I have no clue. Haven't needed to do it yet.

 

I bled the heck out of the system, thinking that there may be some issue with air, but it didn't seem to help.
However, something you said does make some sense. The pedal does go a long way towards the floor, and does almost feel like there is air in the system. At a stand still, I can just about bottom out the pedal, but I was unable to bleed any air from the system.
I will have a look at the ABS tonight.
I have heard that if you force the caliper piston back into the caliper while doing a brake job, you can damage the ABS solenoids. When I put the Hawk brakes in, I noticed that someone had recently replaced the pads. I oppened the bleeders to release the pistons, but there is no guarantee that the last guy did the same. Any thoughts.

 

He's got a 2000, so he doesn't have the integrated brake controller.

Also, it's not that the integrated brake controller doesn't work with electric over hydraulic brakes, it's that it's not guaranteed to work. It works with some and doesn't work with others. Ford doesn't have the time or money to go out and test it with every different kind of electric over hydraulic system out there so they put in a disclaimer that it is not guaranteed to work with them. Since electric brakes all work pretty much exactly the same they know if it works on one it will work with them all so they do say that it is compatible with them.

 

Not true. You might force DIRT back into the ABS unit, which can cause this.

 

I just got off the phone with the local Ford service manager. He said that there is a possibility that there is air trapped in the ABS unit. To remove the air, you need to bleed the system with the ABS activated.
He also said that he has had many complaints regarding poor braking performance on Ford SD's. Some of the complaints he has been able to fix, others he hasn't.
The other tip he offered was to make sure the alignment pis on the calipers are free, and lubricated with anti seize. These pins are available at Autozone for a couple bucks. I replaced all of them, but it didn't seem to help much.

 

I hear an echo But yeah, bleed the system, it might have air in it, or any dirt trapped in the valves will be bled out.

Let us know how it turns out.