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Home >> Ford >> 2002 >> Excursion 7.3 F, RWD >> Repair and Diagnosis >> Accessories & Equipment >> Gauges & Instrument Panels >> Instrument Panel - Analog -- Excursion & F250-F550 Super Duty >> System Tests >> Test K: Red Brake Warning Indicator Always/Never On

Test K: Red Brake Warning Indicator Always/Never On

  1. Verify that the fluid in the brake master cylinder is correct and the parking brake control is completely released. If brake fluid level and parking brake control is okay, go to next step. If brake fluid level and parking brake control is not okay, top off fluid or release parking brake control as necessary and test system for normal operation.
  2. Turn ignition switch to LOCK position. Disconnect parking brake switch 1-pin harness connector. Measure resistance between ground and parking brake switch 1-pin connector (component side) while setting and releasing the parking brake control. If resistance is more than 10 k/ohms with parking brake released and less than 5 ohms with parking brake applied, go to next step. If resistance is not as specified, replace parking brake switch. See PARKING BRAKE SWITCH  under REMOVAL & INSTALLATION. Retest system operation.
  3. Remove instrument cluster to gain access to instrument cluster harness connectors. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. Disconnect instrument cluster harness connector C220b. Measure resistance of Light Green/Red wire between parking brake switch 1-pin harness connector and instrument cluster harness connector C220b terminal No. 11. See Figure. Resistance should be less than 5 ohms. Measure resistance between ground and instrument cluster harness connector C220b terminal No. 11 (Light Green/Red wire). Resistance should be greater than 10 k/ohms. If resistance is as specified, go to next step. If resistance is not as specified, repair open or short to ground in Light Green/Red wire between parking brake switch and instrument cluster. See WIRING DIAGRAMS . Retest system operation.
  4. Reconnect instrument cluster harness connector C220b. Disconnect ABS module harness connector C135. Start engine and observe red brake warning indicator. If red brake warning indicator illuminates, go to next step. If red brake warning indicator does not illuminate, repair brake concern. See appropriate ANTI-LOCK article in BRAKES.
  5. NOTE: Ensure brake fluid level is at correct level.
  6. Turn ignition switch to LOCK position. Disconnect brake fluid level switch 3-pin harness connector. Measure resistance between brake fluid level switch 3-pin connector terminals No. 1 and 3 (component side). Resistance should be greater than 10 k/ohms. Measure resistance between brake fluid level switch 3-pin connector terminals No. 2 and 3 (component side). Resistance should be less than 5 ohms. If resistance is as specified, go to next step. If resistance is not as specified, replace brake fluid level switch and test system operation. See BRAKE FLUID LEVEL SWITCH  under REMOVAL & INSTALLATION.
  7. Remove instrument cluster to gain access to instrument cluster harness connectors. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. Disconnect instrument cluster harness connector C220c. Disconnect ABS module harness connector C135. Measure resistance between ground and harness connector C220c terminals No. 9 (Tan/Light Green wire) and No. 10 (Dark Green/Yellow wire). If resistance at both terminals is greater than 10 k/ohms, go to next step. If resistance is less than 10 k/ohms at either terminal, repair short to ground in appropriate wire and test system operation. See WIRING DIAGRAMS .
  8. Turn ignition switch to LOCK position. Disconnect brake fluid level switch 3-pin harness connector. Measure resistance of Tan/Light Green wire between brake fluid level switch 3-pin harness connector terminal No. 2 and instrument cluster harness connector C220c terminal No. 9. See Figure. Measure resistance of Dark Green/Yellow wire between brake fluid level switch 3-pin harness connector terminal No. 3 and instrument cluster harness connector C220c terminal No. 10. 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 instrument cluster. See WIRING DIAGRAMS . Retest system operation.
  9. Turn ignition switch to LOCK position. Measure resistance between ground and brake fluid level switch 3-pin harness connector 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.
  10. 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 does not exist, system is operating correctly at this time. Clear any DTCs. If problem exists, replace instrument cluster. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. Retest system operation.