.
2. Drive the vehicle at various speeds.
Does the right front anti-lock brake
sensor consistently match the other
two?
→ Yes
GO to E7.
→ No
GO to E3.
E3 CHECK RIGHT FRONT ANTI-LOCK BRAKE SENSOR INDICATOR
1. Raise the vehicle on a hoist.
2.
CAUTION: Examine the anti-lock
brake sensor indicator carefully. Failure to
properly diagnose anti-lock brake sensor
indicator at this time will lead to unnecessary
component replacement and wasted
diagnostic time.
Inspect the anti-lock brake sensor
indicator for damaged or missing teeth.
Rotate the anti-lock brake sensor
indicator to be sure all teeth are checked.
Is the anti-lock brake sensor indicator
damaged or missing teeth?
→ Yes
REPLACE the anti-lock brake sensor indicator.
REFER to Sensor Indicator—Front, 4x2 or
Sensor Indicator—Front, 4x4. TEST the system
for normal operation.
→ No
GO to E4.
E4 CHECK FOR LOOSE ANTI-LOCK BRAKE SENSOR MOUNTING
1. Wiggle the anti-lock brake sensor at wheel
end.
Is any looseness detected?
→ Yes
TIGHTEN anti-lock brake sensor bolt to
specifications. TEST the system for normal
operation.
→ No
GO to E5.
E5 CHECK FOR INTERNAL ANTI-LOCK BRAKE SENSOR SHORT
1.
2.
Right Front Anti-Lock Brake Sensor
C1066 (Motorhome C154)
3.
3. Measure the resistance between the right
front anti-lock brake sensor C1066 (motorhome
C154) terminals and ground.
Is the resistance greater than 10,000
ohms?
→ Yes
GO to E6.
→ No
REPLACE the sensor. REFER to Sensor—
Front, 4x2 or Sensor—Front, 4x4. TEST the
system for normal operation.
E6 CHECK CIRCUIT 514 (Y/R) AND CIRCUIT 516 (Y/BK)
1. Install EEC-IV 60-Pin Breakout Box.
2.
2. Measure the resistance between EEC-IV 60-
Pin Breakout Box pin 10 and pin 22.
Is the resistance less than 10,000 ohms?
→ Yes
REPAIR circuit 514 (Y/R) and circuit 516
(Y/BK). TEST the system for normal operation.
→ No
GO to E8.
E7 CHECK FOR INTERMITTENT WIRING CONCERN
1.
2. Perform the Sensor Failure test for the right
front anti-lock brake sensor; go to Component
Test — Intermittent Failures.
Did the right front anti-lock brake sensor
pass?
→ Yes
System is OK.
→ No
REPAIR as necessary. TEST the system for
normal operation.
E8 INSPECT THE RIGHT FRONT ANTI-LOCK BRAKE SENSOR FOR DAMAGE
1.
2. Remove the right front anti-lock brake
sensor. Refer to Sensor—Front, 4x2 or Sensor—
Front, 4x4.
3. Inspect the housing for stress cracks or
breaks.
4. Inspect the anti-lock brake sensor C1066
(motorhome C154) for evidence of water entry,
pin corrosion, or excessive debris.
Are any of the above conditions present?
→ Yes
REPAIR as necessary. TEST the system for
normal operation.
→ No
REPLACE the anti-lock brake control module;
REFER to Module—Anti-Lock Brake Control.
TEST the system for normal operation.
PINPOINT TEST F: DTC C1230 — REAR ANTI-LOCK BRAKE SENSOR
(ELECTRICAL/STATIC)
CONDITIONS
DETAILS/RESULTS/ACTIONS
F1 CHECK FOR FAULT REPEATABILITY
1.
Scan Tool
2.
Clear Continuous DTCs
3. Drive the vehicle at least 6 km/h (10 mph).
4.
4. Retrieve and document continuous DTCs.
Is DTC C1230 retrieved?
→ Yes
GO to F2.
→ No
If no DTC is retrieved, GO to F6 .
If a different DTC is retrieved. GO to Anti-Lock
Brake Control Module Diagnostic Trouble Code
(DTC) Index.
F2 CHECK ANTI-LOCK BRAKE SENSOR COIL RESISTANCE AT EHCU
CONNECTOR
1.
2. Install EEC-IV 60-Pin Breakout Box.
3.
3. Measure the resistance between EEC-IV 60Pin Breakout Box pin 9 and EEC-IV 60-Pin
Breakout Box pin 21.
Is the resistance between 800 and 3,500
ohms?
→ Yes
GO to F4.
→ No
GO to F3.
F3 DETERMINE LOCATION OF FAULT
1.
Rear Anti-Lock Brake Sensor C404
(Motorhome C302)
2.
2. Measure the resistance between the two
terminals of the rear anti-lock brake sensor
C404 (motorhome C302).
Is the resistance between 800 and 3,500
ohms?
→ Yes
REPAIR circuit 519 (LG/BK) and circuit 523
(R/PK). TEST the system for normal operation.
→ No
REPLACE the rear anti-lock brake sensor.
REFER to Sensor—Rear. TEST the system for
normal operation.
F4 CHECK REAR ANTI-LOCK BRAKE SENSOR CIRCUIT FOR SHORT TO GROUND
1.
1. Measure the resistance between EEC-IV 60Pin Breakout Box pin 9 and ground; and
between EEC-IV 60-Pin Breakout Box pin 21
and ground.
Are the resistances greater than 10,000
ohms?
→ Yes
REPLACE the anti-lock brake control module.
REFER to Module—Anti-Lock Brake Control.
TEST the system for normal operation.
→ No
GO to F5.
F5 CHECK FOR ANTI-LOCK BRAKE SENSOR SHORT
1.
Rear Anti-Lock Brake Sensor C404
(Motorhome C302)
2.
2. Measure the resistance between the rear antilock brake sensor C404 (motorhome C302)
terminals and ground.
Is the resistance greater than 10,000
ohms?
→ Yes
REPAIR circuit 519 (LG/BK) and circuit 523
(R/PK). TEST the system for normal operation.
→ No
REPLACE the rear anti-lock brake sensor.
Refer to Sensor—Rear. TEST the system for
normal operation.
F6 TEST FOR INTERMITTENT ANTI-LOCK BRAKE SENSOR FAULT
1. Perform the Sensor Failure test for the rear
anti-lock brake sensor. Refer to Component Test
— Intermittent Failures.
Did the rear anti-lock brake sensor pass?
→ Yes
System is OK.
→ No
REPLACE the rear anti-lock brake sensor.
REFER to Sensor—Rear. TEST the system for
normal operation.
PINPOINT TEST G: DTCs C1229, C1237 — REAR ANTI-LOCK BRAKE SENSOR
DIAGNOSIS (DYNAMIC)
CONDITIONS
DETAILS/RESULTS/ACTIONS
G1 RETRIEVE DTCs
1.
Scan Tool
2.
Retrieve Continuous DTCs
Is DTC C1230 retrieved?
→ Yes
DIAGNOSE DTC C1230 first. IGNORE all
other DTCs retrieved.
→ No
GO to G2.
G2 REPEATABILITY DRIVE TEST (MISMATCHED OUTPUT)
NOTE: If a hard turn is made, some variation between all three anti-lock brake sensors is
expected.
NOTE: Recording the speeds for later plotting will eliminate the necessity of monitoring the
diagnostic tool while driving.
1.
1. Monitor anti-lock brake control module PIDs
LF_WSPD, RF_WSPD, and R_WSPD.
2. Drive the vehicle at various speeds.
Does the rear anti-lock brake sensor
consistently match the other two?
→ Yes
GO to G7.
→ No
GO to G3.
G3 CHECK REAR ANTI-LOCK BRAKE SENSOR INDICATOR
1. Raise the vehicle on a hoist.
2.
CAUTION: Examine the anti-lock
brake sensor indicator carefully. Failure to
properly diagnose the anti-lock brake sensor
indicator at this time will lead to unnecessary
component replacement and wasted
diagnostic time.
Inspect the anti-lock brake sensor
indicator for damaged or missing teeth.
Rotate the anti-lock brake sensor
indicator to be sure all teeth are checked.
Is the anti-lock brake sensor indicator
damaged or missing teeth?
→ Yes
REPLACE the anti-lock brake sensor indicator.
REFER to Sensor Indicator—Rear. TEST the
system for normal operation.
→ No
GO to G4.
G4 CHECK FOR LOOSE ANTI-LOCK BRAKE SENSOR MOUNTING
1. Wiggle the anti-lock brake sensor at the
differential case (4204).
Is any looseness detected?
→ Yes
TIGHTEN anti-lock brake sensor bolt to
specifications. TEST the system for normal
operation.
→ No
GO to G5.
G5 CHECK FOR ANTI-LOCK BRAKE SENSOR SHORT
1.
2.
Rear Anti-Lock Brake Sensor C404
(Motorhome C302)
3.
3. Measure the resistance between the rear antilock brake sensor C404 (motorhome C302)
terminals and ground.
Is the resistance greater than 10,000
ohms?
→ Yes
GO to G6.
→ No
REPLACE the anti-lock brake sensor. REFER to
Sensor—Rear. TEST the system for normal
operation.
G6 CHECK CIRCUITS
1. Install EEC-IV 60-Pin Breakout Box.
2.
2. Measure the resistance between EEC-IV 60Pin Breakout Box pin 9 and EEC-IV 60-Pin
Breakout Box pin 21.
Is the resistance greater than 10,000
ohms?
→ Yes
GO to G7.
→ No
REPAIR circuit 519 (LG/BK) and circuit 523
(R/PK). TEST the system for normal operation.
G7 CHECK FOR INTERMITTENT WIRING CONCERN
1.
2. Perform the Sensor Failure test for the rear
anti-lock brake sensor. Go to Component Test —
Intermittent Failures.
Did the rear anti-lock brake sensor pass?
→ Yes
GO to G8.
→ No
REPAIR as necessary. TEST the system for
normal operation.
G8 INSPECT THE REAR ANTI-LOCK BRAKE SENSOR FOR DAMAGE
1. Remove the rear anti-lock brake sensor. Refer
to Sensor—Rear.
2. Inspect the rear anti-lock brake sensor
housing for stress cracks or breaks.
3. Inspect the anti-lock brake sensor C404
(motorhome C302) for evidence of water entry,
pin corrosion, or excessive debris.
Are any of the above conditions evident?
→ Yes
REPAIR as necessary. TEST the system for
normal operation.
→ No
REPLACE the anti-lock brake control module.
REFER to Module—Anti-Lock Brake Control.
TEST the system for normal operation.
PINPOINT TEST H: SOFT OR EXCESSIVE PEDAL TRAVEL
CONDITIONS
DETAILS/RESULTS/ACTIONS
H1 CHECK BASE BRAKE COMPONENTS
1. Visually inspect the brake lines from HCU to
wheel cylinders.
2.
2. Visually inspect the calipers and brake
components.
Are any of these components damaged?
→ Yes
REPLACE or REPAIR as necessary. TEST the
system for normal operation.
→ No
GO to H2.
H2 CHECK FOR LEAKING DUMP VALVE
1.
2.
2. Remove the rubber boots from the two HCU
low pressure accumulators (LPA).
3.
3. Insert a clean steel implement (e.g., paper clip
or small screwdriver) into each LPA.
4. NOTE: A leaking dump valve is similar to the
master cylinder bypass condition. It is important
that the pedal be quickly and forcefully applied to
rule out master cylinder bypass as a cause.
Typically, master cylinder bypass occurs only at
low pedal pressure rates.
Have an assistant press hard on the brake
pedal while observing the steel
implements.
Do any of the implements move
significantly?
→ Yes
REPLACE the EHCU. REFER to Hydraulic
Control Unit—Electronic (EHCU).
→ No
REMOVE the steel implements. INSTALL the
rubber boots on each LPA. GO to Symptom
Chart.
PINPOINT TEST J: DTCs C1095, C1096 — PUMP MOTOR FAILURE
CONDITIONS
DETAILS/RESULTS/ACTIONS
J1 CHECK FOR FAULT REPEATABILITY
1. Verify that the ABS pump motor electrical
connector is connected to the anti-lock brake
control module.
2.
Scan Tool
3.
Clear Continuous DTCs
4.
4. Perform anti-lock brake control module OnDemand Self-Test.
5.
5. Retrieve and document continuous DTCs.
Are any DTCs retrieved?
→ Yes
If DTC C1095 is retrieved, REPLACE the
EHCU. REFER to Hydraulic Control Unit—
Electronic (EHCU).
If DTC C1096 is retrieved, GO to J2 .
→ No
System is OK. TEST the system for normal
operation.
If a different DTC is retrieved, GO to Anti-Lock
Brake Control Module Diagnostic Trouble Code
(DTC) Index.
J2 CHECK PUMP MOTOR CIRCUIT 532 (O/Y)
1.
2.
EHCU C1041 (Motorhome C130)
3.
3. Measure the voltage between EHCU C1041-2
(motorhome C130-2), circuit 532 (O/Y), and
ground.
Is the voltage greater than 10 volts?
→ Yes
GO to J3.
→ No
REPAIR circuit 532 (O/Y). TEST the system for
normal operation.
J3 CONCLUDE CIRCUIT CHECK
1.
1. Measure the resistance between EHCU C10411 (motorhome C130-1), circuit 530 (LG/Y), and
ground.
Is the resistance less than 5 ohms?
→ Yes
REPLACE the EHCU. REFER to Hydraulic
Control Unit—Electronic (EHCU). TEST the
system for normal operation.
→ No
REPAIR circuit 530 (LG/Y). TEST the system for
normal operation.
PINPOINT TEST K: DTCs C1113, C1115, C1185 — INTERNAL POWER RELAY
FAILURE
CONDITIONS
DETAILS/RESULTS/ACTIONS
K1 CHECK FOR FAULT REPEATABILITY
1.
Scan Tool
2.
Clear Continuous DTCs
3.
3. Perform anti-lock brake control module OnDemand Self-Test.
4.
Retrieve DTCs
Are any DTCs retrieved?
→ Yes
If DTC C1113 or C1115 is retrieved,
REPLACE the anti-lock brake control module.
REFER to Module—Anti-Lock Brake Control.
TEST the system for normal operation.
If DTC C1185 is retrieved, GO to K2 .
→ No
If no DTCs are retrieved, TEST the system for
normal operation.
K2 ELECTRICAL PRECHECKS
1.
2.
Power Distribution Box Fuse 14 (60A)
(Motorhome Fuse F [60A])
Is the fuse OK?
→ Yes
GO to K3.
→ No
REPLACE the fuse. TEST the system for
normal operation. If the fuse fails again,
CHECK for short to ground. REPAIR as
necessary. TEST the system for normal
operation.
K3 CHECK POWER TO EHCU
1. Reinstall power distribution box fuse 14
(60A) (motorhome fuse F [60A]).
2.
EHCU C1041 (Motorhome C130)
3.
3. Measure the voltage between EHCU C10412 (motorhome C130-2), circuit 532 (O/Y) and
ground.
Is voltage greater than 10 volts?
→ Yes
REPLACE the anti-lock brake control module.
REFER to Module—Anti-Lock Brake Control.
TEST the system for normal operation.
→ No
REPAIR circuit 532 (O/Y). TEST the system
for normal operation.
PINPOINT TEST L: NO COMMUNICATION WITH THE ANTI-LOCK BRAKE
MODULE
CONDITIONS
DETAILS/RESULTS/ACTIONS
L1 VERIFY THE CONNECTION BETWEEN THE DIAGNOSTIC TOOL AND THE
DLC II CONNECTOR
1.
2. Reconnect the diagnostic tool to the DLC
connector.
3.
3. Retrieve and document continuous DTCs.
Are DTCs obtained?
→ Yes
GO to Anti-Lock Brake Control Module
Diagnostic Trouble Code (DTC) Index.
→ No
GO to L2.
L2 CHECK POWER TO THE EHCU
1.
2. Install EEC-IV 60-Pin Breakout Box.
3.
4.
4. Measure the voltage between EEC-IV 60-Pin
Breakout Box pin 14 and ground.
Is the voltage greater than 10 volts?
→ Yes
GO to L3.
→ No
CHECK fuse junction panel fuse 25 (5A)
(motorhome fuse 13 [10A]) and/or REPAIR
circuit 533 (T/R). TEST the system for normal
operation.
L3 CHECK EHCU GROUND
1.
2.
EHCU C1041 (Motorhome C130)
3. Disconnect the battery negative cable.
4.
4. Measure the resistance between EHCU C10411 (motorhome C130-1), circuit 530 (LG/Y), and
ground.
Is the resistance less than 5 ohms?
→ Yes
REFER to Section 418-00.
→ No
REPAIR circuit 530 (LG/Y). TEST the system for
normal operation.
PINPOINT TEST M: DTC C1169 — EXCESSIVE DUMP TIME
CONDITIONS
DETAILS/RESULTS/ACTIONS
M1 CHECK FOR FAULT REPEATABILITY
1.
Scan Tool
2.
Clear Continuous
DTCs
3.
3. Retrieve and document continuous DTCs.
Is DTC C1169 retrieved?
→ Yes
REPLACE the EHCU. REFER to Hydraulic Control Unit—Electronic
(EHCU). TEST the system for normal operation.
→ No
GO to M2.
M2 LOW SPEED ABS STOP
1. Drive the vehicle at approximately 6 km/h (10 mph).
2. NOTE: Wetting down the area where the stop is to be performed
will aid in this test.
NOTE: Momentary lock-up is permissible. An assistant should
be used to monitor the wheels during ABS stop.
Apply the brakes hard enough to lock all four wheels.
Does one wheel lock consistently?
→ Yes
GO to Symptom Chart.
→ No
System is OK. TEST the system for normal operation.
PINPOINT TEST N: DTCs C1184 — ABS SYSTEM TIMEOUT, C1222 — WHEEL
SPEED ERROR (DYNAMIC)
CONDITIONS
DETAILS/RESULTS/ACTIONS
N1 CHECK FOR FAULT REPEATABILITY
1.
Scan Tool
2.
Clear
Continuous
DTCs
3. Drive the vehicle at various speeds.
4.
4. Retrieve and document continuous DTCs.
Was a DTC retrieved and did the ABS activate during normal
stops?
→ Yes
If DTC C1184 is retrieved and the ABS did not activate during normal
stops, REPLACE the anti-lock brake control module. REFER to Module—
Anti-Lock Brake Control. TEST the system for normal operation.
If the ABS activated on normal stops, GO to N2 .
If DTC C1222 is retrieved, INSPECT the tires for mismatched sizes.
INSPECT the sensor indicators for damage. If inspections are normal,
REPLACE the anti-lock brake control module. REFER to Module—AntiLock Brake Control. TEST the system for normal operation.
If a different DTC is retrieved, GO to Anti-Lock Brake Control Module
Diagnostic Trouble Code (DTC) Index.
→ No
System is OK. TEST the system for normal operation.
N2 CHECK FOR AN ERRATIC WHEEL SPEED SIGNAL
1.
Clear
Continuous
DTCs
2.
2. NOTE: When using the diagnostic tool to monitor the wheel speed
signals, monitor one wheel at a time. The information is recorded faster
and the likelihood of diagnosing the faulty signal is greater.
Monitor anti-lock brake control module PIDs LF_WSPD,
RF_WSPD, and R_WSPD while driving at various speeds.
Does one wheel speed signal drop out while driving or braking?
→ Yes
GO to Pinpoint Test C (LF), Pinpoint Test E (RF), Pinpoint Test G (Rear).
→ No
REPEAT the monitoring of anti-lock brake control module PIDs
LF_WSPD, RF_WSPD, and R_WSPD. Intermittent signals may not be
recorded the first time. INSPECT the sensor indicators and sensor wiring
for damage. If damage is found, REPAIR as necessary. If no damage is
found, GO to Component Test — Intermittent Failures for the suspect
wheel sensor. TEST the system for normal operation.
PINPOINT TEST P: DTC B1485 — BRAKE PEDAL POSITION (BPP) SWITCH
CIRCUIT MALFUNCTION
CONDITIONS
DETAILS/RESULTS/ACTIONS
P1 CHECK POWER FEED TO BPP SWITCH
1.
Brake Pedal Position
Switch C279
2. Measure the voltage between connector terminal 3, circuit 22
(LB/BK) and ground.
Is the voltage greater than 10 volts?
→ Yes
GO to P2.
→ No
REPAIR open in circuit 22 (LB/BK). CLEAR DTCs. TEST the
system for normal operation.
P2 CHECK BPP SWITCH CONTINUITY — BRAKE NOT APPLIED
1. Measure the resistance across BPP switch terminal 1, circuit 676
(PK/OG) and terminal 2, circuit 810 (RD/LG).
Is the resistance less than 5 ohms?
→ Yes
GO to P3.
→ No
REPLACE the BPP switch. REFER to Section 417-01. TEST the
system for normal operation.
P3 CHECK BPP SWITCH CONTINUITY — BRAKE APPLIED
1. Press the brake pedal and hold.
2. Measure the resistance across BPP switch terminal 2, circuit 810
(RD/LG) and terminal 3, circuit 22 (LB/BK).
Is the resistance less than 5 ohms?
→ Yes
GO to P4.
→ No
REPLACE the BPP switch. REFER to Section 417-01. TEST the
system for normal operation.
P4 CHECK CONTINUITY OF CIRCUIT 810 (RD/LG)
1.
Anti-Lock Brake
Control Module C104a
2. Measure the resistance between BPP switch connector terminal 3
and module connector terminal 15, circuit 810 (RD/LG).
Is the resistance less than 5 ohms?
→ Yes
GO to P5.
→ No
REPAIR the open in circuit 810 (RD/LG). TEST the system for
normal operation.
P5 CHECK CIRCUIT 810 (RD/LG) FOR A SHORT TO BATTERY
1. Measure the voltage between BPP switch connector terminal 2,
circuit 810 (RD/LG) and ground.
Is the voltage greater than 10 volts?
→ Yes
REPAIR the short to ground on circuit 810 (RD/LG).
→ No
REPLACE the anti-lock brake control module. REFER to Module—
Anti-Lock Brake Control in this section. TEST the system for
normal operation.
Component Test — Intermittent Failures
Power/Ground to Anti-Lock Brake Control Module
If the fuse had failed:
Check the weather packing of the power connector to the EHCU C1041 (motorhome C130).
Remove power distribution box fuse 14 (60A) (motorhome fuse F [60A]).
Measure the resistance between the outside pin of power distribution box fuse 14 (60A)
(motorhome fuse F [60A]), circuit 532 (O/Y), and ground.
Spray with water and wiggle the wiring between the power distribution box and the anti-lock
brake control module.
If any continuity is measured, repair or replace the wiring.
Check for opens in wiring:
Disconnect the EHCU C1041 (motorhome C130).
While measuring the voltage between EHCU C1041-2 (motorhome C130-2), circuit 532
(O/Y), and negative battery post, wiggle the wiring harness.
If the voltage momentary drops below 10 volts while the harness is wiggled, repair or replace
the wiring.
While measuring the resistance between the EHCU C1041-1 (motorhome C130-1), circuit
530 (LG/Y), and ground, wiggle the wiring harness.
If the resistance momentarily goes above 5 ohms, while the harness is wiggled, repair or
replace the wiring.
Yellow ABS Warning Indicator Failure
Does not illuminate (prove out):
Connect EEC-IV 60-Pin Breakout Box to the EHCU with ABS Adapter Cable.
Connect EEC-IV 60-Pin Breakout Box pin 1 (yellow indicator) to the B+ pin.
Wiggle the wire harness at the several points between the anti-lock brake control module and
the instrument cluster.
Repair or replace the wire harness at the location that the indicator flickered off for an open
circuit.
Does illuminate (prove out):
Wiggle the wire harness at the several points between the anti-lock brake control module and
the instrument cluster.
Repair or replace the wire harness at the location that the indicator flickered on for a short to
ground.
Sensor Failure
Connect EEC-IV 60-Pin Breakout Box to the anti-lock brake control module with ABS
Adapter Cable.
Disconnect the suspect anti-lock brake sensor.
Check the harness for short to ground.
NOTE: Use 88 Digital Multimeter with the minimum resistance hold feature enabled
for this test.
Monitor the resistance between EEC-IV 60-Pin Breakout Box pins and ground as
follows:
Sensor
Breakout Box
Pins
Circuits
Left front anti-lock brake
sensor
11 and 23
521 (T/O) and 522 (T/BK)
Right front anti-lock brake
sensor
10 and 22
514 (Y/R) and 516 (Y/BK)
Rear anti-lock brake sensor
9 and 21
523 (R/PK) and 519
(LG/BK)
Drive over rough roads at various speeds.
If there is continuity between either circuit and ground, repair the circuit for a short to
ground.
Check harness for open circuit.
NOTE: Connect jumper securely to the suspect sensor connector.
Connect a jumper between the two pins on the suspect sensor connector.
NOTE: Use 88 Digital Multimeter with the maximum resistance hold feature enabled
for this test.
Monitor the resistance between EEC-IV 60-Pin Breakout Box pins as follows:
Sensor
Breakout Box
Pins
Circuits
Left front anti-lock brake
sensor
11 and 23
521 (T/O) and 522 (T/BK)
Right front anti-lock brake
sensor
10 and 22
514 (Y/R) and 516 (Y/BK)
Rear anti-lock brake sensor
9 and 21
523 (R/PK) and 519
(LG/BK)
Drive over rough roads at various speeds.
If there is an open circuit detected between pins, repair the circuit(s) for an open
circuit.
Check suspect sensor electrical connector.
NOTE: Use 88 Digital Multimeter with the maximum resistance hold feature enabled
for this test.
Monitor the resistance between suspect anti-lock brake sensor terminals while
wiggling the electrical connector:
Sensor
Resistance
Front
4x2 (F250/350) 3300 ohms
4x2 (F450/550) 800 ohms
4x4 (F250/550) 800 ohms
Rear
4x2 or 4x4
3500 ohms
If the resistance is above specifications, replace the anti-lock brake sensor.
NOTE: Use 88 Digital Multimeter with the minimum resistance hold feature enabled
for this test.
Monitor the resistance between suspect anti-lock brake sensor terminals while
wiggling the electrical connector:
Sensor
Resistance
Front
4x2 (F250/350) 2,000 ohms
4x2 (F450/550) 650 ohms
4x4 (F250/550) 650 ohms
Rear
4x2 or 4x4
800 ohms
If the resistance is below specifications, replace the anti-lock brake sensor.
NOTE: Use 88 Digital Multimeter with the minimum resistance hold feature enabled
for this test.
Monitor the resistance between an anti-lock brake sensor terminal and ground on
the highest resistance scale of the meter while wiggling the electrical connector.
If the meter shows anything but open circuit, replace the anti-lock brake sensor.
SECTION 206-09B: Anti-Lock Control — 4Wheel
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Hydraulic Control Unit—Electronic (EHCU)
Removal
CAUTION: Be careful not to damage the finger-like valve cartridges while removing
and installing the anti-lock brake control module.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed
to these charges, damage may result.
Disconnect the battery ground cable (14301).
On F250-550 vehicles, remove the air cleaner; refer to Section 303-12.
On F250-550 vehicles, remove the EVAP canister; refer to Section 303-13.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact
with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush
eyes with running water for 15 minutes. Get medical attention if irritation persists.
If taken internally, drink water and induce vomiting. Get medical attention
immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake
fluid is spilled onto a painted or plastic surface, immediately wash it with water.
NOTE: Plug each port to prevent brake fluid from spilling.
NOTE: F250-550 shown, motorhome similar.
Disconnect the hydraulic brake lines.
Disconnect the inlet hydraulic brake lines.
Disconnect the outlet hydraulic brake lines.
NOTE: F250-550 shown, motorhome similar.
Disconnect the anti-lock brake control module electrical connectors.
On F250-550 vehicles, remove the electronic hydraulic control unit (EHCU).
Remove the EHCU bolts.
Remove the EHCU.
On motorhome vehicles, remove the EHCU.
Remove the nuts.
Remove the bolts.
Installation
NOTE: When the battery (10655) is disconnected and reconnected, some abnormal drive
symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may
need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Bleed the EHCU; refer to Section 206-00.
SECTION 206-09B: Anti-Lock Control — 4Wheel
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Module—Anti-Lock Brake Control
Removal
Remove the electronic hydraulic control unit (EHCU); refer to Hydraulic Control Unit—
Electronic (EHCU).
Disconnect the pump motor electrical connector from the anti-lock brake control module.
Remove the anti-lock brake control module.
Remove the screws.
Remove the anti-lock brake control module.
Installation
To install, reverse the removal procedure.
SECTION 206-09B: Anti-Lock Control — 4Wheel
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Sensor—Rear
Removal
Disconnect the battery ground cable. For additional information, refer to Section 414-01.
Raise and support the vehicle. For additional information, refer to Section 100-02.
CAUTION: Clean off dirt and debris that may have collected around the rear
anti-lock brake sensor before removal to prevent fluid contamination.
Remove the rear anti-lock brake sensor.
1. Disconnect the electrical connector.
2. Remove the bolt.
3. Remove the rear anti-lock brake sensor.
Installation
CAUTION: Use care not to get dirt in the rear axle housing (4010).
Clean and inspect the rear anti-lock brake sensor.
Clean the axle mounting surface.
Inspect and clean the magnetized rear anti-lock brake sensor pole piece.
Inspect the rear anti-lock brake control O-ring (2M060) for damage. Replace if
necessary.
Lightly lubricate the rear anti-lock brake control O-ring with SAE 75W-140 High
Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford
specification WSL-M2C192-A.
Install the rear anti-lock brake sensor.
NOTE: Do not apply force to the plastic rear anti-lock brake sensor connector.
Position the rear anti-lock brake sensor and install the rear anti-lock brake sensor
bolt.
Connect the electrical connector.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms
may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be
driven 16 km (10 mi) or more to relearn the strategy.
Connect the battery ground cable. For additional information, refer to Section 414-01.
SECTION 206-09B: Anti-Lock Control — 4Wheel
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Sensor—Front, 4x2
Removal
Disconnect the battery ground cable.
Disconnect the front anti-lock brake sensor electrical connector.
Disconnect the electrical connector.
Detach the front anti-lock brake sensor wire harness from the brake hose.
Remove the front anti-lock brake sensor.
Remove the bolts.
Remove the front anti-lock brake sensor.
Installation
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms
may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be
driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
SECTION 206-09B: Anti-Lock Control — 4Wheel
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Sensor—Front, 4x4
Removal
Disconnect the battery ground cable.
Disconnect the front anti-lock brake sensor electrical connector.
Remove the front disc brake rotor; refer to Section 206-03.
CAUTION: Clean off debris that may have collected around the front anti-lock
brake sensor before removal.
Remove the front anti-lock brake sensor.
Remove the front anti-lock brake sensor bolt and discard.
Remove the sensor.
Installation
CAUTION: Use care not to get dirt in the front hub.
NOTE: When the battery is disconnected and reconnected, some abnormal drive
symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may
need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Install a new front anti-lock brake sensor bolt.
SECTION 206-09B: Anti-Lock Control — 4Wheel
REMOVAL AND INSTALLATION
Sensor Indicator—Front, 4x2
Special Tool(s)
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
2-3 Jaw Puller or equivalent
205-D027 (D80L-1013-A)
Adapter Set, Step Plate
205-DS011 (D80L-630-A)
Removal
Remove the front disc brake rotor; refer to Section 206-03.
CAUTION: Discard the front anti-lock brake sensor indicator.
Use 2-3 Jaw Puller to remove the front anti-lock brake sensor indicator.
Installation
CAUTION: The front anti-lock brake sensor indicator must be pressed on
straight.
Install the new front anti-lock brake sensor indicator.
Position the front anti-lock brake sensor indicator.
Use an appropriate size cylinder and press to install the front anti-lock brake sensor
indicator.
Install the front disc brake rotor; refer to Section 206-03.
SECTION 206-09B: Anti-Lock Control — 4Wheel
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Sensor Indicator—Front, 4x4
Removal and Installation
NOTE: The front anti-lock brake sensor indicator is integral to the front wheel hub.
For additional information, refer to Section 204-01B.
SECTION 206-09B: Anti-Lock Control — 4Wheel
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Sensor Indicator—Rear
Removal and Installation
NOTE: The rear anti-lock brake sensor indicator is attached to the differential case. It is
necessary to remove the ring gear in order to remove the rear anti-lock brake sensor indicator.
Refer to the appropriate section in Group 205 for the procedure.
SECTION 206-09B: Anti-Lock Control — 4Wheel
REMOVAL AND INSTALLATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Switch—Pressure
Removal and Installation
For additional information, refer to Section 206-06.
SECTION 206-09B: Anti-Lock Control — 4Wheel
REMOVAL AND INSTALLATION
Switch—Brake Pedal Position
Removal and Installation
For additional information, refer to Section 417-01.
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
GROUP 11: Steering System
SECTION 211-00: Steering System — General Information
SECTION 211-02: Power Steering
SECTION 211-03: Steering Linkage
SECTION 211-04: Steering Column
SECTION 211-05: Steering Column Switches
SECTION 211-00:
Steering System — General Information
SPECIFICATIONS
DESCRIPTION AND OPERATION
Steering System
DIAGNOSIS AND TESTING
Steering System
Inspection and Verification
Symptom Chart
Component Tests
Steering Linkage
Pump Flow and Pressure Test
Steering Gear Valve
GENERAL PROCEDURES
System Flushing—CII Power Steering Pump
System Flushing—CIII Power Steering Pump
System Flushing—ZF Power Steering Pump
Purging—CII Power Steering Pump
Purging—CIII Power Steering Pump
Purging—ZF Power Steering Pump
Fill—CII Power Steering Pump
Fill—CIII Power Steering Pump
Fill—ZF Power Steering Pump
Meshload Adjustment—XR50 Steering Gear
Meshload Adjustment—TRW TAS40 Steering Gear
SECTION 211-00: Steering System — General
Information
SPECIFICATIONS
1999 F-Super Duty 250-550
Workshop Manual
Procedure revision date: 01/26/2000
General Specifications
Item
Steering Wheel Free Play — Motorhome
Specification
51 mm (2.04 in.)
Power Steering Gear — Super Duty F-250, F-350, F-450, F-550
Type
XR50 (QSC)
Recirculating Ball
Ratio
17:1
Steering Gear Turns (Stop-to-Stop)
4.0
Steering Gear Meshload Rotating Torque @ Steering Wheel
2 Nm (18 lb/in)
Minimum Steering Meshload Rotating Torque @ Steering Wheel
1 Nm (13 lb/in)
Maximum Worm Bearing Preload (For Inspection Purposes Only)
0.9 Nm (8 lb/in)
Total Meshload Over Worm Bearing Preload Over Ends (For
Inspection Purposes Only)
Worm to Piston Preload (For Inspection Purposes Only)
0.45-1 Nm
(4-9 lb/in)
0.11-0.34 Nm
(1-3 lb/in)
Power Steering Gear — Motorhome
Type
TRW TAS40
Ratio
18.37:1
Steering Gear Turns (Stop-to-Stop)
4.16
Power Steering Pump — Super Duty F-250, F-350, F-450, F-550
Type
Flow Rate @ 74° - 80° C (165° - 175° F) and Engine Speed Set at Idle
Pressure @ 74° - 80° C (165° - 175° F) and Engine Speed Set at Idle
CII
8-9.5 liters/minute
(2.1-2.5 gpm)
1034 kPa
(150 psi)
Minimum Flow Rate @ 74° - 80° C (165° - 175° F) and Power
Steering Analyzer Set at 5102 kPa (750 psi)
5.7 liters/minute
(1.5 gpm)
Relief Pressure
10005-10550 kPa
(1450-1530 psi)
Type
Flow Rate @ 74° - 80° C (165° - 175° F) and Engine
CIII
10.6-12.0 liters/minute
(2.8-3.2 gpm)
Speed Set at Idle
—
Pressure @ 74° - 80° C (165° - 175° F) and Engine Speed Set at Idle
1034 kPa
(150 psi)
Minimum Flow Rate @ 74° - 80° C (165° - 175° F) and Power
Steering Analyzer Set at 5102 kPa (750 psi)
5.3 liters/minute
(1.4 gpm)
Relief Pressure
9660-10,557 kPa
(1400-1530 psi)
Power Steering Pump — Motorhome
Type
Aluminum Modular ZF
Flow Rate @ 74° - 80° C (165° - 175° F) and Engine Speed Set at Idle
Pressure @ 74° - 80° C (165° - 175° F) and Engine Speed Set at Idle
Minimum Flow Rate @ 74° - 80° C (165° - 175° F) and Power
Steering Analyzer Set at 5102 kPa (750 psi)
16 liters/minute
(4.2 gpm)
500.25 kPa
(72.5 psi)
6.1 liters/minute
(1.6 gpm)
Relief Pressure — 15,200 lb and 18,000 lb GVWR
12406 kPa
(1798 psi)
Relief Pressure — 20,500 lb GVWR
17009 kPa
(2465 psi)
Lubricants
MERCON® Multi-Purpose ATF XT-2-QDX
MERCON®
Torque Specifications
Description
Nm Lb/Ft
Steering Gear Sector Shaft Retaining Nut — Super Duty F-250, F-350, F-450, F-550 30
23
Sector Shaft Arm Drag Link Retaining Nut — Super Duty F-250, F-350, F-450, F550
90
67
Steering Gear Sector Shaft Adjusting Screw — Motorhome
14
11
Steering Gear Sector Shaft Jam Nut — Motorhome
58
43
SECTION 211-00: Steering System — General
Information
DESCRIPTION AND OPERATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Steering System
The steering system consists of the following:
Steering System Components — 5.4L and 6.8L Gas Engines with Vacuum Boost Brake
System (CIII Power Steering Pump)
Item
Part Number
Description
1
3A674
Power Steering Pump
2
3691
Power Steering Reservoir Pump Hose
3
3E764
Power Steering Pump Reservoir
4
3A713
Power Steering Return Hose
5
3504
Steering Gear
6
3A713
Power Steering Return Hose
7
3D746
Power Steering Fluid Cooler
8
3A719
Power Steering Pressure Hose
Steering System Components — 5.4L and 6.8L Gas Engines with Hydro Boost Brake
System (CIII Power Steering Pump)
Item
Part Number
Description
1
3A674
Power Steering Pump
2
3691
Power Steering Reservoir Pump Hose
3
3A717
Power Steering Line
4
3E764
Power Steering Pump Reservoir
5
3N999
Power Steering Line
6
3A005
Power Steering Return Line Hose
7
3A714
Power Steering Line
8
3A713
Power Steering Return Hose
9
3504
Steering Gear
10
3A713
Power Steering Return Hose
11
3D746
Power Steering Fluid Cooler
Steering System Components — 7.3L DIT Diesel Engine (CII Power Steering Pump)
Item
Part Number
Description
1
3A713
Power Steering Return Hose
2
3A674
Power Steering Pump
3
3A005
Power Steering Return Line Hose
4
3A717
Power Steering Line
5
3N999
Power Steering Line
6
3A714
Power Steering Line
7
3504
Steering Gear
8
3A713
Power Steering Return Hose
9
3D746
Power Steering Fluid Cooler
Steering System Components — Motorhome with Hydro Boost Brake System (ZF
Power Steering Pump)
Item
Part Number
Description
1
3A717
Power Steering Line
2
3A005
Power Steering Return Line Hose
3
3A714
Power Steering Line
4
3504
Steering Gear
5
3A713
Power Steering Return Hose
6
3691
Power Steering Reservoir Pump Hose
7
3A674
Power Steering Pump
8
3D746
Power Steering Fluid Cooler
9
3A713
Power Steering Return Hose
10
3A697
Power Steering Oil Reservoir
Steering System Components — Motorhome with Hydro Max Brake System (ZF Power
Steering Pump)
Item
Part Number
Description
1
3A714
Power Steering Line
2
3A713
Power Steering Return Hose
3
3504
Steering Gear
4
3691
Power Steering Reservoir Pump Hose
5
3A674
Power Steering Pump
6
3A717
Power Steering Line
7
3D746
Power Steering Fluid Cooler
8
3A713
Power Steering Return Hose
9
3A697
Power Steering Oil Reservoir
For information on the power steering pump reservoir (3E764), refer to Section 211-02.
For information on the steering wheel and column assembly, refer to Section 211-04.
For information on the power steering fluid lines, refer to Section 211-02.
For information on the front wheel spindles (4x2), refer to Section 204-01A.
For information on the power steering fluid cooler (3D746), refer to Section 211-02.
For information on the power steering pump (3A674), refer to Section 211-02.
For information on the steering gear (3504), refer to Section 211-02.
For information on the steering linkage, refer to Section 211-03.
For information on the wheel hub (1104) (4x4), refer to Section 204-01B.
SECTION 211-00: Steering System — General
Information
DESCRIPTION AND OPERATION
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Steering System
The steering system consists of the following:
Steering System Components — 5.4L and 6.8L Gas Engines with Vacuum Boost Brake
System (CIII Power Steering Pump)
Item
Part Number
Description
1
3A674
Power Steering Pump
2
3691
Power Steering Reservoir Pump Hose
3
3E764
Power Steering Pump Reservoir
4
3A713
Power Steering Return Hose
5
3504
Steering Gear
6
3A713
Power Steering Return Hose
7
3D746
Power Steering Fluid Cooler
8
3A719
Power Steering Pressure Hose
Steering System Components — 5.4L and 6.8L Gas Engines with Hydro Boost Brake
System (CIII Power Steering Pump)
Item
Part Number
Description
1
3A674
Power Steering Pump
2
3691
Power Steering Reservoir Pump Hose
3
3A717
Power Steering Line
4
3E764
Power Steering Pump Reservoir
5
3N999
Power Steering Line
6
3A005
Power Steering Return Line Hose
7
3A714
Power Steering Line
8
3A713
Power Steering Return Hose
9
3504
Steering Gear
10
3A713
Power Steering Return Hose
11
3D746
Power Steering Fluid Cooler
Steering System Components — 7.3L DIT Diesel Engine (CII Power Steering Pump)
Item
Part Number
Description
1
3A713
Power Steering Return Hose
2
3A674
Power Steering Pump
3
3A005
Power Steering Return Line Hose
4
3A717
Power Steering Line
5
3N999
Power Steering Line
6
3A714
Power Steering Line
7
3504
Steering Gear
8
3A713
Power Steering Return Hose
9
3D746
Power Steering Fluid Cooler
Steering System Components — Motorhome with Hydro Boost Brake System (ZF
Power Steering Pump)
Item
Part Number
Description
1
3A717
Power Steering Line
2
3A005
Power Steering Return Line Hose
3
3A714
Power Steering Line
4
3504
Steering Gear
5
3A713
Power Steering Return Hose
6
3691
Power Steering Reservoir Pump Hose
7
3A674
Power Steering Pump
8
3D746
Power Steering Fluid Cooler
9
3A713
Power Steering Return Hose
10
3A697
Power Steering Oil Reservoir
Steering System Components — Motorhome with Hydro Max Brake System (ZF Power
Steering Pump)
Item
Part Number
Description
1
3A714
Power Steering Line
2
3A713
Power Steering Return Hose
3
3504
Steering Gear
4
3691
Power Steering Reservoir Pump Hose
5
3A674
Power Steering Pump
6
3A717
Power Steering Line
7
3D746
Power Steering Fluid Cooler
8
3A713
Power Steering Return Hose
9
3A697
Power Steering Oil Reservoir
For information on the power steering pump reservoir (3E764), refer to Section 211-02.
For information on the steering wheel and column assembly, refer to Section 211-04.
For information on the power steering fluid lines, refer to Section 211-02.
For information on the front wheel spindles (4x2), refer to Section 204-01A.
For information on the power steering fluid cooler (3D746), refer to Section 211-02.
For information on the power steering pump (3A674), refer to Section 211-02.
For information on the steering gear (3504), refer to Section 211-02.
For information on the steering linkage, refer to Section 211-03.
For information on the wheel hub (1104) (4x4), refer to Section 204-01B.
SECTION 211-00: Steering System — General
Information
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
System Flushing—CII Power Steering Pump
WARNING: Do not mix oil types. Any mixture or any unapproved oil can lead to seal
deterioration and leaks. A leak can ultimately cause loss of fluid, which can result in a loss
of power steering assist.
Remove the injector driver module (IDM) relay to prevent engine starting.
Loosen the two clamps. Remove the air intake tube.
Disconnect the power steering return hose (3A713). Plug the reservoir fitting.
Attach an extension hose between the power steering return hose and an empty container.
Raise the front wheels off the floor; for additional information, refer to Section 100-02.
Fill the reservoir.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or equivalent
MERCON® fluid.
CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow the
starter to cool for 1 minute before cranking again. Premature starter failure can
occur.
CAUTION: Do not hold the steering wheel against the stops for more than
three to five seconds at a time. Damage to the power steering pump could occur.
Turn the steering wheel from stop-to-stop while cranking the engine until the fluid
exiting the power steering return hose is clear of all contamination and debris.
Add Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERCON®
equivalent as needed.
Lower the vehicle.
Disconnect the extension hose from the power steering return hose. Remove the plug. Attach
the power steering return hose to the reservoir.
CAUTION: Do not overfill the reservoir.
Fill the reservoir.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or equivalent
MERCON® fluid.
Install the air intake tube. Tighten the two clamps.
Install the IDM relay.
CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump could occur.
Start the engine and turn the steering wheel from stop-to-stop.
NOTE: If the power steering system is noisy and accompanied by evidence of aerated fluid
it will be necessary to purge the power steering system.
Check the power steering fluid level.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or equivalent
MERCON® fluid.
SECTION 211-00: Steering System — General
Information
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
System Flushing—CIII Power Steering Pump
WARNING: Do not mix oil types. Any mixture or any unapproved oil can lead to seal
deterioration and leaks. A leak can ultimately cause loss of fluid, which can result in a loss
of power steering assist.
Remove the fuel pump fuse to prevent engine starting.
Remove the bolt. Position the evaporative emissions canister (EVAP canister) (9D653) out of
the way.
Disconnect the power steering return hose. Plug the reservoir fitting.
Attach an extension hose between the power steering return hose and an empty container.
Raise the front wheels off the floor; for additional information, refer to Section 100-02.
Fill the reservoir.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or equivalent
MERCON® fluid.
CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow the
starter to cool for 1 minute before cranking again. Premature starter failure can
occur.
CAUTION: Do not hold the steering wheel against the stops for more than
three to five seconds at a time. Damage to the power steering pump could occur.
Turn the steering wheel from stop-to-stop while cranking the engine until the fluid
exiting the power steering return hose is clear of all contamination and debris.
Add Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERCON®
equivalent as needed.
Lower the vehicle.
Disconnect the extension hose from the power steering return hose. Remove the plug. Attach
the power steering return hose to the reservoir.
CAUTION: Do not overfill the reservoir.
Fill the reservoir.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or equivalent
MERCON® fluid.
Install the evaporative emissions canister and the bolt.
Install the fuel pump fuse.
CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump could occur.
Start the engine and turn the steering wheel from stop-to-stop.
NOTE: If the power steering system is noisy and accompanied by evidence of aerated fluid
it will be necessary to purge the power steering system.
Check the power steering fluid level.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or equivalent
MERCON® fluid.
SECTION 211-00: Steering System — General
Information
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
System Flushing—ZF Power Steering Pump
WARNING: Do not mix oil types. Any mixture or any unapproved oil can lead to seal
deterioration and leaks. A leak can ultimately cause loss of fluid, which can result in a loss
of power steering assist.
NOTE: The Hydro-Boost brake system is shown in this procedure. This procedure is for
motorhome vehicles equipped with either the Hydro-Boost or Hydro-Max brake systems.
Remove the fuel pump fuse to prevent engine starting.
Disconnect the power steering return hose. Plug the reservoir fitting (power steering fluid
cooler to power steering oil reservoir).
Attach an extension hose between the power steering return hose and an empty container.
Raise the front wheels off the floor; for additional information, refer to Section 100-02.
Fill the reservoir.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or equivalent
MERCON® fluid.
CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow the
starter to cool for 1 minute before cranking again. Premature starter failure can
occur.
CAUTION: Do not hold the steering wheel against the stops for more than
three to five seconds at a time. Damage to the power steering pump could occur.
Turn the steering wheel from stop-to-stop while cranking the engine until the fluid
exiting the power steering return hose is clear of all contamination and debris.
Add Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERCON®
equivalent as needed.
Lower the vehicle.
Disconnect the extension hose from the power steering return hose. Remove the plug. Attach
the power steering return hose to the reservoir.
CAUTION: Do not overfill the reservoir.
Fill the reservoir.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or equivalent
MERCON® fluid.
Install the fuel pump fuse.
CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump could occur.
Start the engine and turn the steering wheel from stop-to-stop.
NOTE: If the power steering system is noisy and accompanied by evidence of aerated fluid
it will be necessary to purge the power steering system.
Check the power steering fluid level.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or equivalent
MERCON® fluid.
SECTION 211-00: Steering System — General
Information
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Purging—CII Power Steering Pump
Special Tool(s)
Vacuum Pump
416-D002 (D95L-7559-A) or
Equivalent
CAUTION: If the air is not purged from the power steering system correctly,
premature power steering pump failure could result. This condition can occur on predelivery vehicles with evidence of aerated fluid or on vehicles that have had steering
component repairs.
NOTE: A whine heard from the power steering pump may be caused by air in the system.
The power steering purge procedure must be performed prior to any component repair for
which power steering noise complaints are accompanied by evidence of aerated fluid.
Remove the reservoir cap. Check the fluid.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERCON®
equivalent.
Tightly insert the stopper of the Vacuum Pump into the reservoir.
Start the vehicle.
Apply maximum vacuum and maintain it for a minimum of three minutes with the engine
speed set at idle.
Release the vacuum and remove the vacuum pump.
CAUTION: Do not overfill the reservoir.
Fill the reservoir.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERCON®
equivalent.
Reinstall the Vacuum Pump. Apply and maintain maximum vacuum.
CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump could occur.
Cycle the steering wheel fully to the left and right every 30 seconds for approximately
five minutes.
Stop the engine, release the vacuum, and remove the Vacuum Pump.
Install the reservoir cap.
Check for fluid leaks at all of the connections. If the power steering fluid shows signs of air,
repeat this procedure.
SECTION 211-00: Steering System — General
Information
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Purging—CIII Power Steering Pump
Special Tool(s)
Vacuum Pump
416-D002 (D95L-7559-A) or
Equivalent
CAUTION: If the air is not purged from the power steering system correctly,
premature power steering pump failure could result. This condition can occur on predelivery vehicles with evidence of aerated fluid or on vehicles that have had steering
component repairs.
NOTE: A whine heard from the power steering pump may be caused by air in the system.
The power steering purge procedure must be performed prior to any component repair for
which power steering noise complaints are accompanied by evidence of aerated fluid.
Remove the reservoir cap. Check the fluid.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERCON®
equivalent.
Tightly insert the stopper of the Vacuum Pump into the reservoir.
Start the vehicle.
Apply maximum vacuum and maintain it for a minimum of three minutes with the engine
speed set at idle.
Release the vacuum and remove the vacuum pump.
CAUTION: Do not overfill the reservoir.
Fill the reservoir.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERCON®
equivalent.
Reinstall the Vacuum Pump. Apply and maintain maximum vacuum.
CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump could occur.
Cycle the steering wheel fully to the left and right every 30 seconds for approximately
five minutes.
Stop the engine, release the vacuum, and remove the Vacuum Pump.
Install the reservoir cap.
Check for fluid leaks at all of the connections. If the power steering fluid shows signs of air,
repeat this procedure.
SECTION 211-00: Steering System — General
Information
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Purging—ZF Power Steering Pump
Special Tool(s)
Vacuum Pump
416-D002 (D95L-7559-A) or
Equivalent
CAUTION: If the air is not purged from the power steering system correctly,
premature power steering pump failure could result. This condition can occur on predelivery vehicles with evidence of aerated fluid or on vehicles that have had steering
component repairs.
NOTE: This procedure is for motorhome vehicles equipped with either the Hydro-Boost or
Hydro-Max Brake Systems.
NOTE: A whine heard from the power steering pump may be caused by air in the system.
The power steering purge procedure must be performed prior to any component repair for
which power steering noise complaints are accompanied by evidence of aerated fluid.
Remove the reservoir cap. Check the fluid.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERCON®
equivalent.
Tightly insert the stopper of the Vacuum Pump into the reservoir.
Start the vehicle.
Apply maximum vacuum and maintain it for a minimum of three minutes with the engine
speed set at idle.
Release the vacuum and remove the Vacuum Pump.
CAUTION: Do not over fill the reservoir.
Fill the reservoir.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERCON®
equivalent.
Reinstall the Vacuum Pump. Apply and maintain maximum vacuum.
CAUTION: Do not hold the steering wheel against the stops for more than three to
five seconds at a time. Damage to the power steering pump could occur.
Cycle the steering wheel fully to the left and right every 30 seconds for approximately
five minutes.
Stop the engine, release the vacuum, and remove the Vacuum Pump.
Install the reservoir cap.
Check for fluid leaks at all of the connections. If the power steering fluid shows signs of air,
repeat this procedure.
SECTION 211-00: Steering System — General
Information
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Fill—CII Power Steering Pump
WARNING: Do not mix oil types, any mixture or any unapproved oil could lead to
seal deterioration and leaks. A leak could ultimately cause loss of fluid, which could
result in a loss of power steering assist.
Fill the reservoir.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERCON®
equivalent.
Remove the injector driver module (IDM) relay to prevent engine starting.
Raise the front wheels off the floor; for additional information, refer to Section 100-02.
CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow the
starter to cool for 1 minute before cranking again. Premature starter failure can
occur.
CAUTION: Do not hold the steering wheel against the stops for more than
three to five seconds at a time. Damage to the power steering pump could occur.
Turn the steering wheel from stop-to-stop while cranking the engine.
Lower the vehicle.
CAUTION: Do not overfill the reservoir.
Fill the reservoir.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERCON®
equivalent.
Install the IDM relay.
SECTION 211-00: Steering System — General
Information
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Fill—CIII Power Steering Pump
WARNING: Do not mix oil types, any mixture or any unapproved oil could lead to
seal deterioration and leaks. A leak could ultimately cause loss of fluid, which could
result in a loss of power steering assist.
Fill the reservoir.
Use Motorcraft MERCON® Multi-Purpose (ATF) XT-2-QDX or MERCON®
equivalent.
Remove the ignition coil fuse to prevent engine starting.
Raise the front wheels off the floor. For additional information, refer to Section 100-02.
CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow the
starter to cool for 1 minute before cranking again. Premature starter failure can
occur.
CAUTION: Do not hold the steering wheel against the stops for more than
three to five seconds at a time. Damage to the power steering pump could occur.
Turn the steering wheel from stop-to-stop while cranking the engine.
Lower the vehicle.
CAUTION: Do not overfill the reservoir.
Fill the reservoir.
Use Motorcraft MERCON® Multi-Purpose (ATF) XT-2-QDX or MERCON®
equivalent.
Install the ignition coil fuse.
NOTE: If the power steering is noisy and accompanied by evidence of aerated fluid, it will
be necessary to purge the power steering system. For additional information, refer to
Purging—CIII Power Steering Pump in this section.
Clear the diagnostic trouble codes (DTCs). For additional information, refer to the
Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Run vehicle and check the system for leaks.
SECTION 211-00: Steering System — General
Information
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Fill—ZF Power Steering Pump
WARNING: Do not mix oil types, any mixture or any unapproved oil could lead to
seal deterioration and leaks. A leak could ultimately cause loss of fluid, which could
result in a loss of power steering assist.
Fill the reservoir.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERCON®
equivalent.
Remove the fuel pump fuse to prevent engine starting.
Raise the front wheels off the floor; for additional information, refer to Section 100-02.
CAUTION: Do not crank the engine for more than 15 seconds at a time. Allow the
starter to cool for 1 minute before cranking again. Premature starter failure can
occur.
CAUTION: Do not hold the steering wheel against the stops for more than
three to five seconds at a time. Damage to the power steering pump could occur.
Turn the steering wheel from stop-to-stop while cranking the engine.
Lower the vehicle.
CAUTION: Do not overfill the reservoir.
Fill the reservoir.
Use Motorcraft MERCON® Multi-Purpose ATF XT-2-QDX or MERSON®
equivalent.
Install the fuel pump fuse.
SECTION 211-00: Steering System — General
Information
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Meshload Adjustment—XR50 Steering Gear
Special Tool(s)
Steering Arm Remover
211-003 (T65P-3590-F) or
Equivalent
NOTE: The engine should not be running.
Turn the steering wheel from right lock to left lock at least once.
Remove the driver air bag; for additional information, refer to Section 501-20B.
Raise and support the vehicle; for additional information, refer to Section 100-02.
Remove the castellated nut.
Remove the cotter pin.
Remove the castellated nut.
Separate the steering sector shaft arm drag link.
Use the Pitman Arm Puller to separate the steering sector shaft arm drag link.
NOTE: The front wheel should not touch the ground.
Lower and support the front of the vehicle; for additional information, refer to Section
100-02.
NOTE: Reset the steering gear meshload only if the measured rotating torque for total oncenter load if less than specification.
Attach an in/lb torque wrench to the bolt and measure the steering gear meshload from
center.
Adjust steering gear meshload if rotating torque is not within specification.
Remove the fan blade assembly and fan shroud; for additional information, refer to Section
303-03.
Adjust the sector shaft to proper rotating torque.
Hold the sector shaft and loosen the lock nut.
Adjust the sector shaft.
Verify that the rotating torque is to specification.
Reset if necessary.
Tighten the lock nut.
Hold the sector shaft.
Tighten the lock nut.
Install the steering sector shaft arm drag link, castellated nut and cotter pin.
Lower the vehicle; for additional information, refer to Section 100-02.
Install the driver air bag; for additional information, refer to Section 501-20B.
SECTION 211-00: Steering System — General
Information
GENERAL PROCEDURES
1999 F-Super Duty 250-550 Workshop
Manual
Procedure revision date: 01/26/2000
Meshload Adjustment—TRW TAS40 Steering Gear
CAUTION: This adjustment must be performed with the sector shaft on its center
of travel.
CAUTION: The input shaft must not be rotated more than 1-1/2 revolutions
when the steering sector shaft arm drag link (3304) is disconnected from the
steering gear to avoid possible misadjustment of the automatic poppet system.
NOTE: If the adjusting screw jam nut screw is accessible, this adjustment can be
completed on the vehicle. Otherwise, the steering gear must be removed from the vehicle;
for additional information, refer to Section 211-02.
NOTE: If this adjustment is being performed with the steering gear on the vehicle,
disconnect the steering sector shaft arm drag link.
Put the sector shaft in the center of travel.
Rotate the input shaft until the timing marks across the end of the sector shaft are
perpendicular to the input shaft and the valve worm is in line with the timing
mark on the end of the housing trunnion.
With the steering gear in the center position, grasp and gently try to move the steering sector
shaft arm drag link back and forth in the direction of travel.
Fingertip force is adequate to detect the lash of a loose sector shaft. There must be no
movement of the input shaft or the sector shaft.
Loosen the jam nut on the sector shaft adjusting screw.
If no lash was detected, turn the adjusting screw counterclockwise until lash is
detected at the output shaft.
CAUTION: Overadjustment of the shaft adjusting screw in the clockwise direction
can result in a no-recovery, oversteering or darting condition of the vehicle.
Adjust the shaft adjusting screw.
Slowly turn the adjusting screw clockwise until no lash is felt at the steering sector
shaft arm drag link. Use no more than the specified torque.
From the no-lash position, turn the screw clockwise an additional 1/8-3/16 turn. Hold
the adjusting screw in place and tighten the jam nut to specification.
Turn the input shaft 1/4-turn each side of center and recheck the steering sector shaft arm
drag link for lash. No lash should be felt. If lash exists, repeat Steps 1-4.
CAUTION: Maintain grease in the sector shaft bearing through the grease fitting
in the housing using only a hand-operated grease gun. Add grease until it begins to
extrude past the dirt and water seal. Do not use a power grease gun because it will
supply grease too quickly. This can adversely affect the high-pressure seal and
contaminate the hydraulic fluid.
If the adjustment was done with the steering gear on the vehicle, connect the steering
sector shaft arm drag link. If the steering gear was removed from the vehicle, install the
steering gear.
End of Part 1