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Home >> Ford >> 2001 >> Excursion 7.3 F, 4WD >> Repair and Diagnosis >> Electrical >> Gauges >> Instrument Panels - Analog - Excursion & F250-F550 Super Duty >> System Tests >> Test L: Red Brake Warning Indicator Always/Never On

Test L: Red Brake Warning Indicator Always/Never On

  1. Turn ignition to LOCK position. Connect New Generation Star (NGS) or Worldwide Diagnostic System (WDS) tester to Data Link Connector (DLC). DLC is a 16-pin connector located below center of instrument panel. See Figure. Turn ignition switch to START position. Using NGS/WDS tester, perform Generic Electronic Module (GEM) self-test. Record, then clear continuous DTCs. Perform GEM self-test again. If no DTCs are retrieved, go to next step. If DTC C1125 is retrieved, go to step  6. If DTC C1189 is retrieved, go to step  9. If DTC C1223 or C1225 is retrieved, go to step  4. If DTC C1446 is retrieved, go to step  10. If DTC B1342 is retrieved, go to step  20.
  2. Using NGS/WDS tester, observe GEM PID PARK_SW while engaging and disengaging parking brake. If PID PARK_SW displays OFF when disengaged and ON when engaged, go to next step. If PID always displays OFF, go to step  11. If PID always displays ON, go to step  13.
  3. Ensure parking brake is not engaged. Using NGS/WDS tester, toggle GEM active command BRAKE LAMP to ON. Wait 5 minutes, then toggle BRAKE LAMP off. If brake indicator illuminates for 5 seconds after executing OFF command, go to next step. If brake indicator does not illuminate, go to step  15. If brake indicator stays on at all times, go to step  17.
  4. Turn ignition switch to LOCK position. Disconnect brake fluid level switch 3-pin harness connector C170. Measure resistance between ground and brake fluid level switch 3-pin harness connector C170 terminal No. 1 (Black wire). If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, repair open in Black wire between brake fluid level switch and ground point. Ground point is located in left rear of engine compartment, on cowl panel. See WIRING DIAGRAMS . Retest system operation.
  5. Connect brake fluid level switch harness connector C170. Using NGS/WDS tester, observe GEM PID FLUID_1 while disconnecting brake fluid level switch. If PID FLUID_1 changes from OFF to ON, replace brake fluid level switch. If PID FLUID_1 does not change from OFF to ON, go to step  20.
  6. Turn ignition switch to LOCK position. Disconnect brake fluid level switch 3-pin harness connector C170. Disconnect Generic Electronic Module (GEM) 26-pin harness connector C240A. Measure resistance of Tan/Light Green wire between brake fluid level switch 3-pin harness connector C170 terminal No. 2 and GEM 26-pin harness connector C240A terminal No. 21. See Figure. Measure resistance of Dark Green/Yellow wire between brake fluid level switch 3-pin harness connector C170 terminal No. 3 and GEM 26-pin harness connector C240A terminal No. 24. If both resistances are less than 5 ohms, go to next step. If either resistance is more than 5 ohms, repair open in appropriate wire(s) between brake fluid level switch and GEM. See WIRING DIAGRAMS . Retest system operation.
  7. Turn ignition switch to ON position. Measure voltage between ground and brake fluid level switch 3-pin harness connector C170 terminal No. 2 (Tan/Light Green wire). Measure voltage between ground and brake fluid level switch 3-pin harness connector C170 terminal No. 3 (Dark Green/Yellow wire). If battery voltage is not present, go to next step. If battery voltage is present, repair short to power in appropriate wire(s) brake fluid level switch and GEM. See WIRING DIAGRAMS . Retest system operation.
  8. Turn ignition switch to LOCK position. Measure resistance between ground and brake fluid level switch 3-pin harness connector C170 terminal No. 2 (Tan/Light Green wire). Measure resistance between ground and brake fluid level switch 3-pin harness connector C170 terminal No. 3 (Dark Green/Yellow wire). If both resistances are more than 10 k/ohms, go to next step. If either resistance is 10 k/ohms or less, repair short to ground in appropriate wire(s) brake fluid level switch and GEM. See WIRING DIAGRAMS . Retest system operation.
  9. Using NGS/WDS tester, observe GEM PID FLUIDLVL_1 while connecting a 10-amp fused jumper wire between brake fluid level switch 3-pin harness connector C170 terminals No. 2 (Tan/Light Green wire) and No. 3 (Dark Green/Yellow wire). If PID FLUIDLVL_1 displays OFF with jumper wire connected, replace brake fluid level switch. Retest system operation. If PID FLUIDLVL_1 does not display OFF with jumper wire connected, go to step  20.
  10. Verify parking brake is engaged. If parking brake is engaged, go to next step. If parking brake is not engaged, engage parking brake and repeat GEM self-test.
  11. Turn ignition switch to ON position. Observe GEM PID PARK_SW while connecting a 10-amp fused jumper wire between ground and parking brake switch 1-pin harness connector C276 (Light Green/Red wire). If PID PARK_SW does not display ON with jumper wire connected, go to next step. If PID PARK_SW displays ON with jumper wire connected, replace parking brake switch. Retest system operation.
  12. Disconnect GEM 26-pin harness connector C240A. Disconnect parking brake switch 1-pin harness connector C276. Measure resistance of Light Green/Red wire between parking brake switch 1-pin harness connector C276 and GEM 26-pin harness connector C240A terminal No. 7. See Figure. If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, repair open in Light Green/Red wire between parking brake switch and GEM. See WIRING DIAGRAMS . Retest system operation.
  13. Turn ignition switch to LOCK position. Observe GEM PID PARK_SW while disconnecting parking brake switch 1-pin harness connector C276. If PID PARK_SW does not display OFF with switch disconnected, go to next step. If PID PARK_SW displays OFF with switch disconnected, replace parking brake switch. Retest system operation.
  14. Turn ignition switch to LOCK position. Disconnect parking brake switch 1-pin harness connector C276. Disconnect GEM 26-pin harness connector C240A. Measure resistance between ground and parking brake switch 1-pin harness connector C276 (Light Green/Red wire). If resistance is more than 10 k/ohms, go to step  20. If resistance is 10 k/ohms or less, repair short to ground in Light Green/Red wire parking brake switch and GEM. See WIRING DIAGRAMS . Retest system operation.
  15. Turn ignition switch to LOCK position. Disconnect GEM 26-pin harness connector C240A. Turn ignition switch to ON position. Measure voltage between ground and GEM 26-pin harness connector C240A terminal No. 12 (Violet/White wire). See Figure. If battery voltage is present, go to next step. If battery voltage is not present, go to step  17.
  16. Turn ignition switch to LOCK position. Remove instrument cluster to gain access to instrument cluster harness connectors. See REMOVAL & INSTALLATION . Disconnect instrument cluster harness connectors. Disconnect GEM 26-pin harness connector C240A. Turn ignition switch to ON position. Measure voltage between ground and GEM 26-pin harness connector C240A terminal No. 12 (Violet/White wire). If battery voltage is present, repair short to power in Violet/White wire instrument cluster and GEM. See WIRING DIAGRAMS . Retest system operation. If battery voltage is not present, go to step  20.
  17. Disconnect GEM 26-pin harness connector C240A. Measure resistance between ground and GEM 26-pin harness connector C240A terminal No. 12 (Violet/White wire). If resistance is more than 10 k/ohms, go to next step. If resistance is 10 k/ohms or less, repair short to ground in Violet/White wire between instrument cluster and GEM. See WIRING DIAGRAMS . Retest system operation.
  18. Disconnect GEM 26-pin harness connector C240A. Remove instrument cluster to gain access to instrument cluster harness connectors. See REMOVAL & INSTALLATION . Disconnect instrument cluster 12-pin harness connector C250C. Measure resistance in Violet/White wire between GEM 26-pin harness connector C240A terminal No. 12 and instrument cluster 12-pin harness connector C250C terminal No. 3. See Figure and Figure . If resistance is 5 ohms or less, go to next step. If resistance is more than 5 ohms, repair open in Violet/White wire between instrument cluster and GEM. See WIRING DIAGRAMS . Retest system operation.
  19. Turn ignition switch to LOCK position. Remove Red BRAKE warning indicator bulb. Test bulb for continuity. If bulb is okay, replace instrument cluster. See REMOVAL & INSTALLATION . Retest system operation. If bulb is not okay, replace bulb. Retest system operation.
  20. Turn ignition switch to LOCK position. Check for corrosion, pushed out pins and harness connectors that are not connected correctly. Repair any damage found and reconnect any loose harness connectors. Retest system operation. If problem still exists, replace GEM. See REMOVAL & INSTALLATION . Clear any DTCs. Retest system operation. If problem does not exist, system is operating correctly at this time. Clear any DTCs. Retest system operation.
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