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Ford Falcon. Manual - part 73

206-06-12 Hydraulic

Brake

Actuation 206-06-12

DIAGNOSIS AND TESTING (Continued)

Test Step

Result / Action to Take

PCM CHECK

Back probe an earth at the PCM connector terminal B25 B00 (G-R

Yes

wire).

PCM issue. Refer to Section 303-14.

Ignition ON.

Go to C4

Apply brake pedal.

Do the rear stop lamps now illuminate?

STOP LAMP SWITCH CONTINUITY

Remove the Stop lamp switch. Refer to Section 417-01.

Yes

Stop lamp switch Okay

Carry out a continuity test.

With the stop lamp switch plunger Out = Continuity.

Replace the stop lamp switch. Refer in this

Push the stop lamp switch plunger Inwards = Open circuit.

Section.

Is the stop lamp switch continuity check Okay?

PINPOINT TEST D : CRUISE CONTROL BRAKE PEDAL CUT OFF SWITCH

Test Step

Result / Action to Take

STOP LAMP CIRCUIT FUSE

Check the 15 Amp Fuse ???

Yes

Replace Fuse and recheck.

Was Fuse blown?

NOTE: If Fuse blows again, this could indicate
an electrical system fault.

Go to D2

CRUISE CONTROL SWITCH CONTINUITY

Remove the cruise control switch, colour Green. Refer to Section

Yes

303-14.

Go to D3

Carry out a continuity test.

Replace the cruise control switch. Refer to

With the switch pin Out = Open circuit.

Section 303-14.

Push the switch pin Inwards = continuity.

Is the cruise control switch continuity check Okay?

SWITCH EARTH CIRCUIT CONTINUITY

Disconnect the electrical connector at the cruise control switch and

Yes

the PCM.

PCM issue. Refer to Section 303-14.

Check the LG wire (511) from the switch connector to the PCM

terminal B32 RBS.

Check and repair wiring or terminal fault

Was there continuity?

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206-06-13 Hydraulic

Brake

Actuation 206-06-13

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST E : ADJUSTABLE PEDAL ISSUES

NOTE: The Pedal adjustment motor is equipped with a Thermal cutout feature. If the motor is operated for an

extended period this Thermal cutout will open circuit (trip). In this case wait for 5 Minutes to allow resetting of

the Thermal cutout device.

Test Step

Result / Action to Take

NO ADJUSTMENT RESPONSE - PART 1

Check to see if the electric wiring connector C-379 is connected, to

Yes

the pedal adjustment motor.

Go to E2

Is C-379 connected?

Reconnect the connector and retest

PEDAL BOX HARNESS

Check to see if the electrical wiring connector C-395 is connected.

Yes

Go to E3

Is C-395 connected?

Reconnect the connector and retest

NO PEDAL RESPONSE

Remove the electrical connector C-379 from the pedal adjustment

Yes

motor.

Go to E4

Ignition On.

Electrical issue at the vehicle harness. Refer to

Using a multimeter, check the Voltage at the terminals, Red (+) and

Section 418-00 & Wiring Supplement.

White (-) wires at the vehicle harness connector C-379.

Is the Voltage less than 2 Volts?

ADJUSTMENT SWITCH VOLTAGE CHECK

Remove the electrical connector C-379 from the pedal adjustment

Yes

motor.

Go to E5 (reconnect connector C-379).

Using a multimeter, check the Voltage at the terminals, Red (+) and

White (-) wires at the vehicle harness connector C-379.

Go to E6

Ignition On. Hold down the Brake pedal adjustment switch (at steering
column).

NOTE:

The voltage polarity will change when the switch is held in

the opposite direction.

Is the voltage reading equal to or greater than 12 volts?

BRAKE PEDAL ADJUSTMENT SWITCH

Ignition On.

Yes

Go to E7

Ensure that the "thermal cutout has not "tripped" (will have to wait 5
Minutes for reset).

Replace the Adjustment Motor. Refer to

Operate Pedal adjustment switch.

procedure in this section.

Does the motor emit a "click" sound when the switch is
operated?

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206-06-14 Hydraulic

Brake

Actuation 206-06-14

DIAGNOSIS AND TESTING (Continued)

Test Step

Result / Action to Take

PEDAL ACTIVATION SWITCH

Remove the lower section of the steering shroud. Refer to Section

Yes

211-04.

Carry out vehicle wiring harness testing. Refer to
the appropriate wiring diaghram.

Disconnect the electrical connector from the activation switch
harness.

Replace the pedal activation switch. Refer to

Push the activation switch to the forward position. Using an Ohms

Section 211-05.

meter check for continuity between the Black, Blue/Black and
Blue/Orange wires.

Push the activation switch to the downwards position. Using an Ohms
meter check for continuity between the Black, Yellow and
Blue/Orange wires.

Did the activation switch have continuity in the forward /
downward Ohms check?

MEMORY FUNCTION NOT OPERATING (MEMORY UNIT

ONLY)

Yes

NOTE:

Pedal position sensor faults should have been set by error code

Replace the adjustment cable assembly. Refer

from the memory seat control.

to procedure in this section.

Disconnect the Potentiometer electrical connector C-378 from the

adjustment cable.

If the resistance reading was greater than 10 K

Using a multimeter, check the resistance at the terminals, L - Y (+)

Ω. Replace the adjustment cable. Refer to

and White (-) wires at the vehicle harness connector C-378.

procedure in this section.
Otherwise.

Reconnect connector C-378.

Go to E8

Was the resistance less than 1.5 K

Ω?

POTENTIOMETER - RESISTANCE FEED BACK STAGE-1

(MEMORY ONLY)

Adjust pedals to the fully forward position.

Yes

Go to E9

Using a multimeter, check the resistance at the terminals, L - Y (+)
and White (-) wires at the vehicle harness connector C-378.

Replace the adjustment cable. Refer to

Adjust pedals to the fully rearward position.

procedure in this section.

Using a multimeter, check the resistance at the terminals, L - Y (+)
and White (-) wires at the vehicle harness connector C-378.

Is the resistance value between the fully forward and rearward
positions greater than 600

Ω?

POTENTIOMETER - RESISTANCE FEED BACK STAGE-

2 (MEMORY ONLY)

Using the resistance readings taken in E 7.

Yes

Go to E10

Was the resistance reading for "full forward " position between
1.5 and 4.5 K

Ω?

Adjustment cable incorrectly adjusted. Refer to
procedure in this section.

E10

ADUSTMENT CABLE

Check the adjustment cable for jamming, crushed, twisted or caught

Yes

condition.

Remove the adjustment cable. Refer to
procedure in this section.

Did any of the above occur?

Grasp the inner cable to see if it turns freely, if
not replace the cable. Refer to procedure in this
section or the cause of twisting, jamming etc.

Go to E11

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206-06-15 Hydraulic

Brake

Actuation 206-06-15

DIAGNOSIS AND TESTING (Continued)

Test Step

Result / Action to Take

E11

BRAKE PEDAL ADJUSTMENT TRANSMISSION / CABLE

Gently disconnect the drive cable from the adjustment motor

Yes

transmission (located top of brake pedal).

Go to E12

Using your fingers fully rotate the inner cable 10 times clockwise and

10 times anticlockwise.

Replace pedal box assembly. Refer to
procedure in this section.

View the brake pedal for movement while turning the inner cable.

Clockwise - Rearward pedal movement, anticlockwise - Forward
pedal movement.

NOTE:

When turning the inner cable the pedal will only move very

slightly. Care should be taken when viewing movement.

Does the pedal move when cable turned?

E12

ACCELERATOR ADJUSTMENT TRANSMISSION. PART -

Disconnect the brake pedal transmission drive cable from the brake

Yes

pedal transmission.

Go to E14

Ignition On.

Go to E13

Operate the adjustment switch.

Does the accelerator pedal move?

E13

ACCELERATOR ADJUSTMENT TRANSMISSION. PART-

Remove the pedal box assembly from the vehicle. Refer to procedure

Yes

in this section.

Pedal adjustment transmission operating okay.
Replace the adjusting motor. Refer to procedure

Remove the adjusting motor. Refer to procedure in this section.

in this section.

Using your fingers, fully rotate the accelerator pedal transmission

"short" cable 10 times clockwise and 10 times anti-clockwise. View

Replace the pedal adjustment transmission.

the accelerator pedal for movement while turning the cable.

Refer to procedure in this section.

NOTE:

When turning the cable the accelerator pedal will only move

very slightly. Care should be taken when viewing pedal movement.

Did the cable turn?

E14

STEP OVER HEIGHT CHECK PART 1

Measure the Step over height between the Brake and Accelerator

Yes

pedal.

Rectify the pedal Indexing. Refer to procedure in
this section.

Is the measured height distance more than 40mm?

Go to E15

E15

STEP OVER HEIGHT CHECK PART 2

Measure the Step over height between the Brake and Accelerator

Yes

pedal.

Rectify the pedal Indexing. Refer to procedure in
this section.

Is the measured height distance less than 30mm?

Step Over height okay, no further work required.

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