You might check to see if your truck is one of the ones that had a recall to fix a problem with the emergency brake. My truck, a 1999 6-speed was covered. I had the dealer replace the front cable and pedal assembly under the recall before mine broke.

 

Well that's it.....I'm stumped. I'm beginning to get a real bad feeling about this. Like maybe I have to disassemble the whole EB Assembly pedel ratchet assembly in order to pull the old cable guide out of the floor and insert the new one? I'll wait to see if anyone chips in before I take it to Ford.

 

Recall? I'll check into it. Anybody know anything elese on this?

 

Clay - I had mine break at that same spot in my old ford e-350. I wound up pulling the whole e-brake ***'y. The problem I had was I thought the end actually fit (Snapped) into the assembly, when it actually was just the tension on the cable that held it in place. IIRC I installed it thru the e- brake then re- mounted it and ran the wire down to first connector and put it in there with some vise grip help. There might be a easier way but this was the only way I could do it and I didnt have a manual. Good luck.

 

Clay I have never messesd with the cables but i did find this
AutoZone.com | Vehicle Selection - Year

Towards the end there is some info.

 

AutoZone.com | Vehicle Selection - Year Very helpful Jim, and added to favorites Thanks.

 

Thanks Jim. I found a diagram there for a 2000 F-350 but it's not like mine? Though it helped me visualze how mine works.

No luck finding a 2000 F-350 ER Brake recall. Just the 1999 F-35- mentioned.

guitarpicr - it's looking more and more I'm going to have to do what you did and remove the whole assembly to rethread the front cable. Crapola.

Oh well ...we'll see how tomorrow goes.

 

I'll look at my new cable (I have a spare in my shop) and one of my SDs.
It's been a while, but from what I remember:
The new cable comes with the plastic cable guide that goes through to the outside.
Also the pin will come right out of the e-brake assembly....one side of the pedal assembly has a notch in it. Rotate the pin so that the cable strands stick up through the notch. I want to say the notch is on the side towards the PCM.

I did not have to remove the e-brake pedal.


I can take some pics tomorrow of the cable and how to remove it if it will help.

 

DC any thing you can offer will be appreciated.

Pic #1. Is where the cable pulled out of the pin. I cut the tip off the broke end to pull it through the cable guide when I took it off. After I got the replacement part I then realized the cable guide and cable were a one piece unit.

Pic.#2. Is the cable & guide part number. For anybody else for future reference.

Pic.#3. Is the replacement part.. 1st section.....actual cable guide (black fatter part with the cable running through it) and the other end of the cable that exits through the bottom of the truck and connects to the second section of the three piece emergency brake cable.

The plastic/rubber flange is in the center (hard to see)..that's the part that plugs the hole in the firewall/floor. It can be pushed up or down the length of the cable guide so as to be adjustable.

I've got it apart pretty much. I just need to remove the old cable guide so that I can insert the new replacement part. I can't get the old cable guide out?

I don't know what to try short of removing the whole pedel assembly to get at the old guide. If theres a way without removing the whole assembly ...I'm all ears.

EDIT: I forgot to mention the replacement part was $ 34 and change at the Ford Dealer.

 

sorry to hear you having such trouble. you can't get the "cable guide" out of the floor? mine came out with help from a screw driver. hopefully this don't happen to you again, but if it does get your next cable at NAPA is $15 if i remember correctly.

 

Clay those pictures make me want to replace my cable even though it is not broken yet.
It is getting on to be 10 years old now........

 

Okay guys, I finally (after busting knuckles and learning new words ....like gadfreys!......I've finally gotten the old cable assembly out and have installed the new part!

But.........................................I now have several inches of slack in the cable under the truck hanging down useless.
The first section (the one I replaced) attachés to the brake lever assembly inside the cab and then passes through the to underneath through the cable guide (a fatter rubber sleeve see pic) and exits out the bottom where the swedged end is inserted into a non-adjustable coupler.

Then section # 2. runs the length under the truck and ends at what I think they call an equalizer right at the front of the rear dually along the outside frame.

On DWR manual shift it appears to also be non-adjustable, and no spring. From the equalizer section three is where it branches into two sections where each terminates at a rear wheel drum on each side.

What or how are you able to remove the slack in the cable? I'm starting to have a bad feeling that the Ford dealer gave me the wrong part and it's not the correct length. I don't want to even think that ....but would somebody look under there 2000 F-350 DWR 6 spd. and see where the cable adjusters might be?

There must be some way of shorting or lengthing the cable? The other possibility might be that after the cable broke. And I drove the truck down to the Ford dealear for the part I might have lost something that I need that makes the adjustment? However there are no indications underneath that something is missing like a spring or?

The brake won't "Set" when you step on the lever shortning the cable. It will just flop around. I've spent enough time on this that I could have pulled and re-installed the engine. I'm about ready to wave the flag and go to the dealer and make an appointment.

 

Clay- Can you call ford or go up there & ask them for a picture of the cable system and see if something is missing. Sounds like you,ve got the wrong part. Wish I could be more help. Have patience . You'll get it figured out.

 

There was a recall on this? I wish I would have known. I just got the whole pedal assy from Ed last week for my '03. That was the second time the pedal assy had crapped out in my truck. The first time one of the springs in it broke and it made the popping sound like the OP was talking about. I was able to rig it with parts from another assy to make it work. This last time I said to heck with it and bought the new assy.

From what I've seen there is now adjustment in the cables under the truck. So it may be that the whole assy is crap. To replace mine I did not have to remove the PCM. Just took the supporting bracket off it. It's tight but it can be done. Just when your about to lose it and cuss just stop and have a cold one.

 

From what I'm seeing that is the correct part number for your truck. Like I said I havent seen any adjustment in the cables. See if you can get a look at the pedal assy for broke springs(these are twist springs not push-pull springs) and make sure that they are against the stops like they are supposed to be and all.