Ford F150 Pickup. Instruction — part 387

Fig. 17: Bleeding System (Typical)
Courtesy of FORD MOTOR CO.

PRESSURE BLEEDING

1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder

reservoir with the specified brake fluid.

2. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the

fitting on the adapter.

3. Place a box end wrench on the right rear bleeder screw. Attach a rubber drain tube to the right rear

bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid.

4. Continue bleeding the rear of the system, going in order from the left rear bleeder screw to the right front

disc brake caliper bleeder screw ending with the left front disc brake caliper bleeder screw. See
BLEEDING SEQUENCE table.

5. When bleeding operation is complete, close pressure bleeder valve, and remove tank hose from adapter

fitting. Check brake pedal operation. Ensure master cylinder is full of fluid.

COMPONENT BLEEDING

Master Cylinder Priming (In-Vehicle Or Bench)

1. For in-vehicle priming, disconnect the brake lines.

2. For bench priming, mount brake master cylinder body in a vise.

3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir, and fill the brake

master cylinder reservoir with High Performance DOT 3 Brake Fluid (C6AZ-19542-AB) or equivalent
DOT 3 fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not available use DOT 4 Brake
Fluid meeting Ford specification SAE-J1704-DOT 4.

4. Have an assistant pump the brake pedal, or slowly depress the primary piston until clear fluid flows from

both brake tubes, without air bubbles.

5. If the brake master cylinder has been primed at the bench, install it in the vehicle.

NOTE:

Master cylinder pressure bleeder adapter tools are available from various
manufacturers of pressure bleeding equipment. Follow the instructions of
the manufacturer when installing the adapter.

NOTE:

Bleed the longest line first. Make sure the bleeder tank contains enough
specified brake fluid to complete the bleeding operation. See BLEEDING
SEQUENCE table.

NOTE:

When a new brake master cylinder has been installed or the system has been
emptied, or partially emptied, it should be primed to prevent air from entering
the system.

2003 Ford Pickup F150

2002-04 BRAKES Disc & Drum - Blackwood, F150 Heritage Pickup & F150 Pickup

6. Remove the short brake tubes, and install the brake outlet tubes.

7. Bleed each brake tube at the brake master cylinder as follows:

z

Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal.

z

Loosen the rearmost brake tube fittings until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the brake tube fitting.

z

Repeat this operation until clear, bubble-free fluid comes out.

z

Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front
brake tube.

Four Wheel Anti-Lock Brake System Hydraulic Control Unit

1. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder

reservoir with the specified brake fluid.

2. Connect a clear waste line to the right rear bleeder screw and the other end in a container partially filled

with recommended brake fluid.

3. Loosen the right rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains

pressure on the brake pedal, tighten the right rear bleeder screw. Repeat until clear, bubble-free fluid
comes out. Refill the brake master cylinder reservoir as necessary.

4. Tighten the right rear bleeder screw, and disconnect the waste line.

5. Repeat Steps 2 -4 for the left rear bleeder screw, the right front disc brake caliper bleeder screw, and the

left front disc brake caliper bleeder screw, in that order.

6. Connect the scan tool DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash, and

follow the scan tool instructions.

7. Repeat the system bleed procedure. See MANUAL BLEEDING or PRESSURE BLEEDING .

Caliper

1. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc

brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with
clean brake fluid.

2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.

3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant

maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. Repeat until clear,
bubble-free fluid comes out. Refill the brake master cylinder reservoir as necessary.

4. Tighten the disc brake caliper bleeder screw to specification. See TORQUE SPECIFICATIONS .

NOTE:

This procedure only needs to be performed if a new 4-wheel Anti-Lock Brake
(4WABS) Hydraulic Control Unit (HCU) has been installed or if the HCU lines
have been opened.

NOTE:

It is not necessary to do a complete brake system bleed if only the disc brake
caliper was disconnected.

2003 Ford Pickup F150

2002-04 BRAKES Disc & Drum - Blackwood, F150 Heritage Pickup & F150 Pickup

ADJUSTMENTS

BRAKE SHOES

With Drums Removed

1. Adjust with brake drums cold and parking brake correctly adjusted. Measure brake drum inside diameter

using Brake Adjustment Gauge (D81L-1103-A). See Fig. 18 .

Fig. 18: Measuring Brake Drum & Shoe Diameter
Courtesy of FORD MOTOR CO.

2. Reverse adjustment gauge. Apply gauge to brake shoes on a line parallel to ground and through center of

axle. Hold adjusting lever away from adjusting screw. Turn screw until outside diameter of shoes contacts
gauge. See

Fig. 18

.

3. Install brake drum and wheel assembly. Complete adjustment by applying brakes quickly several times

while driving vehicle alternately forward and backward. Check brake operation by stopping often while
driving forward.

With Drums Installed

Raise vehicle, and support with safety stands. Remove adjusting hole cover rubber plug. Using a screwdriver,
move the brake shoe adjusting lever off the brake shoe adjusting screw nut. Move the adjustment tool handle

NOTE:

Rear brake shoes are automatically adjusted when vehicle is driven forward and
backward and brakes are applied sharply. Instruction adjustment is required if
brakes do not self-adjust or after brake shoes have been removed or replaced.

2003 Ford Pickup F150

2002-04 BRAKES Disc & Drum - Blackwood, F150 Heritage Pickup & F150 Pickup

upward to tighten the brake adjuster screw. Turn the brake shoe adjusting screw nut until the brake drum begins
to drag. Then loosen the brake adjuster screw until the brake drum rotates freely. See Fig. 19 .

Fig. 19: Adjusting Rear Drum Brake Shoes
Courtesy of FORD MOTOR CO.

DISC PADS

As brake pads wear, caliper piston remains in constant contact with brake pad, eliminating need for adjustment.

PARKING BRAKE

Parking Brake Shoe Adjustment

Check the operation of the parking brake system with the vehicle on a hoist and the parking brake control fully
released. Check for any damaged cables and install new components as necessary. Check the rear brake
adjustment. See BRAKE SHOES .

Using Brake Adjustment Gauge (D81L-1103-A), measure inside diameter of drum portion of rear brake disc or

2003 Ford Pickup F150

2002-04 BRAKES Disc & Drum - Blackwood, F150 Heritage Pickup & F150 Pickup