Ford F150 Pickup. Instruction — part 385

Fig. 10: Identifying Rear Disc Brake Components (F150 Pickup & F150 Heritage Pickup)
Courtesy of FORD MOTOR CO.

Rear Drum Brakes

2003 Ford Pickup F150

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

Rear drum brakes are used on F150 Pickup and F150 Heritage Pickup. The drum brake system is the single
anchor type and has active self-adjustment. The drum brake system is split front and rear hydraulically. On rear
drum brake models, the parking brake is actuated by a cable, which pulls the parking brake lever located inside
rear brake assembly. The lever pivots parking brake strut between brake shoes. This movement pushes outward
on brake shoes. Brake shoe linings are made of asbestos-free, fiberglass material. Rear drum brake assembly
consists of a support plate, 2 brake shoes, return springs, automatic adjuster components and one dual-piston
wheel cylinder. See Fig. 11 .

Fig. 11: Identifying Rear Drum Brake Components (F150 Pickup & F150 Heritage Pickup)
Courtesy of FORD MOTOR CO.

Master Cylinder

The brake master cylinder is a dual-piston type. See Fig. 12 . The brake master cylinder is assisted by a power
brake booster. The following conditions are considered normal and not indications that the brake master
cylinder is in need of repair or replacement:

1. Low brake fluid level detected without signs of leakage. This condition is caused by displacement of

brake fluid to the disc brake calipers to compensate for normal brake wear. Add brake fluid as needed.

2. A momentary or slight squirt of brake fluid from the brake master cylinder reservoir upon application of

2003 Ford Pickup F150

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

the brake pedal.

3. A trace of brake fluid found on the outside of the power brake booster below the brake master cylinder

mounting flange. This condition results from the lubricating action of the brake master cylinder wiping
seal.

The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder reservoir. It
consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder
reservoir. See Fig. 13 . When the brake fluid in the brake master cylinder reservoir gets to a predetermined
level, the floating magnet actuates the reed switch, causing the Red brake warning indicator to illuminate. Loss
of brake fluid from either the primary (front) hydraulic circuit or secondary (rear) hydraulic circuit will cause
the warning indicator to activate. If the brake fluid level warning switch is inoperative, the brake master
cylinder reservoir must be installed new.

Fig. 12: Identifying Master Cylinder Components (F150 Pickup & F150 Heritage Pickup Shown;
Blackwood Is Similar)
Courtesy of FORD MOTOR CO.

2003 Ford Pickup F150

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

Fig. 13: Identifying Brake Fluid Level Warning Switch (F150 Pickup & F150 Heritage Pickup Shown;
Blackwood Is Similar)
Courtesy of FORD MOTOR CO.

Parking Brake

The parking brake system is actuated when the parking brake control is depressed. The parking brake control
applies tension to the front parking brake cable and conduit and parking brake cable equalizer. The parking
brake cable equalizer is coupled to the right parking brake rear cable and the left parking brake rear cable. The
respective rear brake assemblies are then applied. See Fig. 14Fig. 15 .

The rear wheel brake disc assembly contains a cable actuated parking brake assembly. See Fig. 16 . If the
parking brake control is not fully released, the parking brake signal switch will illuminate the brake warning
light. The parking brake signal switch is mounted on the parking brake control. The switch is held in place by a
self-tapping screw and aligned with a locator pin. The brake disc parking brake system is not self-adjusting.
Therefore cable tension may need to be adjusted. On 2004 F150 Pickup, parking brake cable tension is self-
adjusting.

2003 Ford Pickup F150

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