Tuesday, September 20, 2011

brake line diagram for 1999 ford f150

Hydraulic Control Unit





the master is under the floor, the easiest way to do it is to run the felxible hoses to the frame from each wheel. Then run the hard lines from the brake hoses together to a 'Tee' fitting near the driver's side, you may or may not need to put a 2 lb residual valve in the line, then run a line connecting the RV (if used) to the front reservoir of the master. Make sure the flex lines don't rub or contact anything.

Metal brake lines carry pressurized fluid from the brake master cylinder to a connector mounted in a bracket inside of the wheel well. Rubber lines with threaded fittings connect the metal lines to the caliper, and contain the pressure of the brake system.

Details regarding Brake Lines replacing:--

  • Locate the mounting bracket inside the fender well where the rubber and metal lines come together. Hold the fitting with a backup wrench and remove the metal line fitting with a flare nut wrench. Use caution to avoid bending the bracket or the metal line.Grasp the U-clip holding the rubber line fitting into the bracket with a pair of pliers. Pull the clip out to release the rubber line from the brakeRemove the rubber line from the caliper. Back out the banjo bolt that holds the rubber line fitting onto the caliper with a wrench. Remove and discard both of the crush washers on the fitting.Install the new rubber line onto the caliper. Place a new crush washer on the banjo bolt. Insert the banjo bolt into the rubber line fitting and slide on another new crush washer. Thread the banjo bolt into the caliper and torque it to 17 to 25 ft. lbs. with a 3/8-inch torque wrench.Insert the hose fitting into the mounting bracket and slide the U-clip in, by hand, to lock it in place. Thread the metal brake line fitting into the female rubber line fitting. Hold the rubber line fitting with a backup wrench and tighten the fitting securely with a flare nut wrench.

Details regarding Bleeding the Brake:---

  • Wipe off the master cylinder reservoir cap with a clean rag. Remove the reservoir cap and diaphragm by hand. Top off the fluid in the reservoir with new DOT 3 brake fluid.Install a small rubber hose onto the brake caliper bleeder screw. Route the hose into the catch pHave a helper pump the brake pedal three times, and then hold it down with moderate pressure. Open the bleeder screw a bit to allow the air to escape and fluid to fill the system. Tighten the bleeder screw when fluid or air flow ceases to come from the bleeder.Repeat Step 3 until the fluid escaping the bleeder is solid and free of air bubbles. Check the fluid level in the reservoir frequently. Add fluid as necessary. Do not let it run dry.Top off the fluid level in the reservoir. Install the diaphragm seal and cap by hand
    There are 5 ports on the EHCU( engine hydraulic control unit) the primary and secondary from the master cylinder, the primary connects in to the far right port, the secondary connects into the far left port.

You can see the 5 ports below:---

Disconnect the hydraulic brake lines.
  1. Disconnect the inlet hydraulic brake lines.
  1. Disconnect the outlet hydraulic brake lines.


Far Left = Front input

2nd from left = Left Front Output

Center = Right Front Output

Center Right = Rear Output

Right = Rear Input

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Hydraulic Control Unit

REMOVAL & INSTALLATION





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Fig. Fig. 1 Disconnect and plug the hydraulic brake lines



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Fig. Fig. 2 Remove the HCU retaining bolts and remove the HCU

  1. Disconnect the negative battery cable.
  2. On Super Duty models, remove the air cleaner assembly.
  3. On Super Duty models, remove the EVAP canister.
  4. Detach the anti-lock brake control module electrical connectors.


CAUTION
Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance.

  1. Disconnect and plug the hydraulic brake lines.
  2. Remove the HCU retaining bolts and remove the HCU.
  3. If necessary, remove the HCU bracket.

To install:

  1. If removed, install the HCU bracket.
  2. Position the HCU.
  3. Install and tighten the retaining bolts.
  4. Connect the hydraulic brake lines.
  5. Connect the anti-lock brake control module electrical connectors.
  6. On Super Duty models, install the EVAP canister.
  7. On Super Duty models, install the air cleaner assembly.
  8. Connect the negative battery cable.
  9. Bleed the 4-wheel ABS.

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Master Cylinder


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Fig. Fig. 5 ... loosen the brake line fittings at the master cylinder




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Fig. Fig. 6 Plug the brake lines and inlet ports of the master cylinder



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Fig. Fig. 7 Remove the 2 retaining nuts and position the RABS valve out of the way



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Fig. Fig. 8 Remove the 2 retaining nuts and ...



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Fig. Fig. 9 ... remove the master cylinder from the brake booster

  1. Disconnect the negative battery cable.
  2. Detach the fluid level electrical harness connector from the master cylinder reservoir.
  3. If equipped with speed control, detach the brake pressure switch electrical harness connector.
  4. Disconnect and plug 2 brake lines at the brake master cylinder ports.
  5. If the vehicle is equipped with rear anti-lock brakes, remove 2 retaining nuts and position the RABS valve out of the way using care not to damage the brake lines.
  6. Remove the 2 brake master cylinder retaining nuts and remove the master cylinder.

To install:

  1. Bench bleed the brake master cylinder before installation.
  2. Place the brake master cylinder to the power brake booster. Install 2 retaining nuts and tighten to 21 ft. lbs. (29 Nm).
  3. If equipped, install the RABS valve and 2 retaining nuts. Tighten to 15-21 ft. lbs. (21-29 Nm).
  4. Unplug and connect 2 brake lines to the brake master cylinder ports and tighten the fittings to 11-15 ft. lbs. (15-20 Nm).
  5. If equipped, connect the brake pressure switch electrical harness connector.
  6. Connect the electrical harness connector to the low fluid level warning switch.
  7. Fill the brake master cylinder with clean DOT 3 or equivalent brake fluid from a closed container.
  8. Bleed the entire brake system following the proper procedure.
  9. Road test the vehicle and check for proper brake system operation.
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Brake Hoses and Lines



Metal lines and rubber brake hoses should be checked frequently for leaks and external damage. Metal lines are particularly prone to crushing and kinking under the vehicle. Any such deformation can restrict the proper flow of fluid and therefore impair braking at the wheels. Rubber hoses should be checked for cracking or scraping; such damage can create a weak spot in the hose and it could fail under pressure.

Any time the lines are removed or disconnected, extreme cleanliness must be observed. Clean all joints and connections before disassembly (use a stiff bristle brush and clean brake fluid); be sure to plug the lines and ports as soon as they are opened. New lines and hoses should be flushed clean with brake fluid before installation to remove any contamination.

REMOVAL & INSTALLATION



  1. Disconnect the negative battery cable.
  2. Raise and safely support the vehicle on jackstands.
  3. Remove any wheel and tire assemblies necessary for access to the particular line you are removing.
  4. Thoroughly clean the surrounding area at the joints to be disconnected.



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Fig. Fig. 1 Use a brush to clean the fittings of any debris

  1. Place a suitable catch pan under the joint to be disconnected.
  2. Using two wrenches (one to hold the joint and one to turn the fitting), disconnect the hose or line to be replaced.



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Fig. Fig. 2 Use two wrenches to loosen the fitting. If available, use flare nut type wrenches

  1. Disconnect the other end of the line or hose, moving the drain pan if necessary. Always use a back-up wrench to avoid damaging the fitting.
  2. Disconnect any retaining clips or brackets holding the line and remove the line from the vehicle.

If the brake system is to remain open for more time than it takes to swap lines, tape or plug each remaining clip and port to keep contaminants out and fluid in.



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Fig. Fig. 3 Any gaskets/crush washers should be replaced with new ones during installation



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Fig. Fig. 4 Tape or plug the line to prevent contamination

To install:

  1. Install the new line or hose, starting with the end farthest from the master cylinder. Connect the other end, then confirm that both fittings are correctly threaded and turn smoothly using finger pressure. Make sure the new line will not rub against any other part. Brake lines must be at least 1/2 in. (13mm) from the steering column and other moving parts. Any protective shielding or insulators must be reinstalled in the original location.


WARNING
Make sure the hose is NOT kinked or touching any part of the frame or suspension after installation. These conditions may cause the hose to fail prematurely.

  1. Using two wrenches as before, tighten each fitting.
  2. Install any retaining clips or brackets on the lines.
  3. If removed, install the wheel and tire assemblies, then carefully lower the vehicle to the ground.
  4. Refill the brake master cylinder reservoir with clean, fresh brake fluid, meeting DOT 3 specifications. Properly bleed the brake system.
  5. Connect the negative battery cable.

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REMOVAL & INSTALLATION



1997-98 F-250HD, F-350 and F-SuperDuty


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Fig. Fig. 1 Master cylinder mounting-1997-98 F-250HD, F-350 and F-SuperDuty

  1. With the engine OFF , depress the brake pedal several times to expel any vacuum.
  2. Disconnect the fluid level warning switch wire.
  3. Disconnect the hydraulic system brake lines at the master cylinder.
  4. Remove the master cylinder retaining nuts and remove the master cylinder.

To install:

  1. Position the master cylinder assembly on the booster and install the retaining nuts. Tighten the nuts to 18-25 ft. lbs. (25-34 Nm).
  2. Connect the hydraulic brake system lines to the master cylinder.
  3. Connect the wiring.
  4. Bleed the master cylinder.

F-150, F-250, Expedition and Navigator


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Fig. Fig. 2 Detach the fluid level electrical harness connector



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Fig. Fig. 3 If equipped with speed control, detach the brake pressure switch electrical harness connector



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Fig. Fig. 4 Use a suitable size flare nut wrench to ...



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Fig. Fig. 5 ... loosen the brake line fittings at the master cylinder



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Fig. Fig. 6 Plug the brake lines and inlet ports of the master cylinder



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Fig. Fig. 7 Remove the 2 retaining nuts and position the RABS valve out of the way



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Fig. Fig. 8 Remove the 2 retaining nuts and ...



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Fig. Fig. 9 ... remove the master cylinder from the brake booster