Fulltext TSBs

Technical Service Bulletins

TSB
05-21-19
  • FRONT BRAKE ROUGHNESS – SHUDDER WHILE BRAKING
Publication Date: October 17, 2005

FORD:
2004-2005 F-150

This article supersedes TSB 05-06-21 to add new parts and update Service Procedure.

ISSUE:

Some 2004/2005 F-150 vehicles built before 11/29/2004 may exhibit front brake roughness and or shudder while braking.

ACTION:

Service the rack and pinion, rotors, and caliper assemblies as needed, based on vehicle build date and current part levels installed on the vehicle. Refer to the following Service Procedure.

SERVICE PROCEDURE

  1. Vehicles built prior to 8/20/2003 require the replacement of the rack and pinion assembly if it has not been replaced. Refer to Workshop Manual, Section 206-03 and 211-02.
  2. Determine if the vehicle has the old or new level rotors (Figure 1).


    Figure 1 – Article 05-21-19

    1. If old level rotors, replace the front rotors and front caliper assemblies. Refer to Workshop Manual, Section 206-00 for front rotor and caliper replacement.

      NOTE:WHEN REPLACING THE ROTORS ON 4X2 UNITS, A NEW SPINDLE NUT IS REQUIRED.

    2. If new level (47 fin) rotors are present, perform one (1) of the following:
      1. If rotors are within minimum thickness specifications, machine the rotors using the Rotunda on vehicle brake lathe and the Rotunda adapter kit 201-R0093. Refer to the Workshop Manual, Section 206-00 for the correct on-vehicle brake lathe procedure.
      2. If rotors are beyond machinable thickness, the front rotors must be replaced.
  3. Install new service fix calipers.

    NOTE:REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE INSTALLED AS A UNIT WITHOUT DISASSEMBLY.


PART NUMBERPART NAME
6L3Z-2B120-ACaliper Asy (Right Side)
6L3Z-2B121-ACaliper Asy (Left Side)
5L3Z-1102-ABRotor (4X2, 6 Lug)
5L3Z-1102-BARotor (4X2, 7 Lug)
5L3Z-1125-AARotor (4X4, 6 Lug)
5L3Z-1125-BARotor (4X4, 7 Lug)
6L3Z-3504-AASteering Gear (Super Cab/Crew 4X2)
6L3Z-3504-BASteering Gear (Super Cab/Crew 4X4)
6L3Z-3504-CASteering Gear (Regular Cab 4X2)
6L3Z-3504-DASteering Gear (Regular Cab 4X4)
6L3Z-3C294-AA Retainer Spindle Nut

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

OPERATIONDESCRIPTIONTIME
052119A2004-2005 F-150 4X2 Built Prior To 8/20/2003: Replace Steering Rack And Pinion, Front Brake Calipers, Refinish Rotors (Do Not Use With 3504A, 2000A, 2001BFA, 2001B2P, 2001B2PT, 2001B5F, 2001B5FT, 2001B8F, 2001B8FT)2.3 Hrs.
052119B2004-2005 F-150 4X2 Built Prior To 8/20/2003: Replace Steering Rack And Pinion, Front Brake Calipers, Replace Rotors (Do Not Use With 3504A, 2000A, 2001BFA, 2001B2P, 2001B2PT, 2001B5F, 2001B5FT, 2001B8F, 2001B8FT) 1.9 Hrs.
052119C2004-2005 F-150 4X2 Built After 8/20/2003: Replace Front Brake Calipers, Refinish Rotors (Do Not Use With 3504A, 2000A, 2001BFA, 2001B2P, 2001B2PT, 2001B5F, 2001B5FT, 2001B8F, 2001B8FT) 1.4 Hrs.
052119D2004-2005 F-150 4X2 Built After 8/20/2003: Replace Front Brake Calipers, Replace Rotors (Do Not Use With 3504A, 2000A, 2001BFA, 2001B2P, 2001B2PT, 2001B5F, 2001B5FT, 2001B8F, 2001B8FT)0.9 Hr.
052119E2004-2005 F-150 4X4 Built Prior To 8/20/2003: Replace Steering Rack And Pinion, Front Brake Calipers, Refinish Rotors (Do Not Use With 3504A, 2000A, 2001BFA, 2001B2P, 2001B2PT, 2001B5F, 2001B5FT, 2001B8F, 2001B8FT)2.6 Hrs.
052119F2004-2005 F-150 4X4 Built Prior To 8/20/2003: Replace Steering Rack And Pinion, Front Brake Calipers, Replace Rotors (Do Not Use With 3504A, 2000A, 2001BFA, 2001B2P, 2001B2PT, 2001B5F, 2001B5FT, 2001B8F, 2001B8FT) 2.0 Hrs.
052119G2004-2005 F-150 4X4 Built After 8/20/2003: Replace Front Brake Calipers, Refinish Rotors (Do Not Use With 3504A, 2000A, 2001BFA, 2001B2P, 2001B2PT, 2001B5F, 2001B5FT, 2001B8F, 2001B8FT) 1.5 Hrs.
052119H2004-2005 F-150 4X4 Built After 8/20/2003: Replace Front Brake Calipers, Replace Rotors (Do Not Use With 3504A, 2000A, 2001BFA, 2001B2P, 2001B2PT, 2001B5F, 2001B5FT, 2001B8F, 2001B8FT)0.9 Hr.

DEALER CODING

BASIC PART NO.CONDITION CODE
2b12042

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company’s on-line technical resources.

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