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05S28-Supplement #15
April 10, 2008
Check the Ford website &/or the NHTSA to see if your VIN is affected.

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Affected title branded & salvaged vehicles are eligible for this Field Service Action.

Q1. What is the Universal Fused Jumper Harness?
A. The Universal Fused Jumper Harness contains a fuse in each side of the circuit to accommodate polarity complexity across vehicle lines, and a connector hardshell that is compatible with all Speed Control Deactivation Switches.
Q2. Why are the Speed Control Deactivation Switches not interchangeable on all vehicle applications?
A. Differences in Speed Control Deactivation Switch (SCDS) activation pressures make it essential that the correct SCDS is installed in the specified vehicle application.
Q3. Can I just remove the fuse for the Speed Control System circuit?
A. No. Removing the fuse will disable more systems on the vehicle than just the Speed Control System.
Q4. Can the customer disconnect the Speed Control Deactivation Switch connector?
A. No. To ensure that the correct connector is disconnected, a dealership technician should perform this service.
Q5. Is the Speed Control Deactivation Switch located on the vehicle steering wheel?
A. No. The Speed Control Deactivation Switch is typically mounted to the brake master cylinder under the hood. On some of the earlier built vehicles, the SCDS was mounted to a junction block or brake proportioning valve located below the master cylinder on or near the frame rail.
Q6. Can customers avoid overheating the switch by not using the Speed Control System?
A. No. The electrical circuit to the Speed Control Deactivation Switch is always energized, so not using the Speed Control System doesn't reduce the potential for overheating of the switch.

SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS.

1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle.
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program.
3. Remove the SCDS.
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS.
5. Tighten the new SCDS as follows:
^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri.
^ 13 Nm (115 lb-in) - 1994 Capri.
6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap.
7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage.
^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step.
^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions.
8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors.
9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip.
10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A.
11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module.
12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector.
__________________________________________________
Field Service Action 05S28 Speed Control System Modification
Supplement #7 (THIS BULLETIN HAS BEEN REVISED SEVERAL TIMES, SO THE INFORMATION BELOW IS NOT CURRENT.)
Check the Ford website &/or the NHTSA to see if your VIN is affected.



Applies to certain vehicles equipped with speed control:
1994-1996 Bronco
1994-2002 F-150/250 (Under 8500 GVW)
1997- 2002 Expedition
1998-2002 Navigator
2002 Blackwood

OVERVIEW :
This program involves performing an inspection procedure to determine which repairs to the speed control system must be performed; either installation of a fused jumper harness or replacement of the speed control deactivation switch. A flow chart has been developed to direct you to the proper service actions.

NOTE: Disconnecting the battery is no longer required when performing these repairs.

INSPECTION - ALL AFFECTED VEHICLES
1. Disconnect the speed control deactivation switch located on the brake master cylinder and inspect the harness connector for the presence of brake fluid. See Figure 1.
a. If no brake fluid is present, install the fused jumper harness (Labor Operation D).
b. If brake fluid is present, disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 2.
c. If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to Labor Operation E.
d. If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions.

LABOR OPERATION D - APPLIES TO VEHICLES WITH NON-LEAKING SWITCHES

1.a. Connect the fused jumper harness (14A411) to the speed control deactivation switch and the vehicle harness.
b. Position the harness alongside the existing harness, located below the master cylinder, so that the fuse holder is higher than the rest of the jumper harness. This will cause any water that enters the engine compartment and gets on the jumper harness to run downhill away from the fuse holder.
c. Secure the jumper to the existing harness with tie straps, making sure the fuse holder is positioned vertically with the cap facing upwards. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation.
2. Release the vehicle.

LABOR OPERATION E - APPLIES TO VEHICLES WITH LEAKING SWITCHES

1. Remove the speed control deactivation switch from the brake master cylinder. CAUTION: Do not allow any foreign material to enter the master cylinder port once the deactivation switch is removed.
2. Add a few drops of MotorCraft High Performance DOT 3 Brake Fluid, PM-1, to the fluid port at the threaded end of the new deactivation switch. CAUTION: DO NOT apply fluid to the electrical connector.
3. Install the new speed control deactivation switch into the master cylinder and tighten to 18 Nm (13 lb-ft).
4. With the speed control servo disconnected, use shop air only to blow the speed control deactivation switch harness electrical connector and the servo connector dry of any trace of brake fluid. DO NOT USE ANY TYPE OF SOLVENT TO CLEAN THE CONNECTORS.
5. Apply Ford Electrical Grease F8AZ-19G208-AA into each cavity of the vehicle harness connector only. It is not necessary to apply grease to the servo side of the connector.
6. Reconnect the servo connector.
7. Install the adapter jumper harness by connecting it to both the deactivation switch and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness.
8. Check the brake fluid level in the master cylinder and adjust if necessary.
9. Release the vehicle.

For more details about the fused jumper harness, see this photo:


See also:
. . .

For other TSBs, check here.