Ford F150 Pickup. Instruction - part 338

 

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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

  

 

 

 

 

 

 

 

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