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Pinpoint Test K: The Brake Warning Indicator Is Never On

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. K1 CHECK THE BRAKE FLUID LEVEL AND PARKING BRAKE 
    • Check the parking brake control and brake fluid level.
    • Is the parking brake control fully disengaged and the brake fluid level at the correct level? 
    • Yes  : GO to K2.
    • No  : DISENGAGE the parking brake control or FILL the brake fluid to the correct level as necessary. TEST the system for normal operation.
  2. K2 CHECK THE PARKING BRAKE SWITCH PID USING THE DIAGNOSTIC TOOL 
    • Key in ON position.
    • Enter the following diagnostic mode on the diagnostic tool: Parking Brake Switch PID.
    • Monitor the instrument cluster parking brake switch PID while applying and releasing the parking brake.
    • Does the PID agree with the parking brake position? 
    • Yes  : GO to  K6.
    • No  : GO to K3.
  3. K3 CHECK THE PARKING BRAKE SWITCH INPUT 
    • Key in OFF position.
    • Disconnect: Parking Brake Switch C2015.
    • Connect a fused (5A) jumper wire between the parking brake switch C2015-1, circuit 162 (LG/RD), harness side and ground.
      Fig 1: Checking Parking Brake Switch Input
      G03924735Courtesy of FORD MOTOR CO.
    • Key in ON position.
    • Does the brake warning indicator illuminate? 
    • Yes  : REMOVE the jumper wire, GO to K4.
    • No  : REMOVE the jumper wire, GO to  K5.
  4. K4 CHECK CIRCUIT 676 (PK/OG) FOR AN OPEN 
    • Key in OFF position.
    • Measure the resistance between the parking brake switch C2015-2, circuit 676 (PK/OG), harness side and ground.
      Fig 2: Checking Circuit 676 (PK/OG) For Open
      G03924736Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : INSTALL a new parking brake switch. TEST the system for normal operation.
    • No  : REPAIR the circuit. TEST the system for normal operation.
  5. K5 CHECK CIRCUIT 162 (LG/RD) FOR AN OPEN 
    • Key in OFF position.
    • Disconnect: Instrument Cluster C220b.
    • Measure the resistance between the instrument cluster C220b-18, circuit 162 (LG/RD), harness side and the parking brake switch C2015-1, circuit 162 (LG/RD), harness side and ground.
      Fig 3: Checking Circuit 162 (LG/RD) For Open
      G03924737Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to  K11.
    • No  : REPAIR the circuit. TEST the system for normal operation.
  6. K6 CHECK CIRCUIT 57 (BK) FOR AN OPEN 
    • Key in OFF position.
    • Disconnect: Brake Fluid Level Switch C124.
    • Measure the resistance between the brake fluid level switch C124-1, circuit 57 (BK), harness side and ground.
      Fig 4: Checking Circuit 57 (BK) For Open
      G03910712Courtesy of FORD MOTOR CO.
    • Is the resistance less than 5 ohms? 
    • Yes  : GO to K7.
    • No  : REPAIR the circuit. TEST the system for normal operation.
  7. K7 CHECK THE BRAKE FLUID LEVEL SWITCH 
    • Connect: Brake Fluid Level Switch C124.
    • Key in ON position.
    • Observe the brake warning indicator.
      • CAUTION: Do not spill brake fluid onto painted or plastic surfaces. If spilled, wipe up immediately before damage to the painted or plastic surface occurs.
    • Using a suitable tool, lightly push the brake fluid level float to the bottom of the reservoir.
    • Does the brake warning indicator illuminate? 
    • Yes  : GO to  K10.
    • No  : GO to K8.
  8. K8 CHECK THE BRAKE FLUID LEVEL SWITCH FOR CORRECT OPERATION 
    • Disconnect: Brake Fluid level Switch C124.
    • Check the brake warning indicator for illumination.
    • Does the brake warning indicator illuminate? 
    • Yes  : INSTALL a new brake fluid level switch. REFER to HYDRAULIC BRAKE ACTUATION . TEST the system for normal operation.
    • No  : GO to K9.
  9. K9 CHECK CIRCUIT 531 (DG/YE) AND CIRCUIT 512 (TN/LG) FOR A SHORT TO GROUND 
    • Key in OFF position.
    • Disconnect: Instrument Cluster C220b.
    • Measure the resistances between the instrument cluster C220b-1, circuit 531 (DG/YE), harness side and ground; and between the instrument cluster C220b-14, circuit 512 (TN/LG), harness side and ground.
      Fig 5: Checking Circuit 531 (DG/YE) And Circuit 512 (TN/LG) For Short To Ground
      G03924739Courtesy of FORD MOTOR CO.
    • Are the resistances greater than 10,000 ohms? 
    • Yes  : GO to  K11.
    • No  : REPAIR circuit 531 (DG/YE) or circuit 512 (TN/LG) as necessary. TEST the system for normal operation.
  10. K10 CARRY OUT THE INSTRUMENT CLUSTER WARNING LAMPS AND CHIME ACTIVE COMMAND USING THE DIAGNOSTIC TOOL 
    • Key in ON position.
    • Enter the following diagnostic mode on the diagnostic tool: Instrument Cluster Active Command.
    • Select the instrument cluster warning lamps and chime active command. Trigger the all lamps active command on and off.
    • Does the brake warning indicator illuminate when triggered on and turn off when triggered off? 
    • Yes  : GO to  K12.
    • No  : GO to K11.
  11. K11 CHECK FOR CORRECT INSTRUMENT CLUSTER OPERATION 
    • Disconnect all the instrument cluster connectors.
    • Check for:
      • corrosion
      • pushed-out pins
    • Correct all the instrument cluster connectors and make sure they seat correctly.
    • Operate the system and verify that concern is still present.
    • Is the concern still present? 
    • Yes  : INSTALL a new instrument cluster. REFER to INSTRUMENT CLUSTER . TEST the system for normal operation.
    • No  : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.
  12. K12 CHECK FOR CORRECT ANTI-LOCK BRAKE SYSTEM (ABS) OPERATION 
    • Disconnect the ABS module connector.
    • Check for:
      • corrosion
      • pushed-out pins
    • Correct the ABS module connector and make sure it seats correctly.
    • Operate the system and verify that concern is still present.
    • Is the concern still present? 
    • Yes  : INSTALL a new ABS module. REFER to ANTI-LOCK CONTROL . TEST the system for normal operation.
    • No  : The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.
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