Ford F150 Pickup. Instruction — part 338

3. Remove corrosion from wheel mounting surface, both disc mounting surfaces, and hub mounting

surface. A die grinder with ScotchBrite(R) surface conditioning disc, or equivalent, is
recommended.

4. Align the match marks and reinstall the disc on the hub.

8. Machine the brake disc using Rotunda Hub-Mount Brake Lathe/Pro-Cut 201-00002, or equivalent.

1. Install the hub adapter and silencer belt, if necessary.

2. Install the cutting lathe.

3. Adjust lathe oscillation using a dial indicator.

4. Center cutting head, adjust cutting bits, and install chip deflector.

5. Matching the brake disc.

6. Remove the lathe and, if installed, the silencer belt.

7. Remove the hub adapter.

9. Remove metal shavings.

10. Install the brake pads. For additional information, refer to DISC & DRUM

11. Install the wheel and tire assembly. For additional information, refer to WHEELS & TIRES - F150

PICKUP .

Symptom Chart

SYMPTOM CHART

and disc lateral runout.

CAUTION: Do not use a bench lathe to machine brake discs.

NOTE:

Read the entire operating instruction and view the video shipped with the
lathe before installing, operating, or servicing the lathe.

NOTE:

Total indicated reading target is 0.000 mm (0.000 in), maximum is 0.08
mm (0.003 in).

NOTE:

Depth of cut should be between 0.10 and 0.20 mm (0.004 and 0.008
in). Lighter cuts will cause the bit to heat up and wear faster. Heavier
cuts will cause poor disc surface finish.

Condition

Possible Sources

Action

z

Brakes pull or drift

z

Tire air pressure.

z

Wheel alignment.

z

GO to PINPOINT TEST A.

2003 Ford Pickup F150

2003 GENERAL INFORMATION Brake System - General Information - F150 Pickup

z

Brake pads.

z

Brake shoes and
linings.

z

Brake components.

z

Suspension
component.

z

Red brake warning
indicator always on

z

Instrument cluster.

z

Circuit.

z

REFER to INSTRUMENT
CLUSTER-CONVENTIONAL -
F150 .

z

Parking brake.

z

Brake fluid level.

z

REFER to INSTRUMENT
CLUSTER-CONVENTIONAL -
F150 .

z

Brake pedal goes down
fast

z

Brake fluid level.

z

FILL the brake master cylinder
reservoir. BLEED the system.

z

Air in system.

z

BLEED the system.

z

Brake master
cylinder.

z

CARRY OUT the BRAKE MASTER
CYLINDER component test.

z

The brake pedal eases
down slowly

z

Air in system.

z

BLEED the system. REFER to
BLEEDING - COMPONENTS.

z

Brake master
cylinder.

z

CARRY OUT the BRAKE MASTER
CYLINDER component test.

z

Brakes lock up during
light brake pedal force

z

Disc brake
component.

z

Drum brake
component.

z

Parking brake
component.

z

Anti-lock brake
control system.

z

GO to PINPOINT TEST B.

z

Excessive/erratic brake
pedal travel

z

Leak in hydraulic
system.

z

Air in system.

z

Disc brake caliper.

z

Drum brake
components.

z

Brake booster-to-
brake master
cylinder push rod
adjustment.

z

Brake master

z

GO to PINPOINT TEST C.

2003 Ford Pickup F150

2003 GENERAL INFORMATION Brake System - General Information - F150 Pickup

cylinder (2140).

z

Slow or incomplete
brake pedal return

z

Carpet, floormat or
other obstruction.

z

REMOVE the obstruction. TEST the
system for normal operation.

z

Binding, damaged
or incorrectly
installed brake
pedal.

z

REPAIR or INSTALL a new brake
pedal. CHECK brake pedal for correct
installation. REFER to HYDRAULIC
BRAKE ACTUATION .

z

Binding, damaged
or incorrectly
installed power
brake booster.

z

REPAIR or INSTALL a new power
brake booster. CHECK for correct
installation. REFER to POWER
BRAKE ACTUATION - F150
PICKUP .

z

Brakes drag

z

Parking brake
component.

z

REPAIR or INSTALL new components
as necessary; REFER to PARKING
BRAKE & ACTUATION - F150
PICKUP .

z

Disc brake caliper.

z

REPAIR or INSTALL new as
necessary; REFER to DISC & DRUM .

z

Drum brake
component.

z

REFER to DISC & DRUM .

z

Brake booster-to-
brake master
cylinder push rod
adjustment.

z

ADJUST the push rod; REFER to
POWER BRAKE ACTUATION .

z

Brake master
cylinder.

z

CARRY OUT the BRAKE MASTER
CYLINDER component test.

z

Excessive brake pedal
effort

z

Power brake
booster (2005).

z

Power brake
booster check valve
(2365).

z

Power brake
booster hose.

z

CARRY OUT the BRAKE BOOSTER
component test.

z

Red brake warning
indicator inoperative

z

Circuit.

z

Bulb.

z

REFER to INSTRUMENT
CLUSTER-CONVENTIONAL -
F150 or to INSTRUMENT
CLUSTER-NATURAL GAS - F150 .

z

Brake noise

z

Disc brake
component.

z

MACHINE or INSTALL new
components as necessary; REFER to
DISC & DRUM .

z

Drum brake
component.

z

REPAIR or INSTALL new components
as necessary; REFER to DISC &

2003 Ford Pickup F150

2003 GENERAL INFORMATION Brake System - General Information - F150 Pickup

Pinpoint Tests

PINPOINT TEST A: BRAKES PULL OR DRIFT

DRUM .

z

Brake
vibration/shudder -
occurs when brakes are
applied

z

Uneven disc or
drum wear.

z

Uneven disc brake
pad or lining
transfer.

z

Suspension
components.

z

REFER to NOISE, VIBRATION &
HARSHNESS .

z

Adjustable brake pedal
does not operate/does
not operate

z

Cable.

z

Motor.

z

Wiring.

z

Switch.

z

GO to PINPOINT TEST D.

2003 Ford Pickup F150

2003 GENERAL INFORMATION Brake System - General Information - F150 Pickup