Hi,

My vehicle is a 1999 F-250 SD w/standard trans.

Last night pulled into the driveway and tried to set the emergency brake pedal as usual. This time there was a loud bang and the pedal went to the floor fast. I checked all the cables front to back and none are broken. So the failure must be in the brake control assembly. The assembly is special order from the dealer at $161.
My question is how do you get the old one out of the truck? There appears to be some kind of connection/computer box right up against the assembly so you can't even see all the bolts holding the assembly in place. Is there any special technique in getting this brake assembly free from the truck. The manual is not very helpful.

Thanks for inputs--Jerry

 

The book recommends the PCM be removed first.

Not sure which engine you have but the general procedure is to ensure the keys are out of the ignition. For extra precaution...disconnect the negative battery cable(s). If dual battery, then remove both negative cables.

From the engine compartment, loosen the 10mm hex drive bolt that secures the PCM connector to the module. The bolt won't come completely out....so just loosen it until the entire connector can be separated from the module.

From inside the cab, remove the two 8mm hex drive bolts that secures the plastic carrier for the PCM and remove. Then grasp the PCM and rotate the non-plug side towards the clutch pedal and then pull the module out.

With the module out of the way you should be able to access the parking brake pedal assembly.

 

My 2001 did the same thing. The best way I can describe it is the pulley that the cable is pulled around when you depress the pedal, separated in the middle. Apparently the pulley is a two piece spot welded together piece. I actually unbolted it from the brace and put some fire retardant cloth on the floor and re-welded it together. It worked great. Got a welder?

 

Thanks much for this info. Now i know how to get the PCM out of the way and the separation of the pulley very much explains what happened without even looking further.
I just need to find a welder. You guys are excellent.

 

You might check your local rental yard to see if they have a spot welder.
You could also use a MIG and you can get that there too.
You other option is Harbor Freight if you have one near.

Sean

 

Hi Shake N Bake

Got another question. Does the wiring harness pull away from the fire wall (end which is under the hood) when the PCM is removed from under the dash? The photo of the PCM in the manual shows many connector pins on the PCM. How easy is it to re-insert the PCM back into the harness connector?

Thanks for your help--Jerry