Brake System

206-00-1 Brake System — General Information 206-00-1
SPECIFICATIONS
General Specifications (Continued)
Item Specification
General Specifications
Lubricant
Item Specification
High Performance DOT 3 ESA-M6C25-A
Brake Pads Motor Vehicle Brake
Brake pad minimum 3.0 mm (0.118 inch) Fluid PM-1 (Canada
thickness CPM-1)
Brake pad maximum 2.0 mm (0.079 inch) High Temperature Nickel ESE-M12A4-A
thickness variation Anti-Seize Lubricant XL-2
(pad-to-pad) (Canada CXG-2-B)
Brake pad maximum taper 3.0 mm (0.118 inch) Silicone Brake Caliper ESE-M1C171-A
wear (in any direction) Grease and Dielectric
Compound XG-3-A
Brake Disc
Brake Parts Cleaner PM-4 —
Front brake disc minimum 26.5 mm (1.04 inch)
thickness
Rear brake disc minimum 11 mm (0.43 inch) Torque Specifications
thickness Description Nm lb-ft
Minimum thickness to 27.1 mm (1.06 inch) Bleeder screw 22 16
machine front disc
Master cylinder brake tube 18 13
Minimum thickness to 11.6 mm (0.45 inch) fittings
machine rear disc
Copyright  2004, Ford Motor Company

Last updated: 9/15/2004 2005 Aviator, 09/2004
DESCRIPTION AND OPERATION

Brake System Programming Adjustable Pedal Positions
The brake system has the following components: Programming adjustable pedal positions can be
accomplished as follows:
• a vacuum-assisted power braking system
• An adjustable pedal position can be stored at any
• a front-to-rear split hydraulic system
time. To store the adjustable pedal position to
• front disc brakes using a dual piston brake caliper memory, the driver must move the pedals to the
and disc system preferred position using the adjustable pedal
• rear disc brakes using a single piston brake caliper switch. The driver must then depress the memory
and disc system SET switch, activating the memory SET switch
light emitting diode (LED). Within 5 seconds
• a mechanical parking brake system that activates a
(before the LED goes out) the driver must select
drum-in hat system within the rear brake disc
memory position 1, 2, or 3.
• a 4-wheel anti-lock brake system (4WABS). For
• If no memory switch input is received within the
additional information, refer to Section 206-09.
5 second time limit, the operation is aborted and
Adjustable Pedals the memory SET switch LED is turned OFF. If
one of the following inputs is received during the
The Lincoln Aviator is equipped with an adjustable
5 second programming limit, the operation is
brake and accelerator pedal system. Using the
aborted and the memory SET switch LED is
adjustable pedal switch located on the instrument
turned OFF:
panel, the driver can adjust the brake and
accelerator pedals for a more comfortable driving — adjustable pedal switch
position. For removal and installation of the — power driver seat switch
adjustable pedals, refer to Section 206-06.
— exterior mirror control switch
Adjustable Pedal Operation — memory SET switch
The adjustable pedals are operational with the
Recalling a Stored Adjustable Pedal Position
ignition switch in the ON or OFF positions. The
pedals can be adjusted forward or rearward using Once the driver has stored a preferred adjustable
the adjustable pedal switch. pedal position, the driver can recall the setting by
depressing the corresponding memory switch, or by
Driver Seat Module using a programmed RKE transmitter. Recalling a
The driver seat module (DSM) controls the memory stored adjustable pedal position can be
adjustable pedals. accomplished by doing the following:
The DSM constantly monitors the systems under its • The driver can recall a preferred adjustable pedal
control and reports a concern in the form of position by pressing one or both of the memory
diagnostic trouble codes (DTCs). DTCs are retrieved recall switches. Pressing memory switch 1
using a diagnostic tool with the appropriate adapter initiates a recall of the adjustable pedal position
cable through the data link connector (DLC). stored in memory No. 1. Pressing memory switch
2 initiates a recall of the adjustable pedal
Memory Adjustable Pedal Operation position stored in memory No. 2. Pressing both
The adjustable pedals with memory feature can be memory No. 1 and memory switch 2 will initiate
controlled by using the memory switches or the a recall of the adjustable pedal position stored in
remote keyless entry (RKE) transmitter. The outside memory No. 3.
rearview mirror and power driver seat positions are
also stored and recalled with the power adjustable
pedal positions. The system can store 3 memory
settings.

DESCRIPTION AND OPERATION (Continued)
• A RKE transmitter can be used to recall • Memory recall occurs when the UNLOCK switch
previously set memory positions. The RKE is pressed on the RKE transmitters. A second
transmitters are manufactured with an assigned press of the UNLOCK switch, which unlocks the
personality number (1, 2, or 3) and are so passenger doors, does not initiate a memory
designated on the back of the RKE transmitter recall.
case. The RKE transmitter assigned with • A memory recall in progress does not prohibit the
personality 1 is capable of only recalling memory initiation of another memory recall; the most
position 1. Similarly, the RKE transmitters recently requested memory recall is executed.
assigned with personalities 1, 2, and 3 can recall
memory positions 1, 2, and 3 respectively.
2005 Aviator, 09/2004

DIAGNOSIS AND TESTING

Brake System Inspection and Verification
Refer to Wiring Diagrams Cell 42 for schematic and WARNING: Use of any brake fluid other
connector information. than the approved DOT 3 will cause permanent
Refer to Wiring Diagrams Cell 127 for schematic damage to brake components and render the
and connector information. brakes inoperative. Failure to follow these
Special Tool(s) instructions may result in personal injury.
Worldwide Diagnostic System WARNING: Brake fluid contains

(WDS) polyglycol ethers and polyglycols. Avoid contact
Vehicle Communication Module with eyes. Wash hands thoroughly after
(VCM) with appropriate handling. If brake fluid contacts eyes, flush eyes
adapters, or equivalent with running water for 15 minutes. Get medical
diagnostic tool attention if irritation persists. If taken
internally, drink water and induce vomiting. Get
medical attention immediately. Failure to follow
73III Automotive Multimeter these instructions may result in personal injury.
105-R0057 or equivalent
CAUTION: Brake fluid is harmful to
painted and plastic surfaces. If brake fluid is
spilled onto a painted or plastic surface,
immediately wash it with water.
NOTE: Always check the fluid level in the brake
Anti-lock Brake System (ABS) master cylinder reservoir before carrying out the test
and Brake Pressure Test Kit procedures. If the fluid level is not at the correct
107-02351 or equivalent
level, clean the reservoir cap before removing, then
add DOT 3 brake fluid.
NOTE: Prior to carrying out any diagnosis, make
sure the red brake warning indicator is functional.
Refer to Section Section 413-01.
On-Car Brake Lathe
201-00002 The first indication that something may be wrong in
the brake system is a change in the feeling through
the brake pedal. The brake warning indicator in the
instrument cluster and the brake fluid level in the
brake master cylinder reservoir are also indicators
of system concerns.
If a wheel is locked and the vehicle must be moved,
Material open a bleeder screw at the locked wheel to let out
Item Specification enough fluid to relieve the pressure. Close the
High Performance DOT 3 ESA-M6C25-A bleeder screw. This bleeding operation may release
Motor Vehicle Brake Fluid the brakes, but will not correct the concern. If this
PM-1 (Canada CPM-1) does not relieve the locked wheel condition, repair
Silicone Brake Caliper ESE-M1C171-A the locked components before proceeding.
Grease and Dielectric Inspect all hoses and connections. All unused
Compound
XG-3-A vacuum connectors should be capped. Make sure
hoses and their connections are correctly secured
Brake Parts Cleaner —
PM-4 and in good condition with no holes, or soft or
collapsed areas.

DIAGNOSIS AND TESTING (Continued)
Road Test • Inspect and measure the thickness of the brake
The technician should have a thorough knowledge pad friction material.
of the brake system operation and accepted general — Install new brake pads if the thickness of the
braking guidelines in order to detect any problems. friction material is less than 3.0 mm (0.118
Select a road that is reasonably smooth and level. inch). Refer to Section 206-03 for front disc
Gravel or bumpy roads are not suitable because the brakes or Section 206-04 for rear disc brakes.
surface does not allow the tires to grip the road — Compare all 4 front or rear pads for uneven
equally. Avoid crowned roads. wear. Install new brake pads if the thickness
A key factor in evaluating brake concerns is the of the friction material varies from pad to pad
deceleration rate. This varies from vehicle to vehicle by more than 2.0 mm (0.079 inch). Refer to
and with changes in operating conditions. It is Section 206-03 for front disc brakes or Section
evident how well the brakes are working after just a 206-04 for rear disc brakes.
few applications. — Install new brake pads if there are missing
For low or spongy brake pedal concerns: chunks or cracks in the lining through to the
backing plate. Refer to Section 206-03 for
• bleed the brake system and retest the brake pedal front disc brakes or Section 206-04 for rear
feel. disc brakes.
• if the brake pedal is still low or feels spongy, — If the friction material shows taper wear (i.e.
check the brake pedal mounting for looseness and the thickness varies by more than 3.0 mm
correct installation. Check the brake booster and [0.118 inch] in any direction), or if the pads
the brake master cylinder for loose mounting. show uneven wear (2.0 mm [0.079 inch]
Correct as necessary and retest the system for difference between the inboard and the
normal operation. outboard pad), verify the caliper guide pins
• check the fluid level. The fluid level must be at or are functioning correctly. Refer to Section
above the minimum mark. If the fluid level is 206-03 for front disc brakes or Section
below the minimum mark, check the system for 206-04 for rear disc brakes.
leaks.
Brake Discs
For a slow or incomplete brake pedal return
concern: CAUTION: Using an impact tool without a
torque socket leads to unevenly tightened lug
• inspect for binding, damage, correct installation, nuts. This causes brake disc on-vehicle lateral
or interference at the brake pedal. runout and brake roughness.
• check the brake booster for binding, damage, and NOTE: It is generally not required to install new
correct installation. brake discs to address noise issues.
Brake Pads • Remove the brake disc. Refer to Section 206-03
NOTE: New brake pads are not required if the for front disc brakes or Section 206-04 for rear
friction material properties are within guidelines. disc brakes.
New brake pads are not required when the brake
discs are machined.
• Remove the brake pads. Refer to Section 206-03
for front disc brakes or Section 206-04 for rear
disc brakes.
2005 Aviator, 09/2004

• Inspect the brake discs and measure the brake disc • Install new brake pads if the lining is not within
thickness in a minimum of 4 places around the specification. Refer to Section 206-03 for front
circumference of the brake disc. Record the disc brakes or Section 206-04 for rear disc
measurements. brakes.
— Install new brake discs if any thickness • Assemble the caliper guide pins using new caliper
measurement is less than the minimum seals, boots, and guide pins. Use an ample amount
specification. Refer to Section 206-03 for front of grease to lubricate the bores and guide pins.
disc brakes or Section 206-04 for rear disc
brakes. Brake Lines and Tubes
— Install new brake discs if cracked. Refer to CAUTION: Never use copper tubing. It is
Section 206-03 for front disc brakes or Section subject to fatigue, cracking, and corrosion, which
206-04 for rear disc brakes. could result in brake tube failure.
— Machine the brake discs if the diagnosis has • Double-wall steel tubing is used throughout the
revealed vibration in the steering wheel, seat, brake hydraulic system. All brake tube fittings
or pedal while braking. Heavily scored brake must be correctly double flared to provide strong,
discs, similar to that caused by pads worn leakproof connections. When bending tubing to fit
down to the backing plate, should also be the underbody or rear axle contours, be careful
machined. In order to machine, the discs must not to kink or crack the tube.
be above the minimum thickness to machine
• If a section of brake tube is damaged, the entire
specification. Refer to Specifications and
section must be installed new with a tube of the
Brake Disc Machining in this section.
same type, size, shape, and length.
Brake Caliper • When installing the hydraulic brake tubing, hoses,
Inspect the brake calipers for the following: or connectors, tighten all connections to
specifications. After installation, bleed the brake
• brake fluid leaks system. For additional information, refer to Brake
• boots and seals for tears or cracks System Bleeding in this section.
• caliper piston for binding and corrosion • The wet appearance on the outer cover of rubber
• guide pins for correct operation. Refer to Section brake hoses is called sweating. This is a normal
206-03 for front disc brakes or Section 206-04 for condition for rayon-braided neoprene hose and is
rear disc brakes. not a sign of leakage or cause to install a new
hose.
Brake Caliper Guide Pins Install a new flexible brake hose if the hose shows
CAUTION: Do not use power tools for signs of softening, cracking, or other damage.
caliper guide pin bore cleaning. When installing a new brake hose, position the hose
The guide pins should slide with a reasonable to avoid contact with other vehicle components.
amount of hand force. If the brake pads show taper Non-Pressure Leaks
wear or the guide pins are difficult to move, carry
out the following steps: The only part of the brake system that could have a
brake fluid loss that does not appear when the
NOTE: If a guide pin kit is not available, install a system is under pressure is the brake master
new caliper assembly. cylinder reservoir under the following conditions:
• Disassemble the guide pins. Refer to Section • missing or poorly-fitted brake master cylinder
206-03 for front disc brakes or Section 206-04 for filler cap
rear disc brakes.
• punctured or otherwise damaged brake master
• Use a wire brush, rolled-up sandpaper, or emery cylinder reservoir
cloth to remove all corrosion and foreign material
from the caliper guide pin bores. Clean remaining • missing or damaged brake master cylinder filler
debris from the bores with brake parts cleaner and cap gasket
compressed air.
2005 Aviator, 09/2004

• missing, damaged, or poorly-fitted sealing 2. Visually inspect for obvious signs of
grommets between the brake master cylinder and mechanical or electrical damage.
the brake master cylinder reservoir
Visual Inspection Chart
The brake master cylinder reservoir grommets are
not repairable and must be installed new as part of Mechanical Electrical
a new brake master cylinder reservoir. • Adjustable pedals • Battery junction box
• Adjustable pedal switch (BJB) fuse 21 (30A)
Brake Master Cylinder — Normal Conditions • Memory set switch • Damaged or corroded
The following conditions are considered normal and connector(s)
• Damaged or corroded
are not indications that the brake master cylinder is wiring harness
in need of service:
Condition 1: During normal operation of the brake
3. If an obvious cause for an observed or reported
master cylinder, the fluid level in the brake master
concern is found, correct the cause (if possible)
cylinder reservoir rises during brake application and
before proceeding to the next step.
falls during release. The net fluid level (such as
after brake application and release) remains 4. If the concern is not visually evident, connect
unchanged. the diagnostic tool to the data link connector
and select the vehicle to be tested from the
Condition 2: A trace of brake fluid exists on the
diagnostic tool menu. If the diagnostic tool does
booster shell below the master cylinder mounting
not communicate with the vehicle:
flange. This results from the normal lubricating
action of the master cylinder bore and seal. • check that the program card is correctly
installed.
Condition 3: The fluid level decreases with pad
wear. • check the connections to the vehicle.
• check the ignition switch position.
Brake Master Cylinder — Abnormal
Conditions 5. If the diagnostic tool does not communicate
with the vehicle, refer to the diagnostic tool
Changes in the brake pedal feel or travel are
operating manual.
indicators that something could be wrong in the
brake system. GO to Symptom Chart for abnormal 6. Carry out the diagnostic tool data link test. If
condition diagnosis. the diagnostic tool responds with:
• SCP, ISO or UBP circuit faults; all
Brake Booster electronic control units no response/not
Inspect the brake booster for the following: equipped, refer to Section 418-00.
• excessive corrosion or damage • No response/not equipped for the driver seat
module (DSM), refer to Section 419-10.
• vacuum connections for leakage
• System passed, retrieve and record the
• vacuum hoses for kinks or leakage
continuous diagnostic trouble codes (DTCs),
• brake booster check valve for correct operation and carry out self-test diagnosis for the
Changes in the brake pedal feel or travel are DSM.
indicators that something could be wrong in the 7. If the DTCs retrieved are related to the concern,
brake system. GO to Symptom Chart for abnormal go to the Driver Seat Module (DSM)
condition diagnosis. Diagnostic Trouble Code (DTC) Index.
Adjustable Pedals With Memory Feature 8. If no DTCs related to the concern are retrieved,
GO to Symptom Chart to continue diagnosis.
1. Verify the customer concern.
2005 Aviator, 09/2004

Driver Seat Module (DSM) Diagnostic Trouble Code (DTC) Index
DTC Description Source Action
B1342 ECU is Defective DSM REFER to Section 419-10.
B1987 Pedal Forward/Rearward Motor DSM GO to Pinpoint Test C.
Stalled
B1988 Pedal Position Forward Switch DSM GO to Pinpoint Test C.
Circuit Short to Battery
B1989 Pedal Position Rearward Switch DSM GO to Pinpoint Test C.
Circuit Short to Battery
B1990 Pedal Forward/Rearward DSM GO to Pinpoint Test D.
Potentiometer Feedback Circuit
Failure
B2275 Pedal Forward/Rearward DSM GO to Pinpoint Test D.
Potentiometer Feedback Circuit
Short to Ground
Symptom Chart
Symptom Chart
Condition Possible Sources Action
• The red brake warning • Brake fluid level • FILL the brake fluid reservoir
indicator is always on to the MAX line.
• Parking brake • CHECK that the parking
brake is fully released.
• Circuitry • REFER to Section 413-01.
• Instrument cluster
• Red brake warning indicator • Circuitry • REFER to Section 413-01.
inoperative • Bulb
• The brakes pull or drift • Tire air pressure • CHECK the tires for uneven
or excessive wear, and correct
inflation.
• Brake pads • CHECK the brake pads for
• Brake components uneven taper or excessive
wear. REPAIR as necessary.
• CHECK the brake discs and
the hubs for damage.
REPAIR as necessary.
• Suspension component • CHECK the wheel alignment.
• Wheel alignment REFER to Section 204-00.
• Brake pedal goes down fast • Brake fluid level • INSPECT the system for
leaks. FILL the brake master
cylinder reservoir. BLEED
the system.
• Air in system • INSPECT the system for
leaks. BLEED the system.
REFER to Brake System
Bleeding in this section.
• Brake master cylinder • CARRY OUT the brake
master cylinder component
test in this section.
2005 Aviator, 09/2004

Symptom Chart (Continued)
• The brake pedal eases down • Air in system • INSPECT the system for
slowly leaks. BLEED the system.
REFER to Brake System
• Brake lockup under light • Brake pads • CHECK the brake pads for
brake pedal force uneven taper or excessive
wear. REPAIR as necessary.
• Brake component • CHECK the brake
components for correct
operation. REPAIR as
necessary.
• Parking brake component • REPAIR or INSTALL new
components as necessary.
REFER to Section 206-05.
• Anti-lock brake control • CHECK the anti-lock brake
system control system. REFER to
Section 206-09.
• Excessive/erratic brake pedal • Leak in hydraulic system • INSPECT the system for
travel • Air in system leaks. BLEED the system.
• Disc brake caliper REFER to Brake System
• Brake pads • CHECK the brake pads for
excessive wear.
• Brake pedal • CHECK the brake pedal for
binding or obstructions.
REPAIR as necessary.
• Brakes drag • Parking brake component • REPAIR or INSTALL new
REFER to Section 206-05.
• Brake caliper guide pins • REPAIR or INSTALL new
caliper guide pins, seals, and
boots. REFER to Brake
Caliper Guide Pins in
Diagnostics and Testing of
this section.
• Disc brake caliper • REPAIR or INSTALL new
brake calipers as necessary.
REFER to Section 206-03 for
front disc brakes or Section
206-04 for rear disc brakes.
• Brake booster • CARRY OUT the brake
booster component test in this
section.
2005 Aviator, 09/2004

• Excessive brake pedal effort • Brake booster • CARRY OUT the brake
booster component test in this
section.
• Brake booster check valve • CARRY OUT the check
valve component test in this
section.
• Brake booster manifold • REROUTE, REPAIR, or
vacuum hose. INSTALL new components
as necessary.
• Rattling noise • Caliper mounting bolts loose • CHECK the caliper bolts.
TIGHTEN to specifications.
• Damaged or worn caliper • CHECK the caliper guide
guide pins or retainers pins and retainers for
lubrication and correct
operation. LUBRICATE or
INSTALL new components
as necessary. REFER to
Brake Caliper Guide Pins in
this section.
• Missing or damaged • CHECK the brake pads for
anti-rattle clips or springs missing clips or broken
springs. INSTALL new
• Loose brake disc shield • TIGHTEN the brake disc
shield bolts to specification.
• Clicking noise — with brakes • ABS hydraulic control unit • Acceptable condition.
applied with anit-lock brake
system (ABS) brakes
• Squealing noise — occurs on • Brake pads • Acceptable condition. Caused
first (morning) brake by humidity and low brake
application pad temperature.
• Squealing noise — a • Brake pads or linings worn • INSPECT brake pads for
continuous squeal below minimum thickness excessive wear, taper wear, or
uneven wear. VERIFY the
brake pads are within the
minimum specification.
REFER to Brake Pads in
this section.
• Squealing noise — an • Brake pads • Acceptable condition.
intermittent squeal brought on
by cold, heat, water, mud, or
snow
• Groaning noise — occurs at • Brake pads • Acceptable condition.
low speeds with brake lightly
applied (creeping)
2005 Aviator, 09/2004

• Grinding noise — continuous • Brake pads or linings worn • INSPECT the brake pads,
below the minimum thickness brake discs, and attaching
hardware for damage.
VERIFY the brake pads are
within the minimum
specification. REFER to
Brake Pads in Diagnostics
and Testing of this section.
• Moaning noise • Brake linings contaminated • INSPECT the brake pads for
with grease or oil contamination. REPAIR or
INSTALL new components
as necessary. REFER to
Section 206-03 for front disc
brakes or Section 206-04 for
rear disc brakes.
• The adjustable brake pedal is • Adjustable pedal switch • GO to Pinpoint Test A.
inoperative • Circuitry
• Adjustable pedal motor
• Driver seat module (DSM)
• The adjustable brake pedal • Circuitry • GO to Pinpoint Test B.
does not operate correctly • Adjustable pedal
potentiometer
• Driver seat module (DSM)
• Vibration when brakes are • Uneven brake pad wear • COMPLETE the brake
applied • Brake disc pad transfer system inspection described
• Brake disc in Inspection and Verification
• Suspension components in this section.
• GO to Pinpoint Test E.
• Brake vibration/shudder — • Brake caliper guide pins • INSPECT the brake caliper
occurs when the brake pedal guide pins for correct
is released operation. REFER to Section
206-03 for front disc brakes
or Section 206-04 for rear
disc brakes.
• Brake drag • INSPECT the brake pads for
premature wear. REPAIR or
INSTALL a new caliper as
necessary. REFER to Section
206-03 for front disc brakes
or Section 206-04 for rear
disc brakes.
Connector Circuit Reference
Driver Seat Module (DSM) C341d
2005 Aviator, 09/2004

Pin Number(s) Circuit Designation/Description Normal Condition/Measurement
10 894 (GY) adjustable pedal potentiometer Resistance between 3,600 and 5,400 ohms, 0
return circuit to DSM (-), ground and voltage, when connected.
diagnostic feedback circuit
20 891 (RD/BK) adjustable pedal potentiometer 10 volt reference applied to adjustable pedal
(+) potentiometer, continuity between adjustable
pedal motor and DSM.
Driver Seat Module (DSM) C341e

1 566 (DG) voltage Greater than 10 volts at all times.
2 1205 (BK) ground Less than 5 ohms resistance to chassis
ground.
Driver Seat Module (DSM) C341f

10 1489 (LB/BK) adjustable pedal motor voltage Greater than 10 volts with the motor in 1
feed/ground (switched) direction and 0 volts when in the opposite
direction.
12 1490 (LB/OG) adjustable pedal motor 0 volts with the motor in 1 direction and
ground/voltage feed (switched) greater than 10 volts with the motor in the
opposite direction.
2005 Aviator, 09/2004

Driver Seat Module (DSM) C341g

6 1203 (BK/LB) DSM ground 0 voltage and less than 5 ohms resistance to
chassis ground.
7 1491 (LB/YE) pedal position feedback Voltage varies with the pedal position.
circuit, DSM uses signal to recall pedal
position from memory
8 1493 (PK/BK) ground input to DSM, moves 0 voltage and less than 5 ohms resistance to
pedal toward driver chassis ground, continuity between switch
and DSM module.
9 1492 (LB/RD) ground input to DSM, moves 0 voltage and less than 5 ohms to chassis
pedal away from driver ground, continuity between switch and DSM
module.
Adjustable Brake Pedal Motor C2003

1 1490 (LB/OG) voltage supply to adjustable Greater than 10 volts with switch in the
pedal motor from driver seat module (DSM), rearward position or when commanded to the
adjustable pedal moves rearward (toward memory position by the DSM.
driver)
2 1489 (LB/BK) voltage supply to adjustable Greater than 10 volts with adjustable pedal
pedal motor from DSM, pedal forward (away control switch in the forward position or
from driver) when commanded to the memory position by
the DSM.
2005 Aviator, 09/2004

Adjustable Pedal Potentiometer C2090

1 891 (RD/BK) adjustable pedal potentiometer 10 volt reference applied to the adjustable
(+) pedal potentiometer, continuity between the
adjustable pedal motor and the driver seat
module (DSM).
2 1491 (LB/YE) pedal position feedback circuit Voltage varies with the pedal position,
(DSM uses signal to recall pedal position continuity between the DSM and the
from memory) adjustable pedal motor.
3 894 (GY) adjustable pedal potentiometer Resistance between 3,600 and 5,400 ohms, 0
return circuit to DSM, (-), ground and voltage, when connected.
diagnostic feedback circuit
Adjustable Brake Pedal Switch C2235

3 1492 (LB/RD) ground input to DSM, moves 0 voltage and less than 5 ohms resistance to
pedal away from driver (forward) chassis ground, continuity between the switch
and the DSM module.
4 1205 (BK) switch common ground 0 voltage and less than 5 ohms resistance to
chassis ground.
7 1493 (PK/BK) ground input to driver seat 0 voltage and less than 5 ohms resistance to
module (DSM), moves pedal toward driver chassis ground, continuity between the switch
(rearward) and the DSM module.
2005 Aviator, 09/2004

Pinpoint Tests Possible Causes
Pinpoint Test A: The Adjustable Brake Pedal • circuit 566 (DG) open or short to ground
Inoperative • circuit 1203 (BK/LB) open
Normal Operation • circuit(s) 1205 (BK) open
The driver seat module (DSM) receives voltage • circuit 1489 (LB/BK) open or short to ground
from the battery junction box (BJB) at all times
• circuit 1490 (LB/OG) open or short to ground
through circuit 566 (DG). The DSM is grounded
through circuits 1203 (BK/LB) and 1205 (BK). • circuit 1492 (LB/RD) open or short to ground
Pressing the switch upward closes circuit 1492 • circuit 1493 (PK/BK) open or short to ground
(LB/RD) to ground circuit 1205 (BK) through the • adjustable pedal switch
manual adjustable pedal switch and the DSM
provides voltage and ground on circuits 1489 • adjustable pedal motor assembly
(LB/BK) and 1490 (LB/OG) as the adjustable pedal • DSM
motor moves the pedal away from the driver.
Pressing the switch downward closes circuit 1493
(PK/BK) to ground circuit 1205 (BK) and the DSM
provides voltage and ground on circuits 1490
(LB/OG) and 1489 (LB/BK) as the adjustable pedal
motor moves the pedal toward the driver.
PINPOINT TEST A: THE ADJUSTABLE BRAKE PEDAL IS INOPERATIVE
Test Step Result / Action to Take
A1 CHECK CIRCUIT 566 (DG) FOR AN OPEN
NOTE: The integrity of the adjustable pedal and their associated
transmission integrity can be verified by removing the drive cables
from the individual adjustable pedal transmission. A firm tug on the
cable allows the cable to be released from the adjustable pedal
transmission. At this time, the adjustable pedal motor can be
operated to determine if the concern may be due to a jammed
adjustable pedal transmission or incorrectly timed adjustable pedal.
Timing the pedal involves installing 1 cable into the respective
transmission and operating the adjustable pedal switch until the
particular pedal involved is bottomed out to the same position as
the other pedal.
• Key in OFF position.
• Disconnect: Driver Seat Module (DSM) C341e.
• Measure the voltage between the DSM C341e-1, circuit 566
(DG), harness side and ground.
Yes
GO to A2.
No
REPAIR the circuit. CLEAR the DTCs.
REPEAT the self-test. TEST the system
• Is the voltage greater than 10 volts? for normal operation.
A2 CHECK CIRCUIT 1203 (BK/LB) AND 1205 (BK) FOR AN OPEN
• Disconnect: DSM 341g.
(Continued)
2005 Aviator, 09/2004

PINPOINT TEST A: THE ADJUSTABLE BRAKE PEDAL IS INOPERATIVE (Continued)
A2 CHECK CIRCUIT 1203 (BK/LB) AND 1205 (BK) FOR AN OPEN
(Continued)
• Measure the resistance between the DSM C341g-6 circuit 1203
(BK/LB), harness side and ground; and between the DSM
C341e-2, circuit 1205 (BK), harness side and ground.
Yes
GO to A3.
No
REPAIR the circuit(s). CLEAR the DTCs.
• Are the resistances less than 5 ohms? for normal operation.
A3 CHECK THE ADJUSTABLE PEDAL SWITCH
• Disconnect: Adjustable Pedal Switch C2235.
• While pressing the adjustable pedal switch in both directions,
measure the resistance between the adjustable pedal switch
pins, component side as follows:
Pins Switch Position Resistance Value

4 and 7 Upward Open
4 and 7 Downward 0 ohms
4 and 3 Upward 0 ohms
4 and 3 Downward Open
Yes
GO to A4.
No
INSTALL a new adjustable pedal switch.
CLEAR the DTCs. REPEAT the self-test.
• Are the resistances as specified in the table? TEST the system for normal operation.
(Continued)
2005 Aviator, 09/2004

A4 CHECK CIRCUIT 1205 (BK) FOR AN OPEN
• Measure the resistance between the adjustable pedal switch
C2235-4, circuit 1205 (BK), harness side and ground.
Yes
GO to A5.
No
• Is the resistance less than 5 ohms? for normal operation.
A5 CHECK CIRCUIT 1492 (LB/RD) FOR AN OPEN OR A SHORT TO
GROUND
C2235-3 circuit 1492 (LB/RD), harness side and the DSM
C341g-9, circuit 1492 (LB/RD), harness side; and between the
adjustable pedal switch C2235-3, circuit 1492 (LB/RD), harness
side and ground.
Yes
GO to A6.
No
• Is the resistance less than 5 ohms between the switch and REPAIR the circuit. CLEAR the DTCs.
the DSM, and greater than 10,000 ohms between the switch REPEAT the self-test. TEST the system
and ground? for normal operation.
(Continued)
2005 Aviator, 09/2004

A6 CHECK CIRCUIT 1493 (PK/BK) FOR AN OPEN OR A SHORT TO
GROUND
C2235-7, circuit 1493 (PK/BK), harness side and the DSM
C341g-8, circuit 1493 (PK/BK), harness side; and between the
adjustable pedal switch C2235-7, circuit 1493 (PK/BK), harness
side and ground.
Yes
GO to A7.
No
• Is the resistance less than 5 ohms between the switch and REPAIR the circuit. CLEAR the DTCs.
the DSM, and greater than 10,000 ohms between the switch REPEAT the self-test. TEST the system
and ground? for normal operation.
A7 CHECK THE ADJUSTABLE PEDAL MOTOR INTEGRITY
• Disconnect: Adjustable Pedal Motor C2003.
• Connect a fused (15A) jumper wire to the adjustable pedal
motor C2003-1, component side and the positive battery
terminal. Connect another jumper wire to the adjustable pedal
motor C2003-2, component side and the negative battery
terminal. Switch the leads to verify the motor operates in both
directions.
Yes
GO to A8.
No
INSTALL a new adjustable pedal motor
assembly. CLEAR the DTCs. REPEAT the
self-test. TEST the system for normal
• Does the motor operate in both directions? operation.
A8 CHECK CIRCUIT 1489 (LB/BK) FOR AN OPEN OR A SHORT TO
GROUND
• Disconnect: DSM C341f.
(Continued)
2005 Aviator, 09/2004

A8 CHECK CIRCUIT 1489 (LB/BK) FOR AN OPEN OR A SHORT TO
GROUND (Continued)
• Measure the resistance between the DSM C341f-10, circuit 1489
(LB/BK), harness side and the adjustable pedal motor C2003-2,
circuit 1489 (LB/BK), harness side; and between the DSM
C341f-10, circuit 1489 (LB/BK), harness side and ground.
Yes
GO to A9.
No
• Is the resistance less than 5 ohms between the DSM and REPAIR the circuit. CLEAR the DTCs.
the adjustable pedal motor, and greater than 10,000 ohms REPEAT the self-test. TEST the system
between the DSM and ground? for normal operation.
A9 CHECK CIRCUIT 1490 (LB/OG) FOR AN OPEN OR A SHORT TO
GROUND
• Measure the resistance between the DSM C341f-12, circuit 1490
(LB/OG), harness side and the adjustable pedal motor C2003-1,
circuit 1490 (LB/OG), harness side and; between the DSM
C341f-12, circuit 1490 (LB/OG), harness side and ground.
Yes
GO to A10.
No
the adjustable pedal motor, and greater than 10,000 ohms REPEAT the self-test. TEST the system
between the DSM and ground? for normal operation.
A10 CHECK FOR CORRECT DSM OPERATION
• Disconnect all the DSM connectors. Yes
• Check for: INSTALL a new DSM. REFER to Section
• corrosion 419-10 for the removal and installation
• pushed-out pins procedure. REPEAT the self-test. TEST
• Connect all the DSM connectors and make sure they seat the system for normal operation.
correctly. No
• Operate the system and verify the concern is still present. The system is operating correctly at this
• Is the concern still present? time. The concern may have been caused
by a loose or corroded connector. CLEAR
the DTCs. REPEAT the self-test. TEST
the system for normal operation.
2005 Aviator, 09/2004

Pinpoint Test B: The Adjustable Brake Pedal Possible Causes
Does Not Operate Correctly • circuit 891 (RD/BK) open or short to ground
Normal Operation • circuit 894 (GY) open or short to ground
The adjustable pedal memory function utilizes a
potentiometer located in the adjustable pedal motor. • circuit 1491 (LB/YE) open or short to ground
The driver seat module (DSM) supplies a reference • adjustable pedal potentiometer
voltage on circuit 891 (RD/BK) to the potentiometer • DSM
and grounds the signal return on circuit 894 (GY)
from the potentiometer. The signal voltage on
circuit 1491 (LB/YE) from the adjustable pedal
potentiometer to the DSM provides an indication to
the DSM of whether or not the adjustable pedal
motor is stalled. When the driver sets a pedal
position in the DSM, it stores the value of where
the adjustable pedal is located using a time frame of
motor operation. When the driver requests a return
to a pedal position in memory, the DSM operates
the adjustable pedal motor until the adjustable
pedal potentiometer output matches the time frame
stored in the memory.
PINPOINT TEST B: THE ADJUSTABLE BRAKE PEDAL DOES NOT OPERATE CORRECTLY
B1 CHECK THE ADJUSTABLE PEDAL OPERATION
• NOTE: The integrity of the adjustable pedal and their associated
transmission integrity can be verified by removing the drive
cables from the individual adjustable pedal transmission. A firm
tug on the cable allows the cable to be released from the
adjustable pedal transmission. At this time, the adjustable pedal
motor can be operated to determine if the concern may be due
to a jammed adjustable pedal transmission or incorrectly timed
adjustable pedal. Timing the pedal involves installing 1 cable
into the respective transmission and operating the adjustable
pedal switch until the particular pedal involved is bottomed out to Yes
the same position as the other pedal. GO to B2.
Operate the adjustable pedal using the manual switch. No
• Does the adjustable pedal operate using the manual switch? GO to Pinpoint Test A.
B2 CHECK CIRCUIT 891 (RD/BK) FOR AN OPEN OR A SHORT TO
GROUND
• Disconnect: Driver Seat Module (DSM) C341d.
• Disconnect: Adjustable Pedal Potentiometer C2090.
(Continued)
2005 Aviator, 09/2004

PINPOINT TEST B: THE ADJUSTABLE BRAKE PEDAL DOES NOT OPERATE CORRECTLY (Continued)
B2 CHECK CIRCUIT 891 (RD/BK) FOR AN OPEN OR A SHORT TO
GROUND (Continued)
• Measure the resistance between the DSM C341d-20, circuit 891
(RD/BK), harness side and the adjustable pedal potentiometer
C2090-1, circuit 891 (RD/BK), harness side; and between the
DSM C341d-20, circuit 891 (RD/BK), harness side and ground.
Yes
GO to B3.
No
the potentiometer, and greater than 10,000 ohms between REPEAT the self-test. TEST the system
the DSM and ground? for normal operation.
B3 CHECK CIRCUIT 894 (GY) FOR AN OPEN OR A SHORT TO
GROUND
• Measure the resistance between the DSM C341d-10, circuit 894
(GY), harness side and the adjustable pedal potentiometer
C2090-3, circuit 894 (GY), harness side; and between the DSM
C341d-10, circuit 894 (GY), harness side and ground.
Yes
GO to B4.
No
B4 CHECK CIRCUIT 1491 (LB/YE) FOR AN OPEN OR A SHORT TO
GROUND
• Disconnect: DSM C341g.
(Continued)
2005 Aviator, 09/2004

B4 CHECK CIRCUIT 1491 (LB/YE) FOR AN OPEN OR A SHORT TO
GROUND (Continued)
• Measure the resistance between the DSM C341g-7, circuit 1491
(LB/YE), harness side and the adjustable pedal potentiometer
C2090-2, circuit 1491 (LB/YE), harness side; and between the
DSM C341g-7, circuit 1491 (LB/YE), harness side and ground.
Yes
GO to B5.
No
B5 CHECK THE ADJUSTABLE PEDAL POTENTIOMETER
• Measure the resistance between the adjustable pedal
potentiometer pins, component side as follows:
Potentiometer Pins Resistance Value

1 and 3 4,000 ohms
2 and 3 Up to 4,000 ohms (max)
1 and 2 Up to 4,000 ohms (max)
Yes
GO to B6.
No
INSTALL a new adjustable pedal
assembly. CLEAR the DTCs. REPEAT the
• Did the adjustable pedal potentiometer pass the component self-test. TEST the system for normal
test? operation.
(Continued)
2005 Aviator, 09/2004

B6 CHECK FOR CORRECT DSM OPERATION
• Disconnect all the DSM connectors. Yes
• Check for: INSTALL a new DSM. REFER to Section
• corrosion 419-10 for the removal and installation
• pushed-out pins procedure. REPEAT the self-test. TEST
• Connect all the DSM connectors and make sure they seat the system for normal operation.
correctly. No
the DTCs. REPEAT the self-test. TEST
the system for normal operation.
Pinpoint Test C: DTCS B1987, B1988, and • adjustable pedal switch

B1989: Pedal Forward/Rearward Motor
• circuit 1489 (LB/BK) short to voltage
Stalled
• circuit 1490 (LB/OG) short to voltage
Normal Operation
The 2-way adjustable pedal motor receives voltage • circuit 1492 (LB/RD) short to ground
from the driver seat module (DSM) through circuit • circuit 1493 (PK/BK) short to ground
1489 (LB/BK) (forward) and circuit 1490 (LB/OG) • adjustable pedal motor
(rearward). The motor runs until the manual switch
is released, until the travel limit is reached, or until
the stored memory position is reached.
Possible Causes
• brake or accelerator pedal obstruction
• binding adjustable motor cable
PINPOINT TEST C: DTCS B1987, B1988, AND B1989 — PEDAL FORWARD/REARWARD MOTOR
STALLED
C1 CHECK THE POSITION OF THE ADJUSTABLE PEDALS
• Note the position of the adjustable pedals. Yes
• Are the adjustable pedals stalled in the fully rearward GO to C2.
position? No
GO to C4 if the adjustable pedals are
stalled in the fully forward position.
C2 CHECK THE ADJUSTABLE PEDAL SWITCH REARWARD
• Disconnect: Adjustable Pedal Switch C2235. Yes
• Measure the resistance between C2235-7, circuit 1492 (LB/RD) GO to C3.
and C2235-4, circuit 1205 (BK), component side. No
• Is the resistance greater than 10,000 ohms? INSTALL a new adjustable pedal switch.
CLEAR the DTC(s). REPEAT the self-test.
C3 CHECK CIRCUIT 1490 (LB/OG) FOR A SHORT TO VOLTAGE
(Continued)
2005 Aviator, 09/2004

PINPOINT TEST C: DTCS B1987, B1988, AND B1989 — PEDAL FORWARD/REARWARD MOTOR
STALLED (Continued)
C3 CHECK CIRCUIT 1490 (LB/OG) FOR A SHORT TO VOLTAGE
(Continued)
• Measure the voltage between adjustable pedal motor C2003-1,
circuit 1490 (LB/OG), harness side and ground.
Yes
REPAIR circuit 1490 (LB/OG). CLEAR the
DTCs. REPEAT the self-test.
No
assembly. REFER to Section 206-06.
• Is any voltage present? CLEAR the DTCs. REPEAT the self-test.
C4 CHECK THE ADJUSTABLE PEDAL SWITCH FORWARD
• Disconnect: Adjustable Pedal Switch C2235. Yes
• Measure the resistance between C2235-3, circuit 1493 (PK/BK) GO to C5.
and C2235-4, circuit 1205 (BK), component side. No
• Is the resistance greater than 10,000 ohms? INSTALL a new adjustable pedal switch.
CLEAR the DTC(s). REPEAT the self-test.
C5 CHECK CIRCUIT 1489 (LB/BK) FOR A SHORT TO VOLTAGE
• Measure the voltage between C2003-2, circuit 1489 (LB/BK),
harness side and ground.
Yes
REPAIR circuit 1489 (LB/BK). CLEAR the
No
assembly. REFER to Section 206-06.
• Is any voltage indicated? CLEAR the DTCs. REPEAT the self-test.
Pinpoint Test D: DTCS B1990 and B2275: Circuit 894 (GY) carries return voltage from the
Pedal Forward/Rearward Potentiometer adjustable pedal potentiometer to the other DSM
Feedback Circuit Fault controlled memory system components.
Normal Operation Possible Causes
Depending on pedal position, the adjustable pedal
potentiometer sends a resistance through feedback • circuit 891 (RD/BK) open, short to ground or
circuit 1491 (LB/YE) to the driver seat module short to voltage
(DSM); that value is stored in the DSM memory for • circuit 894 (GY) open, short to ground or short to
recalling the position of the adjustable pedals. voltage
Circuit 891 (RD/BK) carries a reference voltage
from the DSM to the adjustable pedal potentiometer.
2005 Aviator, 09/2004

• circuit 1491 (LB/YE) open, short to ground or
short to voltage
• DSM
• adjustable pedal potentiometer
PINPOINT TEST D: DTCS B1990 AND B2275: PEDAL FORWARD/REARWARD POTENTIOMETER
FEEDBACK CIRCUIT FAULT
D1 CHECK THE DRIVER SEAT MODULE (DSM) FOR CORRECT
OUTPUT PIDS
• Use the adjustable pedal switch to move the pedals to a central
position.
• Monitor the DSM pedal position PID while moving the adjustable Yes
pedal switch to the forward position, then to the rearward INSTALL a new DSM. REFER to Section
position. 419-10. CLEAR the DTC(s). REPEAT the
• Does the PID value decrease with forward movement, and self-test.
increase with rearward movement, throughout the entire No
pedal travel? GO to D2.
D2 CHECK THE ADJUSTABLE PEDAL POTENTIOMETER CIRCUITS
FOR A SHORT TO VOLTAGE
NOTE: The adjustable pedal potentiometer is attached to the
accelerator pedal.
• Disconnect: DSM C341g.
• Disconnect: Adjustable Pedal Potentiometer C2090.
• Measure the voltage between the adjustable pedal potentiometer
C2090-2, circuit 1491 (LB/YE), harness side and ground; and
between the adjustable pedal potentiometer C2090-1, circuit 891
(RD/BK), harness side and ground; and between the adjustable
pedal potentiometer C2090-3, circuit 894 (GY), harness side and
ground.
Yes
REPAIR the short to battery in circuit 1491
(LB/YE), circuit 891 (RD/BK), or circuit 894
(GY), as necessary. CLEAR the DTC(s).
REPEAT the self-test.
No
• Is voltage present? GO to D3.
(Continued)
2005 Aviator, 09/2004

FEEDBACK CIRCUIT FAULT (Continued)
FOR A SHORT TO GROUND
potentiometer C2090-2, circuit 1491 (LB/YE), harness side and
ground; and between the adjustable pedal potentiometer
C2090-1, circuit 891 (RD/BK), harness side and ground; and
(GY), harness side and ground.
Yes
GO to D4.
No
REPAIR circuit 1491 (LB/YE), circuit 891
(RD/BK) or circuit 894 (GY), as necessary.
• Are the resistances greater than 10,000 ohms? CLEAR the DTC(s). REPEAT the self-test.
FOR AN OPEN
• Disconnect: DSM C341d.
potentiometer C2090-2, circuit 1491 (LB/YE), harness side and
the DSM C341g-7, circuit 1491 (LB/YE), harness side; and
(RD/BK), harness side and the DSM C341d-20, circuit 891
(RD/BK), harness side; and between the adjustable pedal
potentiometer C2090-3, circuit 894 (GY), harness side and
C341d-10, circuit 894 (GY), harness side.
Yes
GO to D5.
No
REPAIR circuit 1491 (LB/YE), circuit 891
(RD/BK) or circuit 894 (GY), as necessary.
• Are the resistances less than 5 ohms? CLEAR the DTC(s). REPEAT the self-test.
(Continued)
2005 Aviator, 09/2004

FEEDBACK CIRCUIT FAULT (Continued)
D5 CHECK THE ADJUSTABLE PEDAL POTENTIOMETER
• Measure the resistance between C2090-2, circuit 1491 (LB/YE),
and C2090-1, circuit 891 (RD/BK), component side; and
between C2090-2, circuit 1491 (LB/YE), and C2090-3, circuit
894 (GY), component side.
Yes
INSTALL a new driver seat module.
REFER to Section 419-10. CLEAR the
DTC(s). REPEAT the self-test.
No
INSTALL a new adjustable pedal
assembly. CLEAR the DTC(s). REPEAT
• Are the resistances between ohms 3,700 and 5,400 ohms? the self-test.
Pinpoint Test E: Vibration When Brakes Are

Applied
Possible Causes
• uneven brake pad wear
• brake disc pad transfer
• brake disc
• suspension components
PINPOINT TEST E: VIBRATION WHEN BRAKES ARE APPLIED
E1 CHECK OASIS AND FOR TSBs
• Check the On-Line Automotive Service Information System Yes
(OASIS) and Technical Service Bulletins for applicable brake REFER to OASIS or the TSB. CARRY
concerns. OUT any necessary repairs that are
• Is there applicable information available on OASIS or in a indicated by OASIS or the TSB. If the
TSB? concern is still present, GO to E2.
No
GO to E2.
E2 ROAD TEST THE VEHICLE — LIGHT BRAKING
• Inspect the wheels and tires. For additional information, refer to
Section 204-04.
• Road test the vehicle. Warm the brakes by slowing the vehicle
from 80 to 32 km/h (50 to 20 mph) using light brake force. At
highway speeds of 89-97 km/h (55-60 mph), apply the brake Yes
using light pedal force. GO to E5.
• Is there a vibration/shudder felt in the steering wheel, seat No
or brake pedal? GO to E3.
E3 ROAD TEST THE VEHICLE — MODERATE TO HEAVY
BRAKING
• Road test the vehicle. At highway speeds of 89-97 km/h (55-60 Yes
mph), apply the brake using a moderate to heavy pedal force. GO to E4.
• Is there a vibration/shudder? No
The concern is not present at this time.
(Continued)
2005 Aviator, 09/2004

PINPOINT TEST E: VIBRATION WHEN BRAKES ARE APPLIED (Continued)
E4 NORMAL ACTUATION OF THE ANTI-LOCK BRAKE SYSTEM
(ABS) SYSTEM DIAGNOSIS
• During moderate to heavy braking, noise from the hydraulic
control unit (HCU) and pulsation in the brake pedal can be
observed. Pedal pulsation coupled with noise during heavy
braking or on loose gravel, bumps, or wet or snowy surfaces is
acceptable and indicates correct functioning of the ABS system.
Pedal pulsation or steering wheel nibble (frequency proportional Yes
to the vehicle speed) indicates a concern with a brake or GO to E6.
suspension component. No
• Is the vibration/shudder vehicle speed sensitive? The concern is not present at this time.
E5 APPLICATION OF THE PARKING BRAKE
• This test is not applicable to vehicles with drum-in-hat type
parking brakes. For vehicles with drum-in-hat parking brakes,
proceed to the next test step. For all other vehicles, apply the
parking brake to identify if the problem is in the front or rear
brake. At highway speeds of 89-97 km/h (55-60 mph), lightly Yes
apply the parking brake until the vehicle slows down. Release GO to E8.
the parking brake immediately after the test. No
• Is there a vibration/shudder? GO to E6.
E6 CHECK THE FRONT SUSPENSION
• Check the front suspension. Refer to Section 204-01A for Yes
2-wheel drive (2WD) or Section 204-01B for all-wheel drive GO to E7.
(AWD). No
• Are all the suspension components in satisfactory REPAIR or INSTALL new components as
condition? necessary. TEST the system for normal
operation.
E7 RESURFACE THE FRONT BRAKE DISCS
• CAUTION: Do not use a bench lathe to machine the

brake discs.
NOTE: Follow the manufacturer’s instructions to machine the
brake discs. After machining, make sure the brake disc meets
the thickness specification.
Resurface the front brake discs. Refer to Brake Disc Machining Yes
in this section. GO to E8.
• Road test the vehicle. No
• Is the vibration/shudder present? The concern is not present at this time.
E8 CHECK THE REAR SUSPENSION
• Check the rear suspension. Refer to Section 204-02. Yes
• Are all the suspension components in satisfactory GO to E9.
condition? No
REPAIR or INSTALL new components as
necessary. TEST the system for normal
operation.
E9 RESURFACE THE REAR BRAKE DISC
• CAUTION: Do not use a bench lathe to machine the

brake discs.
NOTE: Follow the manufacturer’s instructions to machine the
brake discs. After machining, make sure the brake disc meets
the thickness specification. Yes
Resurface the rear brake discs. Refer to Brake Disc Machining Refer to Section 100-04 to continue
in this section. diagnosis of the vibration.
• Road test the vehicle. No
• Is the vibration/shudder present? The concern is not present at this time.
Component Tests 2. With the transmission in NEUTRAL, stop the

engine and apply the parking brake control.
Brake Booster Apply the brake pedal several times to exhaust
1. Check the hydraulic brake system for leaks or all vacuum in the system.
insufficient fluid.
2005 Aviator, 09/2004

3. Apply the brake pedal and hold it in the applied • Disconnect the vacuum booster hose from the
position. Start the engine. If the vacuum system brake booster check valve. Do not remove the
is operating, the brake pedal will tend to move brake booster check valve from the brake booster.
downward under constant foot pressure. If no • There should be enough vacuum retained in the
motion is felt, the brake booster system is not brake booster for at least 1 more power-assisted
functioning. Continue with the following steps. brake operation.
4. Remove the vacuum booster hose from the
check valve connection. Manifold vacuum must Brake Master Cylinder
be available at the check valve end of the Bypass Condition Test
vacuum booster hose with the engine at idle
speed and the transmission in NEUTRAL. If 1. Disconnect the brake lines at the brake master
the manifold vacuum is available to the brake cylinder.
booster, connect the vacuum booster hose to the 2. Plug the outlet ports of the brake master
brake booster check valve and repeat Steps 2 cylinder.
and 3. 3. Apply the brakes. If brake pedal height cannot
5. If no downward movement of the brake pedal is be maintained, the brake master cylinder has an
felt, install a new brake booster. internal leak and must be rebuilt or a new
6. Operate the engine a minimum of 10 seconds at master cylinder must be installed.
fast idle. Stop the engine and let the vehicle Compensator Port Check
stand for 10 minutes. Then apply the brake
pedal with approximately 89 N (20 lb.) of The purpose of the compensator ports in the brake
force. The brake pedal feel should be the same master cylinder is to supply any additional brake
as that noted with the engine operating. If the fluid required by the system due to brake pad wear
brake pedal feels hard (no power assist), install and to allow brake fluid returning from the brake
a new brake booster check valve and retest. If lines to the brake master cylinder to enter the brake
the brake pedal feels spongy, bleed the master cylinder reservoir.
hydraulic system to remove air. Refer to Brake The returning brake fluid causes a slight turbulence
System Bleeding in this section. in the brake master cylinder reservoir. Turbulence
seen in the brake master cylinder reservoir upon
Check Valve application or release of the brake pedal is normal
The function of the brake booster check valve is to and shows that the compensating ports are not
allow manifold vacuum to enter the brake booster plugged.
and prevent the escape of vacuum if manifold
vacuum is lost during sustained full throttle
operation.
To test the function of the brake booster check
valve:
• Start and run the engine for at least 10 seconds.
• Operate the brake pedal to check for power assist.
2005 Aviator, 09/2004

GENERAL PROCEDURES
Brake Disc Machining 2. For vehicles with a 2-piece brake disc and hub
assembly:
Special Tool(s) 1 Mark the brake disc and the wheel stud for
correct indexing during reassembly.
On-Car Brake Lathe
201-00002 or equivalent 2 Remove the brake disc from the hub.
3 CAUTION: Do not use an abrasive
sanding disc since it will remove paint or
other protective finishes from the wheel
or metal from the mounting surfaces,
adversely affecting corrosion protection
Material and brake disc lateral runout.
Item Specification Remove corrosion from the wheel mounting
surface, both disc mounting surfaces, and
High Temperature Nickel ESE-M12A4-A
Anti-Sieze Lubricant hub mounting surface.
XL-2 (Canada CXG-2) 4 Align the match marks and install the brake
Brake Parts Cleaner — disc on the hub.
PM-4
3. Machine the brake disc using an on-car brake
Brake Disc Machining lathe.
1 Install the hub adapter and silencer belt, if
CAUTION: Do not use a bench lathe to necessary.
machine the brake discs.
2 Install the cutting lathe.
NOTE: Read the entire operating manual and view 3 If lathe is not self-adjusting, adjust the lathe
the video shipped with the lathe before installing, oscillation using a dial indicator. The total
operating, or repairing the lathe. indicated reading (TIR) target is 0.000 mm
(0.000 in), and the maximum is 0.08 mm
NOTE: If the thickness of the brake disc is less (0.003 in).
than the minimum thickness to machine
specification, install a new brake disc. Make sure 4 Center the cutting head, adjust the cutting
that the brake disc is above minimum thickness bits, and install the chip deflector.
after machining. 5 NOTE: The depth of cut should be between
0.10 and 0.20 mm (0.004 and 0.008 in).
NOTE: Do not machine new brake discs. Lighter cuts cause the bit to heat up and
wear faster. Heavier will cause poor brake
NOTE: Lateral runout and disc thickness variation
disc surface finish.
measurements are not required because correct
adjustment of the on-vehicle brake lathe will make Machine the brake disc.
sure that these dimensions are within specifications. 6 Remove the lathe and, if installed, the
silencer belt.
1. NOTE: It is not necessary to disconnect the
7 Remove the hub adapter.
brake line from the brake caliper.
Position the brake caliper and brake caliper 4. Remove metal shavings.
anchor bracket aside. For additional
information, refer to Section 206-03 for front
disc brakes or Section 206-04 for rear disc
brakes.

GENERAL PROCEDURES (Continued)
5. For vehicles with a 2-piece brake disc and hub 6. NOTE: It is not necessary to install new brake
assembly: pads if the friction material properties are
1 Remove the brake disc from the hub. within the guidelines. Refer to Brake Pads in
this section.
2 Remove metal shavings from the hub, the
brake disc mounting surfaces, and the ABS Install the brake caliper and brake caliper
sensors. anchor bracket. For additional information, refer
to Section 206-03 for front disc brakes or
3 Apply anti-seize lubricant to the hub Section 206-04 for rear disc brakes.
mounting surface to prevent corrosion.
4 Align the match marks and install the brake
disc on the hub.
2005 Aviator, 09/2004

GENERAL PROCEDURES
Brake System Bleeding 1. NOTE: When a new brake master cylinder has
been installed or the system has been emptied
Special Tool(s) or partially emptied, it should be primed to
prevent air from getting into the system.
Worldwide Diagnostic System
(WDS) Disconnect the 2 master cylinder brake tube
Vehicle Communication Module fittings.
(VCM) with appropriate
adapters, or equivalent
diagnostic tool.
Material
Item Specification
Motor Vehicle Brake Fluid
PM-1 (Canada CPM-1)
Master Cylinder Bleeding
WARNING: Brake fluid contains 2. NOTE: Original equipment lines are not
polyglycol ethers and polyglycols. Avoid contact intended to be used during this procedure.
with eyes. Wash hands thoroughly after
Install the 2 short brake tubes with the ends
handling. If brake fluid contacts eyes, flush eyes
submerged in the brake master cylinder
with running water for 15 minutes. Get medical
reservoir and fill the brake master cylinder
attention if irritation persists. If taken
reservoir with DOT 3 motor vehicle brake fluid.
these instructions may result in personal injury.
CAUTION: Do not allow the brake master

cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder
reservoir filled with the specified brake fluid.
Never reuse the brake fluid that has been
drained from the hydraulic system.

immediately wash it with water. 3. Have an assistant pump the brake pedal until
NOTE: When any part of the hydraulic system has clear fluid flows from both brake tubes without
been disconnected for repair or new installation, air air bubbles.
may get into the system and cause spongy brake
4. Remove the 2 short brake tubes and install the
pedal action. This requires bleeding of the hydraulic
2 master cylinder brake tube fittings.
system after it has been correctly connected. The
hydraulic system can be gravity bled, manually bled
or bled using pressure bleeding equipment.

GENERAL PROCEDURES (Continued)
5. Bleed each brake tube fitting at the brake Brake Caliper Bleeding
master cylinder as follows:
1 Have an assistant pump the brake pedal and NOTE: It is not necessary to bleed the entire brake
then hold firm pressure on the brake pedal. system. It is possible to bleed only the opened part
of the system.
2 Loosen the rear brake tube fitting until a
stream of brake fluid comes out. Have an 1. Connect one end of a clear flexible hose to the
assistant maintain pressure on the brake caliper screw. Submerge the other end in a
pedal while tightening the brake tube fitting. container partially filled with the specified
3 Repeat this operation until clear, bubble-free brake fluid.
fluid comes out.
4 Refill the brake master cylinder reservoir as 2. Have an assistant pump and then hold firm
necessary. Repeat the bleeding operation at pressure on the brake pedal.
the front brake tube fitting.
3. Open the caliper bleeder screw until brake fluid
6. While the assistant maintains pressure on the flows into the container.
brake pedal, tighten the 2 master cylinder brake
4. When fluid stops flowing, close the bleeder
tube fittings.
screw.
• Tighten to 18 Nm (13 lb-ft)
• Tighten to 22 Nm (16 lb-ft)
5. Repeat the previous 3 steps until there are no

air bubbles in the brake fluid.
Anti-Lock Brake System Hydraulic Control
Unit Bleeding
NOTE: This procedure is required only when a new

hydraulic control unit is installed.
1. Connect the diagnostic tool and follow the ABS

system bleed instructions.
2. Use the caliper bleed procedure to bleed the

system. Begin at the RH rear caliper.
2005 Aviator, 09/2004

206-03-1 Front Disc Brake 206-03-1
SPECIFICATIONS
Item Specification
Item Specification Anti-Seize Lubricant XL-2
Brake Pads Silicone Brake Caliper ESE-M1C171-A
Brake pad minimum 3.0 mm (0.118 inch) Grease and Dielectric
thickness Compound XG-3-A
Brake pad maximum 2.0 mm (0.079 inch) Brake Parts Cleaner PM-4 —
thickness variation Penetrating and Lock —
(pad-to-pad) Lubricant XL-1
Brake pad maximum taper 3.0 mm (0.118 inch)
wear (in any direction)
Torque Specifications
Brake Disc
Description Nm lb-ft
Front brake disc minimum 26.5 mm (1.04 inch)
thickness Brake caliper anchor plate 210 155
bolts
Minimum thickness to 27.1 mm (1.06 inch)
machine front disc Bleeder screw 22 16
Lubricant Brake caliper bolt 44 32
High Performance DOT 3 ESA-M6C25-A Brake flexible hose flow bolt 35 26
Motor Vehicle Brake
Fluid PM-1 (Canada
CPM-1)

Last updated: 6/29/2004 2005 Lincoln Aviator, 09/2004

Front Disc Brake
The front disc brake system includes the brake
caliper, the brake pads, the brake caliper anchor
plate, the brake disc, and the brake disc shield. The
brake caliper is a dual piston floating design and is
mounted to the brake caliper anchor plate by the
brake caliper bolts. The brake caliper slides, or
floats, on the brake caliper guide/locating pins. The
brake disc is a cast, ventilated type disc. When
mechanical force is applied by the driver to the
brake pedal, the force is converted into hydraulic
pressure by the master cylinder. The hydraulic force
is directed to the disc brake calipers and transferred
to the brake pads. The brake pads are then forced
against the brake friction surfaces by the brake
caliper pistons. The friction of the brake pads on
the brake disc causes the slowing of wheel rotation
and the vehicle.

REMOVAL AND INSTALLATION

Disc Brake System — Exploded View
Item Part Number Description Item Part Number Description

1 — Brake caliper bolts (part of 5 2027 Brake caliper anchor plate
kit 2B513, 2B296) (2 bolt (one kit each side) (2
required) required)
2 2B294/2B302 Brake caliper (RH/LH) 6 — Brake caliper anchor plate
3 2001 Brake pads (kit) (part of kit 2B513)
4 26200 Spring clips (part of kit 2001) 7 — Guide pin and boot (part of
(2 required) kit 2B513, 2B296)
(Continued)
(Continued)

REMOVAL AND INSTALLATION (Continued)

8 — Locator pin and boot (part of 13 2K004/2K005 Brake disc shield (LH/RH)
kit 2B513, 2B296) 14 2208 Bleeder screw
9 1125 Brake disc 15 2L126 Bleeder screw cap
10 385116-S2 Brake flexible hose flow bolt
11 2149 Copper washers (2 required) 1. For additional information, refer to the
12 W701950-S100 Rivets (4 required) procedures in this section.
(Continued)
2005 Lincoln Aviator, 09/2004


Brake Pads 3. CAUTION: Do not pry in the brake
caliper sight hole to retract the pistons as
Material this can damage the pistons and boots.
Item Specification CAUTION: When removing the disc
High Performance DOT 3 ESA-M6C25-A brake caliper, never allow it to hang from
Motor Vehicle Brake Fluid the brake flexible hose. Provide a suitable
PM-1(Canada CPM-1) support.
Removal Remove the 2 brake caliper bolts and position
the caliper aside.
WARNING: Use of any other than
approved DOT 3 motor vehicle brake fluid will 4. CAUTION: Install new brake pads if
cause permanent damage to brake components they are worn past the specified thickness or
and will render the brakes inoperative. Failure to above the metal backing plate or rivets.
follow these instructions may result in personal Install new brake pads in complete axle sets.
injury. Inspect the brake pads for wear and
contamination.
WARNING: Brake fluid contains
polyglycol ethers and polyglycols. Avoid contact 5. Remove the brake pads and the 2 spring clips.
with eyes. Wash hands thoroughly after • Discard the spring clips.
with running water for 15 minutes. Get medical Installation
internally, drink water and induce vomiting. Get 1. Install the 2 spring clips and the brake pads.
these instructions may result in personal injury. 2. NOTE: Use a suitable tool to protect pistons
and boots when pushing the caliper pistons into
CAUTION: Brake fluid is harmful to the caliper piston bores.
painted and plastic surfaces. If brake fluid is Compress the disc brake caliper pistons into the
spilled onto a painted or plastic surface, caliper piston bores.
3. CAUTION: Tighten the bottom locator
1. Check the brake fluid level in the brake master
pin caliper bolt before tightening the top
cylinder reservoir.
guide pin caliper bolt.
• If required, remove fluid until the brake
Position the brake caliper and install the 2
master cylinder reservoir is half full.
bolts.
2. With the vehicle in NEUTRAL, position it on a • Tighten to 44 Nm (32 lb-in).
hoist. For additional information, refer to
Section 100-02. 4. Fill the brake master cylinder reservoir with
clean brake fluid.
5. Test the brakes for normal operation.


Brake Caliper 2. Remove the front brake flexible hose flow bolt
and discard the 2 copper washers.
Material
3. CAUTION: Do not pry in the brake
Item Specification
caliper sight hole to retract the pistons as
High Performance DOT 3 ESA-M6C25-A this can damage the pistons and boots.
PM-1(Canada CPM-1) NOTE: Do not allow the brake caliper to hang
from the brake flexible hose. Use a suitable tool
Removal to support the brake caliper.
Remove the 2 brake caliper bolts and the brake
WARNING: Use of any other than caliper.
approved DOT 3 motor vehicle brake fluid will
cause permanent damage to brake components 4. Inspect the brake caliper for defects.
and will render the brakes inoperative. Failure to • If leaks or damaged boots are found, install
follow these instructions may result in personal a new brake caliper.
injury.
Installation
polyglycol ethers and polyglycols. Avoid contact
1. CAUTION: Tighten the bottom locator
pin caliper bolt before tightening the top
attention if irritation persists. If taken Position the brake caliper and install the 2
internally, drink water and induce vomiting. Get bolts.
medical attention immediately. Failure to follow • Tighten to 44 Nm (32 lb-ft).
2. Using 2 new copper washers, position the brake
CAUTION: Brake fluid is harmful to flexible hose and install the brake caliper flow
painted and plastic surfaces. If brake fluid is bolt.
spilled onto a painted or plastic surface, • Tighten to 35 Nm (26 lb-ft).
3. Bleed the brake caliper. For additional
1. With the vehicle in NEUTRAL, position it on a information, refer to Section 206-00.
Section 100-02. 4. Test the brake system for normal operation.


Brake Caliper Anchor Plate 2. Remove and discard the 2 brake caliper anchor
plate bolts.
Material • To install, tighten to 210 Nm (155 lb-ft).
Item Specification
3. Remove the brake caliper anchor plate.
Silicone Brake Caliper ESE-M1C171-A
Grease and Dielectric 4. To install, reverse the removal procedure.
Compound
XG-3-A • Lubricate the brake caliper guide and locator
pins with silicone grease.
Removal and Installation
1. Remove the brake pads. For additional

information, refer to Brake Pads in this section.


Brake Disc Installation
Material 1. NOTE: If machining is necessary, use a

hub-mounted brake lathe to machine the front
Item Specification
brake disc. For additional information, refer to
High Temperature Nickel ESE-M12A4-A Section 206-00.
Anti-Seize Lubricant
XL-2 Measure the front brake disc and resurface as
Penetrating and Lock — necessary. Install a new front brake disc if the
Lubricant disc thickness is beyond specifications.
XL-1
Brake Parts Cleaner — 2. Clean any rust or debris from the brake disc
PM-4 and wheel hub.
• Use parts cleaner to clean the front brake
Removal
disc and hub surfaces.
1. Remove the 2 brake caliper anchor plate bolts 3. Apply a thin coat of anti-seize to the hub
and position the brake caliper and anchor plate flange.
assembly aside.
4. Install the brake disc, aligning the marks on the
2. Mark a wheel stud and mark the corresponding disc and the wheel stud.
brake disc wheel stud hole.
• This minimizes front brake disc runout 5. CAUTION: Tighten the bottom locator
during reassembly. pin caliper bolt before tightening the top
3. NOTE: If the brake disc cannot be removed
Position the brake caliper and brake caliper
easily, apply rust penetrant on the brake
anchor plate assembly and install the 2 bolts.
disc-to-hub mating surfaces.
• Tighten to 210 Nm (155 lb-ft).
Remove the brake disc.


Brake Disc Shield
Removal
1. Remove the brake disc. For additional

information, refer to Brake Disc in this section.
2. Remove and discard the 4 brake disc shield

bolts.
3. Remove the brake disc shield.

Installation
2. Position the shield on to the wheel knuckle.
1. Drill four 6.35 mm (0.25 in) holes into the
3. Secure the brake disc shield to the wheel
wheel knuckle.
knuckle with four 6.35 mm (0.25 in) rivets
W701950-S100.
4. Install the brake disc. For additional

information, refer to Brake Disc in this section.

206-04-1 Rear Disc Brake 206-04-1
SPECIFICATIONS
Item Specification
Item Specification Anti-Seize Lubricant
Brake Pads XL-2
Brake pad minimum 3.0 mm (0.118 inch) Silicone Brake Caliper ESE-M1C171-A
thickness Grease and Dielectric
Compound XG-3-A
Brake pad maximum 2.0 mm (0.079 inch)
thickness variation Brake Parts Cleaner PM-4 —
(pad-to-pad) Penetrating and Lock —
Brake pad maximum taper 3.0 mm (0.118 inch) Lubricant XL-1
wear (in any direction)
Brake Disc Torque Specifications
Rear brake disc minimum 11.0 mm (0.43 inch) Description Nm lb-ft
thickness
Bleeder screw 22 16
Minimum thickness to 11.6 mm (0.45 inch)
machine rear disc Brake caliper bolt 32 24
Lubricants Brake flexible hose flow bolt 35 26
High Performance DOT 3 ESA-M6C25-A Brake disc shield bolts 12 9
Motor Vehicle Brake Brake tube fitting 17 13
Fluid
PM-1 (Canada CPM-1)

206-04-1 Rear Disc Brake 206-04-1

Rear Disc Brake
Rear Disc Brake
The rear disc brake system includes the brake
caliper, the disc brake pads, and the brake disc. The
brake caliper is a single piston floating design. The
brake caliper is mounted to the rear knuckle by the
caliper guide bolts. The brake caliper slides, or
floats, on the caliper guide pins. The brake disc is a
cast, non-ventilated type disc. When mechanical
force is applied by the driver to the brake pedal, the
force is converted into hydraulic pressure by the
master cylinder. The hydraulic force is directed to
the brake calipers and transferred to the brake pads.
The brake pads are then forced against the brake
friction surfaces by the brake caliper pistons. The
friction of the brake pads on the brake disc causes
the slowing of wheel rotation and the vehicle.

206-04-1 Rear Disc Brake 206-04-1

Disc Brake System — Exploded View
Rear Disc Brake

1 2333 Brake caliper bolts (2 5 2C026 Brake disc
required) 6 385116-S2 Brake flexible hose flow bolt
2 2552/2553 Brake caliper (RH/LH) 7 2179 Copper washers (2 required)
3 2200 Brake pads 8 2C028/2C029 Brake disc shield bolts (part
4 — Spring clips (part of kit 2200) of kit 2213/2214) (4 required)
(2 required) 9 2C028/2C029 Brake disc shield (RH/LH)
(Continued) (Continued)

206-04-2 Rear Disc Brake 206-04-2
10 W505223-S Brake flexible hose bracket 13 2C339 Brake flexible hose
bolt 14 2208 Bleeder screw
11 — Brake tube fitting (part of 15 2208 Bleeder screw cap
2267)
12 — Brake tube crossover line
fitting (part of 2267) 1. For additional information, refer to the
(Continued) procedures in this section.
2005 Aviator, 09/2004

206-04-1 Rear Disc Brake 206-04-1

Brake Caliper 1. With the vehicle in NEUTRAL, position it on a
Material Section 100-02.
Item Specification 2. Remove the 2 brake caliper bolts.
Motor Vehicle Brake Fluid 3. Remove the brake flexible hose flow bolt and
PM-1 (Canada CPM-1) discard the 2 copper washers.
Anti-Seize Lubricant 4. Remove the brake caliper.
XL-2
Silicone Brake Caliper ESE-M1C171-A Installation
Grease and Dielectric
Compound 1. Position the brake caliper and install the 2
XG-3-A
bolts.
PM-4 • Tighten to 32 Nm (24 lb-ft).
Removal 2. Using 2 new copper washers, position the brake

flexible hose and install the flow bolt.
WARNING: Use of any other than • Tighten to 35 Nm (26 lb-ft).
approved DOT 3 motor vehicle brake fluid will
cause permanent damage to brake components 3. Bleed the system. For additional information,
and will render the brakes inoperative. Failure to refer to Section 206-00.
follow these instructions may result in personal
injury. 4. Test the brake system operation.



206-04-1 Rear Disc Brake 206-04-1

Brake Pads 4. CAUTION: Install a new pad if it is
worn past the specification.
Material Remove the pads and spring clips.
Item Specification • Discard the spring clips.
Motor Vehicle Brake Fluid Installation
PM-1 (Canada CPM-1)
1. NOTE: One brake disc pad kit contains the
Removal
linings required for both sides.
Install the spring clips and brake pads.
1. Check the brake fluid level in the brake master
cylinder reservoir.
2. Use a suitable tool to push the brake caliper
• If required, remove fluid until the brake pistons into the caliper bore.
master cylinder reservoir is half full.
3. Position the brake caliper and install the brake
2. With the vehicle in NEUTRAL, position it on a caliper bolts.
Section 100-02.
4. Fill the brake master cylinder reservoir with
3. CAUTION: Do not pry in caliper sight clean brake fluid.
hole to retract pistons as this can damage the
pistons and boots. 5. Test the brakes for normal operation.
CAUTION: Do not allow the brake
caliper to hang from the flexible hose. Us a
suitable tool to support the brake caliper.
Remove the 2 brake caliper bolts and position
the caliper aside.

206-04-1 Rear Disc Brake 206-04-1

Brake Disc Installation
Material NOTE: If the adjustment hole knockout panel or

access plug was removed, it is necessary to install
Item Specification an access plug to prevent the entry of contaminants.
PM-4 1. Clean any rust or debris from brake disc and
Penetrating and Lock — wheel hub.
Lubricant
XL-1 • Use parts cleaner to clean the front brake
disc and hub surfaces.
Anti-Seize Lubricant
XL-2 2. CAUTION: Do not allow the lubricant
to make contact with the wheel studs, brake
Removal pads or brake disc.
Apply a thin coat of anti-seize lubricant to the
1. Remove the brake pads. For additional hub flange.
information, refer to Brake Pads in this section.
3. Install the brake disc.
2. NOTE: If the brake disc binds on the parking
brake shoe and lining, remove the adjustment 4. Install the brake pads. For additional
hole knockout panel or access plug and contract information, refer to Brake Pads in this section.
the parking brake shoe and lining.
NOTE: If the brake disc cannot be removed
easily, apply rust penetrant on the brake
disc-to-hub mating surfaces.
Remove the brake disc.

206-04-1 Rear Disc Brake 206-04-1

Brake Disc Shield
Material
Item Specification
PM-4
Removal
1. Remove the parking brake shoes. For additional

information, refer to Section 206-05.
2. Remove the 3 brake disc shield bolts. Installation
3. Cut the shield at the perforations and remove 1. NOTE: If installing a new brake disc shield,
the brake disc shield halves. cut the new shield in two at the perforations.
Position the brake disc shield halves, and install
the 2 bolts (part number W505321-S426) in
each half.
2. Install the parking brake shoes. For additional


206-04-1 Rear Disc Brake 206-04-1
DISASSEMBLY AND ASSEMBLY

Brake Caliper
Special Tool(s)
Adapter for 303-2244 (Handle)
205-153 (T80T-4000-W)
Installer, Rear Wheel Hub Dust

Seal
206-053 (T92P-2588-AH)
Material
Item Specification
PM-1 (Canada CPM-1)

206-04-2 Rear Disc Brake 206-04-2
DISASSEMBLY AND ASSEMBLY (Continued)
Item Part Number Description 5. NOTE: Do not hone the piston bores. If the
1 2L126 Bleeder screw cap bores are excessively scored or corroded, install
a new brake caliper.
2 2208 Bleeder screw
3 2K395 Brake caliper piston Remove and discard the piston seal and dust
boot.
4 2K407 Brake caliper seal (kit)
5 2B514 Guide pin and boot (kit) Assembly
Disassembly 1. Lubricate the cylinder bore, piston seal, caliper

piston, and dust boot with clean brake fluid.
CAUTION: Brake fluid contains polyglycol
ethers and polyglycols. Avoid contact with eyes. 2. Install the piston seal.
Wash hands thoroughly after handling. If brake
fluid contacts eyes, flush eyes with running water 3. Using the special tools, install the dust boot.
for 15 minutes. Get medical attention if irritation
persists. If taken internally, drink water and
induce vomiting. Get medical attention
immediately.

painted or plastic surfaces. If brake fluid is
1. Remove the brake caliper. For additional

information, refer to Brake Caliper in this
section.
2. Remove the bleeder screw cap and bleeder 4. Install the brake caliper piston.
screw.
5. Install the bleeder screw and cap.
3. Secure the brake caliper in a vise.
6. Install the brake caliper. For additional
information, refer to Brake Caliper in this
4. CAUTION: Apply moderate air
section.
pressure in short bursts to prevent an
uncontrolled release of the piston.
Place a piece of wood in the caliper. Remove
the piston by applying moderate air pressure
through the bleeder screw port.
2005 Aviator, 09/2004

206-05-1 Parking Brake and Actuation 206-05-1
SPECIFICATIONS
Description Nm lb-ft lb-in
Bulkhead connector 5 — 44
Item Specification
Parking brake cable 15 11 —
Parking brake cage 1.07 mm (0.04 in) bracket bolt
clearance
Wire form retainer bolt 15 11 —
Parking brake control 20 15 —
bolts


Parking Brake The parking brake cable tension is self-adjusting.
The parking brake system is a mechanical system
that activates a shoe-and-drum parking brake within
the rear brake disc.
The parking brake system is cable-actuated and
controlled by an independent foot-operated parking
brake control. The parking brake system is actuated
when the parking brake control is pressed. The
parking brake control applies tension to the rear
parking brake shoes through the front parking brake
cable and the LH and RH rear parking brake cables.
The respective rear parking brake assemblies are
then applied.


Parking Brake Visual Inspection Chart
Mechanical
Inspection and Verification
• Parking brake controller
1. Verify the customer concern. • Parking brake cables
2. Visually inspect for obvious signs of • Parking brake shoes
mechanical damage.
3. If an obvious cause for an observed or reported
concern is found, correct the cause (if possible)
before proceeding to the next step.
4. If the cause is not visually evident, GO to
Symptom Chart.
Symptom Chart
Symptom Chart
• The parking brake will not • Parking brake cable • GO to Pinpoint Test A.
apply • Rear shoes and linings
• Parking brake control
• The parking brake will not • Parking brake cable • GO to Pinpoint Test B.
release • Parking brake control
• Rear shoes and linings
Pinpoint Test A: The Parking Brake Will Not Possible Causes

Apply
• parking brake cables
Normal Operation • parking brake control
The parking brake system is an independent • parking brake shoe and lining clearance
cable-actuated system controlled by a foot-operated
parking brake control. The parking brake control
engages the rear parking brake shoes through cables
and an equalizer on the front cable. Parking brake
cable tension is adjusted automatically.
PINPOINT TEST A: THE PARKING BRAKE WILL NOT APPLY
A1 CHECK THE PARKING BRAKE CABLE
• With the vehicle in NEUTRAL, position it on a hoist. Refer to Yes
Section 100-02 REPAIR or INSTALL a new parking brake
• Inspect for broken or binding parking brake cables. cable as necessary. REFER to Parking
• Is there a parking brake cable concern? Brake Cable — Front, Parking Brake
Cable — LH Rear, or Parking Brake
Cable — RH Rear in this section.
No
GO to A2.
A2 CHECK THE PARKING BRAKE CONTROL
• Operate the parking brake control. Yes
• Does the parking brake control operate smoothly? GO to A3.
No
REPAIR or INSTALL the parking brake
control. REFER to Parking Brake Control
in this section. TEST the system for
normal operation.
(Continued)

PINPOINT TEST A: THE PARKING BRAKE WILL NOT APPLY (Continued)
A3 CHECK THE PARKING BRAKE COMPONENTS
• Remove the rear brake discs. Refer to Section 206-04. Yes
• Operate the parking brake control and observe the parking brake CHECK the parking brake shoe and lining
components. clearance to the drum of the brake disc.
• Do the parking brake components operate? The minimum clearance between the
shoes and lining and the parking brake
drum is 1.07 mm (0.04 in). REFER to
Parking Brake Shoes in this section to
continue diagnosis.
No
REPAIR the worn or damaged parts.
TEST the system for normal operation.
Pinpoint Test B: The Parking Brake Will Not Possible Causes

Release
• parking brake cables
Normal Operation • parking brake control
The parking brake system is an independent • parking brake shoe and lining clearance
cable-actuated system controlled by a foot-operated
parking brake control. The parking brake control
engages the rear parking brake shoes through cables
and an equalizer on the front cable. Parking brake
cable tension is adjusted automatically.
PINPOINT TEST B: THE PARKING BRAKE WILL NOT RELEASE
B1 CHECK THE PARKING BRAKE CABLE
• Release the parking brake control. Yes
• If the vehicle cannot be moved, raise and support it. Refer to INSPECT the parking brake cable for
Section 100-02 binding. INSPECT the parking brake
• Release the parking brake cable tension. control. INSTALL new components as
• Remove the rear brake disc and disconnect the parking brake necessary. TEST the system for normal
rear cable and conduit. Refer to Parking Brake Shoes in this operation.
section to continue diagnosis. No
• Does the parking brake release? REPAIR the worn or damaged rear brake
component. TEST the system for normal
operation.
2005 Aviator, 09/2004

GENERAL PROCEDURES
Parking Brake Cable Tension Release 3. NOTE: Make sure the cable-to-cable union is
connected to the front and rear cable before
removing the brake control retaining pin, and
1. Remove the LH cowl side trim panel. For
the cable tension is reloaded slowly.
additional information, refer to Section 501-05.
Disconnect the cable at the cable-to-cable
2. With an assistant, release the parking brake union.
cable tension by pulling down on the
intermediate cable at the cable-to-cable union
until the parking brake control sector rotates to
its stop and a 4 mm (0.15 in) x 150 mm (5.9
in) retainer pin can be inserted.
4. To reload the tension on the parking brake

cable, follow the release procedure in reverse.


Parking Brake Control

1 — Pin 5 N806497 Parking brake control bolts (3
2 — Parking brake release handle required)
grommet (part of 2780) 6 2780 Parking brake control
3 — Parking brake switch screw 7 2853 Front parking brake cable
(part of 15852) 8 — Parking brake control pedal
4 15852 Parking brake switch pad (part of 2780)
(Continued)

1. Release the tension on the parking brake cable.

For additional information, refer to Parking
Brake Cable Tension Release in this section.
2. Remove the screws and the instrument panel

steering column cover.
3. Disconnect the battery. For additional

4. Loosen the bolt and disconnect the bulkhead

connector. 8. Remove the 3 bolts from the parking brake
• To install, tighten to 5 Nm (44 lb-in). control.
• To install, tighten to 20 Nm (15 lb-ft).
5. Release the parking brake release handle
grommet from the bracket. 9. Position the carpet aside and position the cable
conduit grommet up through the floor.
6. Disconnect the parking brake switch electrical
connector. 10. Remove the parking brake control from the
vehicle.
7. Remove the wiring harness bracket screw and
position the harness and bracket aside. 11. To install, reverse the removal procedure.
• Test the parking brake system for correct
operation.
2005 Aviator, 09/2004


Parking Brake Cable — Front
1. Remove the parking brake control. For

additional information, refer to Parking Brake
Control in this section.
2. NOTE: The parking brake control take-up

spool tab may need to be bent aside to allow
the cable to be removed.
Disconnect the front parking brake cables from
the parking brake control. 3. Disconnect the front parking brake cable
conduit from the parking brake control.
4. To install, reverse the removal procedure.

operation.


Parking Brake Cable — LH Rear
Item Part Number Description 4. Remove the wire form retainer bolt from the
1 2A809 Parking brake cable (LH) lower arm.
2 N802324 Wire form retainer bolt • To install, tighten to 15 Nm (11 lb-ft).
3 2A826 Wire form retainer
5. Disconnect the LH parking brake cable from
the parking brake lever and remove the cable
from the vehicle.
1. Release the parking brake cable tension. For 6. To install, reverse the removal procedure.
Cable Tension Release in this section.
operation.
2. Disconnect the intermediate cable from the LH
rear cable at the cable equalizer.
3. Disconnect the front of the LH rear cable

conduit at the frame bracket.


Parking Brake Cable — RH Rear

1 — Cable union (part of 2A793) 4 2A635 Parking brake cable (RH)
2 2A793 Intermediate parking brake 5 N500213 Parking brake cable bracket
cable bolt
3 — Cable equalizer (part of 6 N802324 Wire form retainer bolt
2A793) 7 2A826 Wire form retainer
(Continued)

Removal and Installation 5. Remove the wire from retainer bolt from the
lower arm.
1. Release the parking brake cable tension. For • To install, tighten to 15 Nm (11 lb-ft).
Cable Tension Release in this section. 6. Disconnect the RH parking brake cable from
the parking brake levers and remove the
2. Disconnect the intermediate parking brake cable parking brake cable from the vehicle.
from the RH rear parking brake cable at the
parking brake cable equalizer. 7. To install, reverse the removal procedure.
3. Disconnect the front of the RH parking brake
operation.
cable conduit at the frame bracket.
4. Remove the parking brake cable bracket bolt

from the top of the crossmember.
2005 Aviator, 09/2004


Parking Brake Shoes Installation
Special Tool(s) 1. Position the parking brake shoes and attach the
retracting spring.
Gauge, Brake Adjusting
206-D002 (D81L-1103-A) or
equivalent 2. Install the 2 parking brake shoe hold-down pins
and springs.
3. Install the parking brake shoe adjusting screw

spring.
4. NOTE: Completely retract the parking brake

Removal
adjusting screw before installation.
NOTE: A parking brake shoe kit contains the Install the brake shoe adjusting screw.
linings required for both the LH and RH side.
5. Use the Brake Adjusting Gauge to measure the
1. NOTE: Make sure the parking brake control is inside diameter of the parking brake drum.
fully released.
6. Adjust the parking brake shoe clearance of 1.07
Release the tension on the parking brake cable. mm (0.04 in) less than the inside diameter of
For additional information, refer to Parking the parking brake drum.
Brake Cable Tension Release in this section.
• Make sure that the parking brake shoes are
2. Remove the rear brake disc. For additional correctly centered and measure across the
information, refer to Section 206-04. center point of the shoes.
• Rotate the parking brake shoe adjuster wheel
3. Remove the parking brake shoe adjusting screw. to achieve the correct parking brake
shoe-to-brake disc clearance.
4. Remove the parking brake shoe adjusting screw
spring. 7. Install the rear brake disc. For additional
5. Remove the 2 parking brake shoe hold-down
springs and pins. 8. Reload the tension on the parking brake cable.
For additional information, refer to Parking
6. Remove the parking brake shoe retracting Brake Cable Tension Release in this section.
spring and the parking brake shoes.

206-06-1 Hydraulic Brake Actuation 206-06-1
SPECIFICATIONS
Torque Specifications (Continued)
Instrument 25 18 —
Item Specification panel-to-cowl support
Lubricant bolt
High Performance DOT 3 ESA-M6C25-A Instrument panel duct 9 — 80
Motor Vehicle Brake support bolt
Fluid PM-1 (Canada Instrument panel 9 — 80
CPM-1) support bracket bolt
Instrument panel 9 — 80
Torque Specifications support bracket nut
Brake tube fitting 18 13 —
Passenger assist handle 11 8 —
Adjustable pedal motor 3 — 27 bolts
screw
Steering intermediate 30 22 —
Brake booster nut 22 16 — shaft pinch bolt
Brake master cylinder 25 18 — Side instrument 30 22 —
nut panel-to-cowl support
Brake master cylinder 18 13 — bolt
pressure switch Top instrument 30 22 —
Brake pedal bracket 13 10 — panel-to-cowl support
bolt bolt
Adjustable accelerator 7 — 62
pedal bracket nut


Hydraulic Brake Actuation Adjustable Pedal Operation
The brake system consists of the following The adjustable pedals with or without memory
components: feature are operational with the ignition switch in
the ON or OFF position. The pedals are adjusted
• a vacuum-assisted power braking system forward or rearward using the adjustable pedal
• a front-to-rear split hydraulic system switch.
• front disc brakes using a dual piston brake caliper Driver Seat Module (DSM)
and disc system
The DSM controls the memory adjustable pedals.
• rear disc brakes using a single piston brake caliper
and disc system The DSM constantly monitors the systems under its
control and records concerns in the form of
• a mechanical parking brake system that activates a diagnostic trouble codes (DTCs). A DTC can be
drum-in hat system within the rear brake disc retrieved with the diagnostic tool through the data
• a 4-wheel anti-lock brake system (4WABS) with link connector (DLC).
roll stability control (RSC) (For additional
information, refer to Section 206-09.) Memory Adjustable Pedal Operation
• adjustable pedals (if equipped) The adjustable pedals with memory feature is
controlled by using the memory switches or the
• adjustable pedals with memory (if equipped) remote keyless entry (RKE) transmitter. The exterior
• fixed pedals (if equipped) mirror and power driver seat positions are also
stored and recalled with the power adjustable pedal
Adjustable Pedals positions. The system can store 3 memory settings.
Using the adjustable pedal switch located on the
instrument panel, the driver can adjust the brake and
accelerator pedals for a more comfortable driving
position. For removal and installation of the
adjustable pedals, refer to Brake Pedal and Bracket
in this section.


Brake Pedal and Bracket

1 9C872 Speed control deactivation 6 13480 Stoplamp switch
switch 7 — Brake booster rod (part of
2 2475 Brake booster rod redundant 2005)
self-locking clip cover 8 W520112-S Brake booster nuts (4
3 380699-S Self-locking clip required)
4 2A309 Stoplamp switch bushing 9 W707402-S Brake pedal bracket bolt
5 — Spacer (2 required) (Continued)
(Continued)

Item Part Number Description
10 — Adjustable pedal motor
electrical connector
11 — Accelerator cable
12 90907 Adjustable accelerator pedal
bracket nuts (3 required)
13 2450/9F856 Brake pedal bracket
(fixed/adjustable)
14 — Adjustable pedal motor
screws (2 required)
15 2C429 Adjustable pedal motor
Removal
7. Remove and discard the 4 brake booster nuts.
1. NOTE: When removing the adjustable pedal 8. Position the brake master cylinder and brake
assembly, make sure the pedals are adjusted to booster assembly forward to allow the brake
the full forward position. pedal assembly to clear the studs.
Depower the supplemental restraint system
(SRS). For additional information, refer to 9. Remove the 3 adjustable accelerator pedal
Section 501-20B. bracket nuts.
10. Remove the 2 wiper arms.

2. CAUTION: The brake pedal must be
connected to the brake booster rod and in
11. Remove the cowl grille.
the at-rest position before removing the
speed control deactivation switch, or the • The grille is secured with 14 spring clips.
switch will be damaged. Pull upward on the grille to release the
clips.
Remove the speed control deactivation switch.
12. Remove the instrument panel-to-cowl support
3. Disconnect the brake booster rod redundant
bolt.
self-locking clip cover and the self locking clip.
4. Remove the stoplamp bushing, spacer and the

brake booster rod from the brake pedal and
position the stoplamp switch aside.
5. Disconnect the adjustable pedal motor electrical

connector.
6. Disconnect the accelerator cable.

1 Release the retainer from the grommet.
2 Release the grommet from the accelerator.
3 Position the accelerator cable assembly
aside.
13. Remove the front floor console. For additional
2005 Aviator, 09/2004

14. Remove the 4 nuts and 4 bolts from the LH 22. Remove the 2 steering column opening cover
and RH instrument panel support brackets and screws and the steering column opening cover
position the 2 support brackets aside. panel.
23. CAUTION: Do not allow the steering

wheel to rotate while the steering column
intermediate shaft is disconnected, or damage
to the clockspring can result. If there is
evidence the steering column shaft has
rotated, the clockspring must be removed
and centered. For additional information,
refer to Section 501-20B.
Secure the steering wheel to prevent it from
rotating.
24. Remove the steering intermediate shaft pinch

bolt and separate the steering shafts.
15. Remove the 2 door scuff plates.
25. Loosen the bolt and disconnect the bulkhead
16. Remove the retainer and the 2 A-pillar lower
electrical connector.
trim panels.
26. Remove the 4 side instrument panel-to-cowl
17. Remove the 2 instrument panel side finish
support bolts.
panels.
27. Position the instrument panel approximately
18. Remove the 2 A-pillar passenger assist handles.
25.4 mm (1 inch) away from the dash panel.
• Remove the 4 passenger assist handles caps.
• Remove the 4 bolts and the assist handles. 28. Remove the brake pedal assembly from the
vehicle.
19. Remove the 2 windshield side garnish
mouldings. Installation
20. Remove the defroster grille. 1. Position the brake pedal assembly in the
vehicle.
21. Remove the duct bolt and the top instrument
panel-to-cowl bolt. 2. Position the instrument panel.
3. Position the bulkhead electrical connector.

• Tighten to 5 Nm (44 lb-in).
2005 Aviator, 09/2004

4. Install the 4 side instrument panel to cowl 15. Install the instrument panel-to-cowl support
support bolts. bolt.
• Tighten to 30 Nm (22 lb-ft). • Tighten to 25 Nm (18 lb-ft).
5. Connect the steering intermediate shaft and

install the pinch bolt.
6. Position the steering column opening cover

panel and install the 2 screws.
7. Install the top instrument panel-to-cowl and

duct support bolts.
1 Tighten to 9 Nm (80 lb-in).
2 Tighten to 30 Nm (22 lb-ft).
16. Install the cowl grille.
17. Install the 2 wiper arms.
18. Install the front floor console. For additional

19. Install the 3 adjustable accelerator pedal bracket

nuts.
• Tighten to 7 Nm (62 lb-in).
20. Position the brake master cylinder and brake

booster assembly into the brake pedal bracket
8. Install the defroster grille. assembly.
9. Install the 2 windshield side garnish mouldings. 21. Install 4 new brake booster nuts.
10. Position the 2 A-pillar passenger assist handles • Tighten to 22 Nm (16 lb-ft).
and install the 4 bolts.
22. Connect the adjustable pedal motor electrical
• Tighten to 11 Nm (8 lb-ft). connector.
• Install the 4 A-pillar passenger assist
handles caps. 23. Connect the accelerator pedal cable.
11. Install the 2 instrument panel side finish panels. 24. Position the stoplamp switch, stoplamp switch
bushing, spacers, and the brake booster rod on
12. Install the 2 A-pillar lower trim panels and the to the brake pedal.
retainer.
25. Install the redundant self-locking clip and cover.
13. Install the 2 door scuff plates.
26. CAUTION: The brake pedal must be
14. Position the 2 instrument support brackets and connected to the brake booster rod and in
install the 4 nuts and 4 bolts. the at-rest position before installing the speed
• Tighten to 9 Nm (80 lb-in). control deactivation switch, or the switch will
be damaged.
Install the speed control deactivation switch.
2005 Aviator, 09/2004
27. Repower the supplemental restraint system
(SRS). For additional information, refer to
Section 501-20B.
2005 Aviator, 09/2004


Brake Pedal Motor 2. NOTE: Do not discard the screws. These
screws must be used to reinstall the adjustable
Removal and Installation pedal motor.
NOTE: Make sure the brake pedal and the
1. Remove the brake pedal and bracket. For accelerator pedal are in the same position
additional information, refer to Brake Pedal and before connecting the drive cable to the
Bracket in this section. adjustable pedal motor.
Remove the 2 brake pedal motor screws and the
motor.


Brake Master Cylinder
Material
Item Specification
PM-1 (Canada CPM-1)

1 — Brake master cylinder 4 382802-S427 Brake master cylinder nut (2
pressure switch electrical required)
connector (part of 14289) 5 2A032 Brake master
2 — Brake fluid level warning cylinder/reservoir assembly
switch electrical connector 6 — Brake master cylinder
(part of 14289) pressure switch
3 — Brake tube fittings (2
required)
(Continued)

Removal and Installation 1. Disconnect the battery. For additional
WARNING: Use of any other than
approved DOT 3 motor vehicle brake fluid will 2. Use a suitable suction device to drain the
cause permanent damage to brake components reservoir before removal.
and will render the brakes inoperative. Failure to
3. Disconnect the brake fluid level warning switch
follow these instructions may result in personal
electrical connector.
injury.
4. Disconnect the brake master cylinder pressure
switch electrical connector.
with eyes. Wash hands thoroughly after 5. Disconnect the 2 brake tube fittings from the
handling. If brake fluid contacts eyes, flush eyes master cylinder.
attention if irritation persists. If taken • To install, tighten to 18 Nm (13 lb-ft).
6. Remove the 2 nuts and the brake master
cylinder.
painted and plastic surfaces. If brake fluid is 7. To install, reverse the removal procedure.
spilled onto a painted or plastic surface, • Bleed the brake system. For additional
immediately wash it with water. information, refer to Section 206-00.
2005 Aviator, 09/2004

206-07-1 Power Brake Actuation 206-07-1
SPECIFICATIONS
Description Nm lb-ft
Brake booster nut 22 16


Brake Booster If the power assist fails, the brake system will
continue to operate with increased brake pedal
Brake Booster effort.
The vacuum type power brake booster:
Active Brake Booster With Stability Assist
• is a dual diaphragm, vacuum assisted power brake The active brake booster functions like a
booster. conventional brake booster with the added feature
• reduces brake pedal force and travel distance. that it can be actuated electrically by the stability
• is located on the LH side of the bulkhead in the assist module. For further information on the
engine compartment, between the brake pedal and stability assist brake booster, refer to Section
the brake master cylinder. 206-09.
• is divided into separate chambers by the
diaphragms.
• will not operate if vacuum is restricted or if any
of the vacuum related power brake components
fail.
• is installed as an assembly.


Brake Booster
Item Part Number Description Removal and Installation

1 — Brake booster solenoid
electrical connector 1. Remove the master cylinder. For additional
2 9C482 Brake booster vacuum fitting information, refer to Section 206-06.
3 — Electrical harness connector
bracket (part of 14289) 2. Disconnect the brake booster solenoid electrical
connector.
4 W520112-S309 Brake booster nuts (4
required)
3. Disconnect the brake booster transducer
5 2475 Booster rod redundant
self-locking pin cover electrical connector.
6 830399-S Self-locking pin 4. Disconnect the electrical harness connector
7 13480 Brake stoplamp switch bracket from the brake booster housing,
8 2A309 Brake stoplamp switch
bushing 5. Disconnect the brake booster vacuum hose.
9 — Spacers (2 Required)
10 — Brake booster rod (part of 6. Remove the redundant self-locking pin cover
2005) and the self-locking pin.
11 2005 Brake booster assembly
7. Position the brake stoplamp switch aside.
8. Remove the brake stoplamp switch bushing,

spacer and the brake booster push rod.


9. NOTE: Use new nuts when installing the brake 10. To install, reverse the removal procedure.
booster.
Remove the brake booster nuts and the booster.
2005 Lincoln Aviator, 09/2004

206-09-1 Anti-Lock Control 206-09-1
SPECIFICATIONS
Torque Specifications (Continued)
Bracket-to-brake line 9 — 80
Item Specification holder nuts
Lubricant Bracket-to-hydraulic 17 13 —
Electrical Grease WSB-M1C239-A control unit (HCU)
F8AZ-19G208-AA bolts
High Performance DOT 3 ESA-M6C25-A Brake line-to-brake line 18 13 —
Motor Vehicle Brake nuts
Fluid PM-1 (Canada Brake line-to-HCU nuts 18 13 —
CPM-1) (M10-1)
Brake line-to-HCU nuts 23 17 —
Torque Specifications (M12-1)
Front wheel speed 17 13 —
Description Nm lb-ft lb-in sensor bolt
Accelerometer nuts 7 — 62 HCU bracket nuts 23 17 —
Anti-lock brake system 6 — 53 Rear wheel speed 27 20 —
(ABS) module screws sensor bolt


Anti-Lock Control • brake pedal travel sensor
• brake pedal force switch (integral to the brake
Anti-Lock Brake System (ABS)
booster)
The ABS consists of these additional components:
• brake booster solenoid (integral to the brake
• rear wheel speed sensors booster)
• rear wheel speed sensor ring (integral to the The front wheel speed sensors rings are integral to
halfshaft) the front hub and bearing assemblies. For additional
• sensor cluster (includes the accelerometer[s], roll information, refer to Section 204-01A or Section
rate sensor, and yaw rate sensor) 204-01B.
• steering wheel rotation sensor (integral to the The rear wheel speed sensor rings for 4 channel
clockspring) ABS are integral to the rear halfshaft. For additional
• primary brake pressure transducer


Anti-Lock Control Panic Assist Braking
Refer to Wiring Diagrams Cell 42 for schematic and Panic assist braking functions by fully applying the
connector information. brakes during a panic stop using a specially
developed pressure/pedal movement mechanism.
Special Tool(s) Depending on the vehicle speed, if the brake pedal
Worldwide Diagnostic System stroke is more rapid than normal, the brake booster
(WDS), automatically applies full brake boost. Panic assist is
Vehicle Communication Module disabled when the driver releases the brake pedal.
(VCM) with appropriate
adapters, or equivalent Stability Assist
diagnostic tool
With the ignition switch in the START or RUN
positions, the stability assist module functions
73III Automotive Meter similarly to a conventional anti-lock brake module
105-R0057 or equivalent by monitoring and comparing the rotational speed of
each wheel. Wheel speeds are measured by the
wheel speed sensor, which electrically senses each
tooth of the anti-lock sensor ring as they pass
through the sensor’s magnetic field. When the
stability assist module detects an impending wheel
lock, wheel spin, or vehicle motion that is
Flex Probe Kit
105-R025B inconsistent with the driver commands, brake
pressure is modulated to the appropriate brake
caliper(s). The stability assist module triggers the
hydraulic control unit (HCU) to open and close the
appropriate solenoid valves. Once the affected
wheel(s) return to the desired speed, the stability
assist module returns the solenoid valves to their
Principles of Operation normal position, and normal base brake operation is
restored.
The ABS module communicates with the powertrain
The ABS module manages anti-lock braking, control module (PCM) to assist with traction
traction control, stability assist, and engine control control. At speeds under 100 km/h (62 mph), when
systems to maintain vehicle control during the drive wheels lose traction and begin to spin, the
deceleration and acceleration. stability assist module requests the PCM to reduce
When the ignition switch is in the RUN position, engine torque while simultaneously applying and
the ABS module does a preliminary electrical check, releasing the appropriate brake caliper(s) to maintain
and at approximately 20 km/h (12 mph), the traction. The PCM accomplishes this by minor
hydraulic pump motor is turned on for incremental timing changes and fewer fuel injector
approximately 1 half-second. Any malfunction of pulses until the stability assist module ends the
the ABS disables the stability assist and the ABS request. The request ends when the driven wheel
warning indicator illuminates. However, the speed returns to the desired speed. After the vehicle
power-assist braking system functions normally. speed exceeds 100 km/h (62 mph), traction control
is accomplished only through the PCM torque
Electronic Brake Distribution (EBD) control.
The EBD controls the rear brake pressure and acts
as an electronic proportioning valve. It is controlled
by the ABS module. When EBD is disabled, the
ABS warning indicator illuminates.

The stability assist system constantly monitors the Roll Stability Control (RSC)
vehicle motion relative to the driver’s intended The roll stability control (RSC) system monitors the
course. This is done by using sensors to compare roll-rate sensor and existing stability assist sensors
the driver’s steering input and brake application and calculates if the vehicle may be approaching a
with that of the actual vehicle motion. The system situation where rollover is probable. If such a
does not activate when the vehicle is traveling in situation exists, the RSC system applies preemptive
reverse; however, the ABS and stability assist action. When activated, the RSC system adjusts the
continue to function as usual. brake torque at specific wheels in response to direct
The stability assist control switch allows the driver measurement of the vehicle roll motion. By
to control use of the stability assist system. This is adjusting brake torque, the system can reduce the
independent of the ABS function, which cannot be cornering forces and, therefore, the total roll
switched off by the driver. The stability assist moment acting on the vehicle. Systems with RSC
system status is indicated by a stability assist have an additional roll-rate sensor located within the
warning lamp in the traction control switch. An sensor cluster and additional programming within
illuminated traction control switch indicates that the the ABS module to help control the vehicle during
stability assist system is switched off. In vehicles sudden maneuvers.
with a message center, the message AdvTrac Off,
Information from the roll-rate sensor is fed into the
T/C ON is displayed. The anti-lock brake function
ABS module. The computer uses information from
continues to work as designed unless the yellow
the ABS wheel speed sensors, the throttle position
anti-lock brake warning indicator is also illuminated.
sensor, the steering wheel angle, the steering wheel
Normal braking function always occurs, unless the
rate of change, and a yaw rate sensor that measures
red brake warning indicator is illuminated.
the change in vehicle direction. If the computer
When stability assist activates, any of the following determines from all these inputs that conditions
can occur: exist for a potential roll over, the system applies 1
• a rumble or grinding sound much like ABS or or more brakes and reduces engine torque to make
traction control the vehicle more stable.
• a small deceleration or a reduction in the Sensor Cluster
acceleration of the vehicle The sensor cluster (also called the accelerometer)
• the stability assist indicator flashes consists of the yaw rate sensor, roll rate sensor (if
• if the driver’s foot is on the brake pedal, a equipped with roll stability control), lateral
vibration is felt in the pedal much like ABS accelerometer, and longitudinal accelerometer. The
lateral accelerometer measures the acceleration
• if the event is severe and the driver’s foot is not
which corresponds to the force involved when the
on the brake, the brake pedal moves to apply
vehicle slides sideways. This acceleration has 2
higher brake forces. A whooshing sound can also
forms. The first is the centrifugal acceleration which
be heard from under the instrument panel in an
is generated when the vehicle travels around in a
event this severe.
circle. The second is the acceleration due to
Some drivers may notice a slight movement of the gravity. On level ground there is no contribution
brake pedal when the system checks itself. The from this acceleration. However, if the vehicle is
brake pedal moves when an active test of the brake parked sideways on a bank or incline, the sensor
booster is run. During this test a small amount of measures some lateral acceleration due to gravity
pressure is generated at the master cylinder, but no even though the vehicle is not moving.
pressure is generated in the brake calipers.
The longitudinal accelerometer measures the
acceleration corresponding to the force involved
when the vehicle moves forward and rearward in
the horizontal plane, along the centerline of the
vehicle’s front and rear wheels.
The yaw rate sensor measures the relative vehicle
motion about the vertical axis through its center of
gravity.
2005 Aviator, 09/2004
The roll rate sensor measures the rate of the A solenoid within the active brake booster has a
rotational motion along the front to rear axis. release switch to indicate when the driver is
stepping on the brake pedal. The solenoid provides
Steering Wheel Rotation Sensor electrical actuation of the brake booster. Without the
The steering wheel rotation sensor measures the rate force of the input rod, the air valve is directly
of rotation of the steering wheel by monitoring the opened due to the movement of the energized
steering wheel rotation ring as it passes through the solenoid. With increasing current applied to the
sensor gap. The steering wheel rotation sensor uses solenoid, the air valve opens and output force is
2 signal lines to transmit information to the created. With decreasing current applied to the
stability assist module about whether the steering solenoid, the air valve is closed and the vacuum
wheel is being turned left or right and how far it is valve opens, reducing output force. The release
being turned. The steering wheel rotation sensor switch indicates when the brake pedal has been
does not indicate the position of the steering wheel applied. It is integrated into the booster key that
relative to straight-ahead. The stability assist normally sits against the rear shell of the boot in its
system learns this position by comparing the rest position, and it adjoins the valve body when in
steering wheel position with other signals and stores its balance position. The switch itself provides
the position it has learned. The stability assist indication from 2 positions. In its rest position it
system confirms this position and modifies it as supplies 2 signals, normally open and normally
necessary during every new driving cycle. closed. Upon application of sufficient force to
initiate movement of the key away from the valve
Active Brake Booster body, the brake booster switch changes state,
The active brake booster functions like a signifying a driver application.
conventional brake booster with the added feature When the stability assist module is activating the
that it can be actuated electrically by the stability brake booster, the brake pedal is pulled forward as
assist module. The electrical brake booster actuation the valve body moves. The release switch is held in
is necessary in severe stability assist events and position by the input rod spring and remains against
ensures that the HCU can generate enough brake the valve body. Although the stoplamp switch
pressure to maintain vehicle stability. The brake changes state when the brake pedal drops, the
assist from the brake booster is especially useful in release switch remains inactive until it encounters
cold weather when the HCU cannot draw the brake an external force from the driver or a stability assist
fluid from the reservoir quickly at cold event controlled by the stability assist module.
temperatures.
The brake pedal force switch sends a brake
application input to the stability assist module. This
signal is called driver brake application. This signal
only changes state when the driver has applied the
brake. If the ignition switch is in the RUN
position, the brake booster is not electrically
actuated, and no failure has been detected, the
driver brake application signal indicates a brake
application when either the BPP switch or the
release switch (built into the brake booster)
indicates that the driver has applied the brake pedal.
If the ignition switch is in the OFF position, the
driver brake application signal indicates a brake
apply only when the BPP switch indicates that the
driver is applying the brake pedal.
2005 Aviator, 09/2004

When the ignition switch is in the OFF position, When carrying out the lateral or longitudinal
failures cannot be detected. If there are failures, accelerometer yaw or roll rate calibration using the
several layers of redundancy attempt to keep the diagnostic tool, the vehicle must be on a level
driver brake application signal accurate. Control of surface, must not be moving, and the ignition switch
the stoplamp operation is also required because the must be in the RUN position. When carrying out
BPP switch can change states during a stability the steering wheel rotation sensor calibration on the
assist event when the driver is not applying the diagnostic tool, the ignition switch must be in the
brake pedal. The switch can also change states RUN position with the engine running and the
during the system check of the brake booster. Only steering wheel must be rotated back and forth from
the stability assist system can interpret these lock position to lock position.
changed states and determine which are actually due
to driver brake application. Similarly, the stability Inspection and Verification
assist system can take advantage of its other sensors NOTE: If a new anti-lock brake system (ABS)
to detect BPP switch failures. module is installed, it must be configured. If
equipped with stability assist, the ABS module must
ABS Module Calibration also be calibrated. Follow the diagnostic tool
If a new ABS module is installed, it must be directions.
configured. The ABS module also needs to be 1. Verify the customer concern.
calibrate whenever a component specific to the
stability assist system is disconnected or a new 2. Verify the stoplamps operate correctly by
component is installed. For additional information pressing and releasing the brake pedal with the
regarding the DTCs that require the calibration ignition switch in the OFF position. If the
procedure, refer to the ABS Calibration List in this stoplamps do not operate correctly, refer to
section. If a DTC is logged for any component of Section 417-01. If the stoplamps operate
the stability assist system, the DTC must be cleared correctly, proceed to the next step.
before carrying out the calibration procedure. The 3. Verify that the PRNDL operates correctly on
need to calibrate the ABS module is also indicated the instrument cluster. If the PRNDL does not
by the active/fail lamp flashing. The lamp will flash operate correctly, refer to Section 307-01. If the
after clearing the DTCs that are indicated on the PRNDL operates correctly, proceed to the next
ABS Calibration List. If a DTC is retrieved after step.
calibration, refer to the Anti-Lock Brake System 4. Visually inspect for obvious signs of
(ABS) Module Diagnostic Trouble Code (DTC) mechanical or electrical damage.
Index. If installing a new stability assist module, the
calibration procedures, as well as the configuration
procedure, must be carried out. For additional
information regarding the module configuration and
calibration, follow the diagnostic tool directions for
the calibration procedure.
2005 Aviator, 09/2004

Visual Inspection Chart 6. If the diagnostic tool still does not communicate
Mechanical Electrical with the vehicle, refer to the diagnostic tool
operating manual.
• Wheel speed sensor ring • Battery junction box
• Hydraulic control unit (BJB) fuse(s): NOTE: The vehicle must be at a complete standstill
(HCU) — 5 (40A) (HCU when carrying out the self-test. Any movement of
• Base brake system pump) the vehicle during the self-test may result in false
• Brake booster vacuum — 10 (30A) (HCU
hose valves) DTCs being set.
• Ford specified steering • Central junction box 7. Carry out the diagnostic tool data link test. If
components, suspension (CJB) fuse(s): the diagnostic tool responds with:
components, and tire — 21 (10A) (traction
size control switch) • SCP, ISO, or UBP circuit fault; all
— 22 (10A) (ABS electronic control units no response/not
module) equipped, refer to Section 418-00.
• ABS module
• Brake pedal position • No response/not equipped for the ABS
(BPP) switch module, GO to Pinpoint Test A.
• Steering wheel rotation • System passed, retrieve and record the
sensor
• Brake booster solenoid continuous diagnostic trouble codes (DTCs),
• Brake booster release erase the continuous DTCs, and carry out
switch self-test diagnostics for the ABS module.
• Brake pressure
transducer 8. If the DTCs retrieved are related to the concern,
• Brake pedal travel go to the Anti-Lock Brake System (ABS)
sensor Module Diagnostic Trouble Code (DTC) Index.
• Sensor cluster (also 9. If no DTCs related to the concern are retrieved,
called accelerometer)
• Brake pedal relay GO to Symptom Chart.
• Brake fluid level switch NOTE: The need to calibrate the module is
• Circuitry indicated by the active/fail lamp flashing. There are
• Traction control switch
• Steering wheel rotation other service actions that can require calibration
sensor when there is no flashing lamp. The lamp flashes
• Wheel speed sensor after clearing the DTCs that are indicated in the
ABS module calibration list.
5. If the cause is not visually evident, connect the NOTE: Always retrieve the continuous DTCs after
diagnostic tool to the data link connector (DLC) running the self-test.
and select the vehicle to be tested from the NOTE: For a complete master list of DTCs, refer
diagnostic tool menu. If the diagnostic tool does to Section 419-10.
not communicate with the vehicle: NOTE: If DTCs B2900, C1805, and U1900 are set
• check that the program card is correctly at the time, diagnose the concern for U1900 first.
installed. NOTE: DTC C1730 (Reference Voltage Out Of
• check the connections to the vehicle. Range) must be repaired before DTCs C1279,
• check the ignition switch position. C1280, C1281, C1282, C1288, or C1289.
2005 Aviator, 09/2004

Anti-Lock Brake System (ABS) Module Diagnostic Trouble Code (DTC) Index
B1342 ECU is Defective ABS Module NOTE: If other DTCs are present,
REPAIR them before installing a new
component.
CLEAR the DTCs. RETRIEVE the
DTCs. If DTC B1342 is retrieved,
INSTALL a new module. REFER to
Anti-Lock Brake System (ABS) Module
in this section. REPEAT the self-test.
B1483 Brake Pedal Input Circuit Failure ABS Module GO to Pinpoint Test B.
B1676 Battery Pack Voltage Out of Range ABS Module GO to Pinpoint Test C.
B2477 Module Configuration Failure ABS Module FOLLOW the diagnostic tool directions
for the configuration procedure.
B2734 Pedal Travel Sensor (PTS) Supply Error ABS Module GO to Pinpoint Test N.
B2736 Pedal Travel Sensor (PTS) Circuit Fault ABS Module GO to Pinpoint Test N.
B2737 Pedal Travel Sensor (PTS) Jammed Error ABS Module GO to Pinpoint Test N.
B2738 Pedal Travel Sensor (PTS) Velocity Error ABS Module GO to Pinpoint Test N.
B2740 Pedal Travel Sensor (PTS) Spike Error ABS Module GO to Pinpoint Test N.
B2741 Sensor Cluster Loop End ABS Module FOLLOW the diagnostic tool directions
for the calibration procedure.
B2900 VIN Mismatched ABS Module VERIFY that the module has the correct
as-built data.
CHECK for correct PCM and ABS
module configurations using the
diagnostic tool. CONFIGURE the
component as necessary. FOLLOW the
diagnostic tool directions for the ABS
module configuration or REFER to
Section 303-14 for the PCM. CLEAR the
DTC. REPEAT the self-test.
C1095 ABS Hydraulic Pump Motor Circuit ABS Module GO to Pinpoint Test D.
Failure
C1145 Wheel Speed Sensor RF Input Circuit ABS Module GO to Pinpoint Test E.
Failure
C1155 Wheel Speed Sensor LF Input Circuit ABS Module GO to Pinpoint Test E.
Failure
C1165 Wheel Speed Sensor RR Input Circuit ABS Module GO to Pinpoint Test E.
Failure
C1175 Wheel Speed Sensor LR Input Circuit ABS Module GO to Pinpoint Test E.
Failure
C1233 Wheel Speed LF Input Signal Missing ABS Module GO to Pinpoint Test F.
C1234 Wheel Speed RF Input Signal Missing ABS Module GO to Pinpoint Test F.
C1235 Wheel Speed RR Input Signal Missing ABS Module GO to Pinpoint Test F.
C1236 Wheel Speed LR Input Signal Missing ABS Module GO to Pinpoint Test F.
C1277 Steering Wheel Angle 1 and 2 Circuit ABS Module GO to Pinpoint Test G.
Failure
C1278 Steering Wheel Angle 1 and 2 Signal ABS Module GO to Pinpoint Test G.
Faulted
2005 Aviator, 09/2004

Anti-Lock Brake System (ABS) Module Diagnostic Trouble Code (DTC) Index (Continued)
C1279 Yaw Rate Sensor Circuit Failure ABS Module GO to Pinpoint Test H.
C1280 Yaw Rate Sensor Signal Fault ABS Module GO to Pinpoint Test H.
C1281 Lateral Accelerometer Circuit Failure ABS Module GO to Pinpoint Test H.
C1282 Lateral Accelerometer Signal Fault ABS Module GO to Pinpoint Test H.
C1285 Booster Solenoid Circuit Failure ABS Module GO to Pinpoint Test I.
C1287 Booster Pedal Force Switch Circuit ABS Module GO to Pinpoint Test J.
Failure
C1288 Brake Pressure Transducer Input Circuit ABS Module GO to Pinpoint Test K.
Failure
C1440 Pressure Transducer Input Circuit Failure ABS Module GO to Pinpoint Test K.
C1516 Roll Rate Signal Fault ABS Module GO to Pinpoint Test H.
C1517 Roll Rate Sensor Circuit Fault ABS Module GO to Pinpoint Test H.
C1730 Reference Voltage Out of Range (+5 V) ABS Module GO to Pinpoint Test L.
C1805 Mismatched PCM and/or ABS/TC ABS Module CHECK for correct PCM and ABS
Module module configurations using the
diagnostic tool. RECONFIGURE the
component as necessary. FOLLOW the
diagnostic tool directions for the ABS
module configuration or REFER to
Section 303-14 for the PCM. CLEAR the
DTC. REPEAT the self-test.
C1960 Driver Brake Apply Circuit Fault ABS Module GO to Pinpoint Test M.
C1963 Stability Control Inhibit Warning ABS Module This DTC is for information only.
CLEAR the DTC. REPEAT the self-test.
C1991 Module Calibration Failure ABS Module Follow the diagnostic tool directions for
the calibration procedure.
C1996 Active Yaw Control Disabled ABS Module This DTC sets if the stability assist
system is activated for 15 seconds of
continuous operation. CHECK for any
major chassis modifications, gross
suspension misalignment, or other items
that can alter the vehicle tracking
dynamics. CLEAR the DTC. REPEAT
the self-test.
C1998 Module Calibration Not Complete ABS Module GO to Pinpoint Test P.
C2769 Longitudinal Acceleration Sensor Circuit ABS Module GO to Pinpoint Test H.
Failure
C2770 Longitudinal Acceleration Sensor Signal ABS Module GO to Pinpoint Test H.
Fault
C2777 Sensor Cluster Bus Failure ABS Module GO to Pinpoint Test H.
C2778 Sensor Cluster Voltage Supply Failure ABS Module GO to Pinpoint Test H.
U1900 CAN Communication Bus Fault-Receive Network GO to Pinpoint Test H.
Error Fault
U1901 CAN Network #2 Communication Bus Network GO to Pinpoint Test H.
Fault-Receive Error Fault
U2023 Fault received from external node Network GO to Pinpoint Test H.
Fault
2005 Aviator, 09/2004

Anti-Lock Brake System (ABS) Calibration List

NOTE: The need to calibrate the ABS module is indicated by the stability assist active/fail lamp
flashing. The lamp flashes after the DTCs on the calibration list are cleared.
DTC Description Calibration
C1277 Steering Wheel Angle 1 and 2 Circuit Failure YES
C1278 Steering Wheel Angle 1 and 2 Signal Fault YES
C1279 Yaw Rate Sensor Circuit Failure YES
C1280 Yaw Rate Sensor Signal Fault YES
C1281 Lateral Accelerometer Circuit Failure YES
C1282 Lateral Accelerometer Signal Fault YES
C1285 Booster Solenoid Circuit Failure YES
C1287 Booster Pedal Force Switch Circuit Failure YES
C1288 Brake Pressure Transducer Input Circuit Failure YES
C1440 Pressure Transducer Input Signal Failure YES
C1516 Roll Rate Signal Fault YES
C1517 Roll Rate Sensor Circuit Fault YES
C1730 Reference Voltage Out of Range (+5 V) YES
C1960 Driver Brake Apply Circuit Failure NO
C1963 Stability Control Inhibit Warning NO
C1991 Module Calibration Failure YES
C1996 Active Yaw Control Disabled YES
C1998 Module Calibration Not Complete NO
C2769 Longitudinal Acceleration Sensor Circuit Failure YES
C2770 Longitudinal Acceleration Sensor Signal Fault YES
C2777 Sensor Cluster Bus Failure YES
C2778 Sensor Cluster Voltage Supply Failure YES
Symptom Chart
Symptom Chart
• No communication with the • Circuitry • GO to Pinpoint Test A.
anti-lock brake system (ABS) • ABS module
module
• The red brake warning • Circuitry • REFER to Section 413-01.
indicator stays on when the • Instrument cluster
ignition switch is in RUN • Brake fluid level sensor
• Anti-lock brake system (ABS)
module
• The yellow anti-lock brake • Circuitry • REFER to Section 413-01.
system (ABS) warning • Instrument cluster
indicator does not self-check • ABS module
• Spongy brake pedal with no • Air in brake hydraulic system • REFER to Section 206-00.
warning indicator
2005 Aviator, 09/2004

• The stability assist system • Circuitry • GO to Pinpoint Test O.
cannot be disabled • Traction control switch
module
• The traction control switch • Circuitry • GO to Pinpoint Test Q.
indicator is never/always on • Traction control switch
module
Connector Circuit Reference
Primary Brake Pressure Transducer C147

1 3603 (RD) brake pressure transducer ground 0 volts, less than 5 ohms between the
primary brake pressure transducer and the
anti-lock brake system (ABS) module.
2 3600 (RD/WH) brake pressure transducer 0 volts, less than 5 ohms between the
signal primary brake pressure transducer and the
ABS module. Greater than 10,000 ohms
between the primary brake pressure
transducer and ground.
3 3601 (WH/RD) brake pressure transducer Approximately 5 volts with the ignition
voltage switch in the ON position. Less than 5 ohms
between the primary brake pressure
transducer and the ABS module. Greater than
10,000 ohms between the primary brake
pressure transducer and ground.
2005 Aviator, 09/2004

Brake Pedal Travel Sensor C148

1 3010 (TN) brake pedal travel sensor voltage Approximately 5 volts with the ignition
switch in the ON position. Less than 5 ohms
between the brake pedal travel sensor and the
ABS module. Greater than 10,000 ohms
between the brake pedal travel sensor and
ground.
2 3011 (BK/OG) brake pedal travel sensor 0 volts, less than 5 ohms between the brake
signal pedal travel sensor and the ABS module.
Greater than 10,000 ohms between the brake
pedal travel sensor and ground.
3 3012 (WH) brake pedal travel sensor ground 0 volts, less than 5 ohms between the brake
pedal travel sensor and the ABS module.
Active Brake Booster C149

1 1581 (PK/LB) brake pedal force switch 0 volts, less than 5 ohms between the active
normally open (NO) brake booster and the ABS module. Greater
than 10,000 ohms between the active brake
booster and ground.
2 1580 (WH/LG) brake pedal force switch 0 volts, less than 5 ohms between the active
normally closed (NC) brake booster and the ABS module. Greater
than 10,000 ohms between the active brake
booster and ground.
3 1583 (BN/WH) active brake booster voltage Approximately 5 volts (PWM) with the
ignition switch in the ON position, less than
5 ohms between the active brake booster and
the ABS module. Greater than 10,000 ohms
between the active brake booster and ground.
2005 Aviator, 09/2004

4 1582 (LG/RD) active brake booster PWM 0 volts, greater than 10 volts with the
voltage ignition switch in the ON position. Less than
5 1579 (OG/RD) brake pedal force switch 0 volts, greater than 10 volts with the
signal ignition switch in the ON position. Less than
LH Front Wheel Speed Sensor C150, RH Front Wheel Speed Sensor C160

1 (C150) 521 (TN/OG) LH front wheel speed (-) 0 volts, less than 5 ohms between the wheel
speed sensor and the ABS module.
2 (C150) 522 (TN/BK) LH front wheel speed (+) Greater than 10 volts with the ignition switch
in the ON position Less than 5 ohms
between the wheel speed sensor and the ABS
module. Greater than 10,000 ohms between
the wheel speed sensor and ground.
1 (C160) 514 (YE/RD) RH front wheel speed (-) 0 volts, less than 5 ohms between the wheel
2 (C160) 516 (YE/BK) RH front wheel speed (+) Greater than 10 volts with the ignition switch
2005 Aviator, 09/2004

LH Rear Wheel Speed Sensor C440, RH Rear Wheel Speed Sensor C426

1 (C440) 518 (LG/RD) LH rear wheel speed (+) Greater than 10 volts with the ignition switch
2 (C440) 519 (LG/BK) LH rear wheel speed (-) 0 volts, less than 5 ohms between the wheel
1 (C426) 523 (RD/PK) RH rear wheel speed (+) Greater than 10 volts with the ignition switch
2 (C426) 524 (PK/BK) RH rear wheel speed (-) 0 volts, less than 5 ohms between the wheel
Anti-Lock Brake System (ABS) C155

1 534 (YE/LG) hydraulic control unit (HCU) B+ voltage at all times.
pump voltage
3 1572 (DG) steering wheel rotation sensor 0 volts. Greater than 10,000 ohms between
angle 1 the ABS module and ground. Less than 5
ohms between the ABS module and the
steering wheel rotation sensor.
4 601 (LB/PK) ignition voltage Greater than 10 volts with the ignition switch
in the ON position.
2005 Aviator, 09/2004

5 1577 (RD/LB) steering wheel rotation sensor 0 volts. Greater than 10,000 ohms between
ground the ABS module and ground. Less than 5
steering wheel rotation sensor, and less than
5 ohms between the ABS module yaw rate
sensor.
6 1573 (YE) steering wheel rotation sensor 0 volts. Greater than 10,000 ohms between
angle 2 the ABS module and ground. Less than 5
7 1576 (TN/BK) steering wheel rotation 0 volts. Greater than 10,000 ohms between
sensor/accelerometer/yaw rate sensor voltage the ABS module and ground. Less than 5
13 960 (BK/LB) stability assist OFF indicator Greater than 10 volts with the ignition switch
in the ON position. Less than 5 ohms
between the ABS module and the traction
control switch.
16 274 (BK/WH) ABS module ground 0 volts, less than 5 ohms between the ABS
module and ground.
17 1582 (LG/RD) active brake booster voltage 0 volts, less than 5 ohms between the ABS
module and the active brake booster. Greater
than 10,000 ohms between the ABS module
and ground.
18 3601 (WH/RD) brake pressure transducer 0 volts, less than 5 ohms between the ABS
voltage module and the brake pressure transducer.
Greater than 10,000 ohms between the ABS
module and ground.
19 3603 (RD) brake pressure transducer ground 0 volts, less than 5 ohms between the ABS
module and the brake pressure transducer.
module and ground.
20 3600 (RD/WH) brake pressure transducer 0 volts, less than 5 ohms between the ABS
signal module and the brake pressure transducer.
module and ground.
24 3011 (BK/OG) brake pedal travel sensor 0 volts, less than 5 ohms between the ABS
ground module and the brake pedal travel sensor.
module and ground.
25 1879 (PK/BK) sensor cluster CAN Bus (-) 0 volts, less than 5 ohms between the ABS
module and the sensor cluster. Greater than
10,000 ohms between the ABS module and
ground.
26 3010 (TN) brake pedal travel sensor voltage 0 volts, less than 5 ohms between the ABS
module and the brake pedal travel sensor.
module and ground.
27 1581 (PK/LB) brake pedal force switch 0 volts, less than 5 ohms between the ABS
normally open (NO) module and the active brake booster. Greater
and ground.
2005 Aviator, 09/2004

28 1579 (OG/RD) brake pedal force switch 0 volts, less than 5 ohms between the ABS
signal module and the active brake booster. Greater
and ground.
29 1878 (WH/BK) sensor cluster CAN Bus (+) 0 volts, less than 5 ohms between the ABS
module and the sensor cluster. Greater than
10,000 ohms between the ABS module and
ground.
30 1580 (WH/LG) brake pedal force switch 0 volts, less than 5 ohms between the ABS
normally closed (NC) module and the active brake booster. Greater
and ground.
31 1583 (BN/WH) active brake booster voltage 0 volts, less than 5 ohms between the ABS
module and the active brake booster. Greater
and ground.
32 493 (BK/PK) HCU valve voltage Greater than 10 volts with the ignition switch
in any position.
33 514 (YE/RD) RF active wheel speed sensor
CAUTION:
voltage No measurements should be taken with
the wheel speed sensor connected. Damage
to the wheel speed sensor will result.
0 volts, less than 5 ohms between the ABS
module and the wheel speed sensor. Greater
and ground.
34 516 (YE/BK) RF active wheel speed sensor
CAUTION:
ground No measurements should be taken with
and ground.
36 518 (LG/RD) LH rear (or axle) active wheel
CAUTION:
speed sensor voltage No measurements should be taken with
and ground.
37 519 (LG/BK) LH rear (or axle) active wheel
CAUTION:
speed sensor ground No measurements should be taken with
and ground.
2005 Aviator, 09/2004

38 959 (GY) traction control switch input Greater than 10 volts with traction control
switch pressed. Less than 5 ohms between
the ABS module and the traction control
switch.
41 511 (LG) stoplamp switch input 0 volts with the brake pedal released, greater
than 10 volts with the brake pedal pressed.
42 524 (PK/BK) RH rear active wheel speed
CAUTION:
sensor ground No measurements should be taken with
and ground.
43 523 (RD/PK) RH rear active wheel speed
CAUTION:
sensor voltage No measurements should be taken with
and ground.
44 810 (RD/LG) driver brake apply signal (to 0 volts, less than 5 ohms between the ABS
trailer tow relay) module and the PCM.
45 522 (TN/BK) RH rear active wheel speed
CAUTION:
sensor ground No measurements should be taken with
and ground.
46 521 (TN/OG) LH front active wheel speed
CAUTION:
sensor voltage No measurements should be taken with
and ground.
47 530 (LG/YE) ABS module ground 0 volts, less than 5 ohms between the ABS
module and ground.
2005 Aviator, 09/2004

Steering Wheel Rotation Sensor C226

1 1003 (GY/YE) steering wheel rotation sensor Greater than 10 volts with ignition switch in
voltage the START or RUN position. Less than 5
ohms between the steering wheel rotation
sensor and the ABS module. Greater than
10,000 ohms between the steering wheel
rotation sensor and ground.
2 1573 (YE) steering wheel rotation sensor 0 volts, less than 5 ohms between the
angle 2 steering wheel rotation sensor and the ABS
the steering wheel rotation sensor and
ground.
3 1572 (DG) steering wheel rotation sensor 0 volts, less than 5 ohms between the
angle 1 steering wheel rotation sensor and the ABS
the steering wheel rotation sensor and
ground.
4 1571 (BK) steering wheel rotation sensor 0 volts, less than 5 ohms between the
return steering wheel rotation sensor and the ABS
module.
2005 Aviator, 09/2004

Traction Control Switch C280

1 959 (GY) stability assist signal 0 volts, less than 5 ohms between the
traction control switch and the ABS module.
Greater than 10,000 ohms between the
traction control switch and ground.
5 1003 (GY/YE) traction control switch voltage 0 volts with the ignition switch in the OFF
position, greater than 10 volts with the
ignition switch in the ON position.
6 960 (BK/LB) stability assist OFF indicator 0 volts, less than 5 ohms between the
traction control switch and the ABS module.
Greater than 10,000 ohms between the
traction control switch and ground.
Sensor Cluster C3179 (2WD)

1 3125 (RD/YE) sensor cluster CAN Bus (-) 0 volts, less than 5 ohms between the sensor
cluster and the ABS module. Greater than
10,000 ohms between the sensor cluster and
ground.
2 3126 (TN/YE) sensor cluster CAN Bus (+) 0 volts, less than 5 ohms between the sensor
cluster and the ABS module. Greater than
10,000 ohms between the sensor cluster and
ground.
3 1574 (DB) sensor cluster voltage 0 volts, greater than 10 volts with ignition
switch in the ON position. Less than 5 ohms
between the sensor cluster and the ABS
the sensor cluster and ground.
5 1575 (BK/WH) sensor cluster return 0 volts, less than 5 ohms between the sensor
cluster and the ABS module.
2005 Aviator, 09/2004

Sensor Cluster C3179 (4WD)

1 1815 (PK/LB) accelerometer/yaw rate sensor CAN communication low current.
CAN Bus (-)
2 1814 (WH/LB) accelerometer/yaw rate sensor CAN communication high current.
CAN Bus (+)
3 1576 (TN/BK) steering wheel 0 volts with the key in the OFF position.
sensor/accelerometer/yaw rate sensor voltage Greater than 10 volts with the key in the
START or ON positions.
5 1575 (BK/WH) steering wheel 0 volts, less than 5 ohms between the sensor
sensor/accelerometer/yaw rate sensor ground cluster and the brake system module.
Pinpoint Test A: No Communication With the Voltage is supplied by circuit 601 (LB/PK) (ignition
Anti-lock Brake System (ABS) Module feed) and circuit 493 (BK/PK) (voltage hot at all
times). Ground is provided through circuit 274
Normal Operation
(BK/WH).
The operating voltage required to supply the ABS
Possible Causes
module, hydraulic pump, and isolation valves is in a
range between 10 and 17 volts. • circuit 274 (BK/WH) open
• circuit 493 (BK/PK) open
• circuit 601 (LB/PK) open
PINPOINT TEST A: NO COMMUNICATION WITH THE ANTI-LOCK BRAKE SYSTEM (ABS) MODULE
CAUTION: Use the flex probe kit for all test connections to prevent damage to the
wiring terminals. Do not use standard multimeter probes.
A1 CHECK CIRCUITS 601 (LB/PK) AND 493 (BK/PK) FOR AN OPEN
• Disconnect: ABS Module C155.
• Key in ON position.
(Continued)
2005 Aviator, 09/2004

PINPOINT TEST A: NO COMMUNICATION WITH THE ANTI-LOCK BRAKE SYSTEM (ABS) MODULE
(Continued)
A1 CHECK CIRCUITS 601 (LB/PK) AND 493 (BK/PK) FOR AN OPEN
(Continued)
• Measure the voltage between the ABS module C155-4, circuit
601 (LB/PK), harness side and ground; and between the ABS
module C155-32, circuit 493 (BK/PK), harness side and ground.
Yes
GO to A2.
No
REPAIR the circuit(s) in question.
• Are the voltages greater than 10 volts? REPEAT the self-test.
A2 CHECK CIRCUIT 274 (BK/WH) FOR AN OPEN
• Measure the resistance between the ABS module C155-16,
circuit 274 (BK/WH), harness side and ground.
Yes
CHECK the module communications
network. REFER to Section 418-00.
No
• Is the resistance less than 5 ohms? REPAIR the circuit. REPEAT the self-test.
Pinpoint Test B: DTC B1483 — Brake Pedal Possible Causes

Input Circuit Failure • circuit 511 (LG) open
Normal Operation • ABS module
When the brake pedal is pressed, the stoplamp
switch routes voltage to circuit 511 (LG) to the
anti-lock brake system (ABS) module.
2005 Aviator, 09/2004

PINPOINT TEST B: DTC B1483 — BRAKE PEDAL INPUT SIGNAL FAILURE
B1 CHECK THE STOPLAMP OPERATION
• Key in OFF position. Yes
• Observe the stoplamps while pressing and releasing the brake GO to B2.
pedal. No
• Do the stoplamps operate correctly? REFER to Section 417-01 to diagnose the
stoplamps. Clear the DTCs. REPEAT the
self-test.
B2 CHECK CIRCUIT 511 (LG) FOR AN OPEN
• Disconnect: Anti-lock Brake System (ABS) Module C155.
511 (LG), harness side and ground while pressing the brake
pedal.
Yes
GO to B3
No
• Is the voltage greater than 10 volts? REPEAT the self-test.
B3 CHECK FOR CORRECT ABS MODULE OPERATION
• Disconnect all the ABS connectors. Yes
• Check for: INSTALL a new ABS module. REFER to
• corrosion Anti-Lock Brake System (ABS) Module in
• pushed-out pins this section. TEST the system for normal
• Connect all the ABS connectors and make sure they seat operation.
correctly. No
the DTCs. REPEAT the self-test.
Pinpoint Test C: DTC B1676 — Battery Pack Possible Causes

Voltage Out Of Range • charging system
Normal Operation • circuit 274 (BK/WH) open
The vehicle electrical system supplies 12 volts to • circuit 493 (BK/PK) open
the anti-lock brake system (ABS) module. • ABS module
Voltage is supplied by circuit 493 (BK/PK) (voltage
hot at all times). Ground is provided through circuit
274 (BK/WH).
2005 Aviator, 09/2004

PINPOINT TEST C: DTC B1676 — BATTERY PACK VOLTAGE OUT OF RANGE
C1 CHECK THE BATTERY VOLTAGE
• Measure the battery voltage between the positive and negative Yes
battery posts with the key ON engine OFF (KOEO), and with the GO to C2.
engine running. No
• Is the battery voltage between 10 and 13 volts with KOEO, CHECK the charging system. REFER to
and between 11 and 17 volts with the engine running? Section 414-00. TEST the system for
normal operation.
C2 CHECK CIRCUIT 493 (BK/PK) FOR AN OPEN
493 (BK/PK), harness side and ground.
Yes
GO to C3.
No
C3 CHECK CIRCUIT 274 (BK/WH) FOR AN OPEN
circuit 274 (BK/WH), harness side and ground.
Yes
GO to C4.
No
• Is the resistance less than 5 ohms? REPEAT the self-test.
C4 CHECK FOR CORRECT ABS MODULE OPERATION
correctly. No
2005 Aviator, 09/2004

Pinpoint Test D: DTC C1095 —Anti-lock Possible Causes
Brake System (ABS) Hydraulic Pump Motor • circuit 530 (LG/YE) open
Circuit Failure
• circuit 534 (YE/LG) open
Normal Operation • hydraulic pump motor
The operating voltage required to run the hydraulic • ABS module
pump motor is in a range between 10 and 17 volts.
Voltage is supplied by circuit 534 (YE/LG) (voltage
hot at all times). Ground is provided through circuit
530 (LG/YE).
PINPOINT TEST D: DTC C1095 — ANTI-LOCK BRAKE SYSTEM (ABS) HYDRAULIC PUMP MOTOR
CIRCUIT FAILURE
D1 CHECK THE ABS PUMP MOTOR
• Key in ON position. Yes
• Is the ABS pump motor running all the time? GO to D5.
No
GO to D2.
D2 CHECK THE PUMP MOTOR OPERATION
• Connect the diagnostic tool. CLEAR the DTCs. CHECK the yellow ABS
• Key in ON position. warning indicator while driving the vehicle
• Enter the following diagnostic mode on the diagnostic tool: (brakes must not be applied) above 20
Active Command. km/h (12 mph). If the yellow ABS warning
• Trigger the ABS module pump motor ON active command. indicator illuminates, RETRIEVE the
• Does the ABS pump motor run for approximately 2 DTCs. If DTC C1095 is retrieved, GO to
seconds? D5.
No
TRIGGER the ABS module pump motor
OFF active command. GO to D3.
D3 CHECK CIRCUIT 534 (YE/LG) FOR AN OPEN
534 (YE/LG), harness side and ground.
Yes
GO to D4.
No
D4 CHECK CIRCUIT 530 (LG/YE) FOR AN OPEN
(Continued)
2005 Aviator, 09/2004

PINPOINT TEST D: DTC C1095 — ANTI-LOCK BRAKE SYSTEM (ABS) HYDRAULIC PUMP MOTOR
CIRCUIT FAILURE (Continued)
D4 CHECK CIRCUIT 530 (LG/YE) FOR AN OPEN (Continued)
circuit 530 (LG/YE), harness side and ground.
Yes
INSTALL a new hydraulic control unit
(HCU). REFER to Hydraulic Control Unit
(HCU) in this section. CLEAR the DTCs.
No
• Is the resistance less than 5 ohms? REPEAT the self-test.
D5 CHECK FOR CORRECT ABS MODULE OPERATION
correctly. No
Pinpoint Test E: DTC C1145, DTC C1155, • circuit 516 (YE/BK) open, short to voltage or
DTC C1165, DTC C1175 — Wheel Speed ground
Sensor Input Circuit Failure
• circuit 518 (LG/RD) open, short to voltage or
Normal Operation ground
The active wheel speed sensor generates a signal • circuit 519 (LG/BK) open, short to voltage or
that is sent to the anti-lock brake system (ABS) ground
module. The wheel speed sensor circuitry connects • circuit 521 (TN/OG) open, short to voltage or
to the ABS module connector C155 through 2 wires ground
and a connector at each wheel speed sensor. When
• circuit 522 (TN/BK) open, short to voltage or
the ignition switch is turned to the RUN position,
ground
the ABS module carries out a self-test by sending a
reference voltage through the right front wheel • circuit 523 (RD/PK) open, short to voltage or
speed sensor and its circuitry to determine if they ground
are functional. • circuit 524 (PK/BK) open, short to voltage or
Voltage is supplied to the active wheel speed ground
sensors from the ABS module. The wheel speed • ABS module
sensor ground is supplied by the ABS module.
Possible Causes
• wheel speed sensor
• circuit 514 (YE/RD) open, short to voltage or
ground
2005 Aviator, 09/2004

PINPOINT TEST E: DTC C1145, DTC C1155, DTC C1165, DTC C1175 — WHEEL SPEED SENSOR INPUT
CIRCUIT FAILURE
NOTE: DTCs C1165 and C1175 set if there is a rear wheel speed sensor input circuit failure;
DTC C1165 can be disregarded.
E1 CHECK THE WHEEL SPEED CIRCUITS FOR A SHORT TO
VOLTAGE
CAUTION: No measurements should be taken with the

wheel speed sensor connected. Damage to the wheel speed
sensor will result.
NOTE: Both circuits must be checked for each DTC.
• Disconnect: Suspect Wheel Speed Sensor.
• Measure the voltage between the ABS module connector,
harness side and ground as follows:
ABS Module
DTC Connector-Pin Circuit
C1145 C155-33 514 (YE/RD)
C1145 C155-34 516 (YE/BK)
C1155 C155-45 522 (TN/BK)
C1155 C155-46 521 (TN/OG)
C1165 C155-42 524 (PK/BK)
C1165 C155-43 523 (RD/PK)
C1175 C155-36 518 (LG/RD)
C1175 C155-37 519 (LG/BK)
Yes
REPAIR the circuit(s) in question. CLEAR
No
• Is any voltage present? GO to E2.
GROUND
• Measure the resistance between the ABS module connector,
(Continued)
2005 Aviator, 09/2004

GROUND (Continued)
ABS Module
DTC Connector-Pin Circuit
C1145 C155-33 514 (YE/RD)
C1145 C155-34 516 (YE/BK)
C1155 C155-45 522 (TN/BK)
C1155 C155-46 521 (TN/OG)
C1165 C155-42 524 (PK/BK)
C1165 C155-43 523 (RD/PK)
C1175 C155-36 518 (LG/RD)
C1175 C155-37 519 (LG/BK)
Yes
GO to E3.
No
• Are the resistances greater than 10,000 ohms? the DTCs. REPEAT the self-test.
E3 CHECK THE WHEEL SPEED CIRCUITS FOR AN OPEN
harness side and the suspect wheel speed sensor connector,
harness side as follows:
(Continued)
2005 Aviator, 09/2004

E3 CHECK THE WHEEL SPEED CIRCUITS FOR AN OPEN
(Continued)
Wheel Speed
ABS Module Sensor
DTC Circuit Connector-Pin Connector-Pin
C1145 516 (YE/BK) C155-34 RH front wheel
speed sensor
C160-2
C1145 514 (YE/RD) C155-33 RH front wheel
speed sensor
C160-1
C1155 522 (TN/BK) C155-45 LH front wheel
speed sensor
C150-2
C1155 521 (TN/OG) C155-46 LH front wheel
speed sensor
C150-1
C1165 523 (RD/PK) C155-43 RH rear wheel
speed sensor
C426-1
C1165 524 (PK/BK) C155-42 RH rear wheel
speed sensor
C426-2
C1175 518 (LG/RD) C155-36 LH rear wheel
speed sensor
C440-1
C1175 519 (LG/BK) C155-37 LH rear wheel
speed sensor
C440-2
Yes
GO to E4.
No
REPAIR the circuit in question. CLEAR the
• Are the resistances less than 5 ohms? DTCs. REPEAT the self-test.
(Continued)
2005 Aviator, 09/2004

E4 CHECK FOR SHORTED WHEEL SPEED SENSOR CIRCUITS
• Measure the resistance between the suspect wheel speed
sensor pins, harness side.
Yes
GO to E5.
No
• Is the resistance greater than 10,000 ohms? the DTCs. REPEAT the self-test.
E5 CHECK THE ABS MODULE OUTPUT
• Connect: ABS Module C155.
• Measure the voltage between the suspect wheel speed sensor
pins, harness side.
Yes
INSTALL a new wheel speed sensor.
REFER to Wheel Speed Sensor — Front
or Wheel Speed Sensor — Rear in this
section. CLEAR the DTCs. REPEAT the
self-test.
No
• Is the voltage greater than 10 volts? GO to E6.
E6 CHECK FOR CORRECT ABS MODULE OPERATION
correctly. No
2005 Aviator, 09/2004

Pinpoint Test F: DTC C1233, DTC C1234, Possible Causes
DTC C1235, DTC C1236 — Wheel Speed • mismatched tire sizes
Sensor Input Signal Missing
• wheel speed sensor ring
Normal Operation • wheel speed sensor
The wheel speed sensor and sensor ring generate a • ABS module
signal to the anti-lock brake system (ABS) module
that is proportional to the wheel speed. The ABS
module compares the wheel speed inputs from all
wheel speed sensors to determine an impending
wheel lockup.
PINPOINT TEST F: DTC C1233, DTC C1234, DTC C1235, DTC C1236 — WHEEL SPEED SENSOR INPUT
SIGNAL MISSING
NOTE: DTCs C1235 and C1236 set if there is a rear wheel speed sensor input signal missing;
C1235 can be disregarded.
F1 CHECK THE DTCs FROM THE SELF-TEST
• Check the recorded results from the anti-lock brake system Yes
(ABS) self-test. GO to Pinpoint Test E.
• Are DTCs C1145, C1155, C1165, or C1175 present? No
GO to F2.
F2 MONITOR THE WHEEL SPEED PIDS
• Connect the diagnostic tool. Yes
• Key in ON position. CLEAR the DTCs. DRIVE the vehicle.
• Enter the following diagnostic mode on the diagnostic tool: ABS RETRIEVE the DTCs. If DTC C1233,
Module PIDs. C1234, C1235, or C1236 is present, GO
• Use the diagnostic tool to monitor the ABS module wheel speed to F9.
sensor PIDs while driving the vehicle at a constant speed. No
• Are all the wheel speed sensor PID values similar? GO to F3.
F3 INSPECT THE WHEEL SPEED SENSOR MOUNTING
• With the vehicle in NEUTRAL, position it on a hoist. Refer to TIGHTEN the wheel speed sensor to
Section 100-02. specification. CLEAR the DTCs. GO to F4.
• Inspect the wheel speed sensor for looseness. No
• Is the wheel speed sensor loose? GO to F5.
F4 RECHECK THE WHEEL SPEED PIDS
• Connect the diagnostic tool.
• Enter the following diagnostic mode on the diagnostic tool: ABS The vehicle is OK. The concern may have
Module PIDs. been caused by a loose wheel speed
• Use the diagnostic tool to monitor the ABS module wheel speed sensor.
sensor PIDs while driving the vehicle at a constant speed. No
• Are all the wheel speed sensor PID values similar? GO to F5.
F5 CHECK THE WHEEL SPEED SENSOR FOR DAMAGE
• With the vehile in NEUTRAL, positon it on a hoist. Refer to Yes
Section 100-02. GO to F6.
• CAUTION: Examine the wheel speed sensor wire No
carefully with a good light source. Failure to verify damage INSTALL a new wheel speed sensor.
in the wheel speed sensor wire can lead to unnecessary REFER to Wheel Speed Sensor — Front
installation of a new component. or Wheel Speed Sensor — Rear in this
Inspect the wheel speed sensor for general damage. section. CLEAR the DTCs. REPEAT the
• Is the wheel speed sensor OK? self-test.
(Continued)
2005 Aviator, 09/2004

PINPOINT TEST F: DTC C1233, DTC C1234, DTC C1235, DTC C1236 — WHEEL SPEED SENSOR INPUT
SIGNAL MISSING (Continued)
F6 CHECK FOR WHEEL SPEED SENSOR RING DAMAGE
• Inspect the wheel speed sensor ring for damaged or missing Yes
teeth. Rotate the wheel to verify that no teeth are missing. GO to F7.
• Is the wheel speed sensor ring OK? No
INSTALL a new hub and bearing (front
wheel) or rear halfshaft. REFER to Section
204-01A, Section 204-01B or Section
204-02 respectively. CLEAR the DTCs.
F7 CHECK FOR BEARING DAMAGE
• Inspect the wheel bearings for damage. Yes
• Are the wheel bearings OK? GO to F8.
No
INSTALL a new wheel bearing as
necessary. REFER to Section 204-00 .
CLEAR the DTCs. REPEAT the self-test.
F8 CHECK THE ABS MODULE OUTPUT
• Disconnect: Suspect Wheel Speed Sensor.
• Measure the voltage between the suspect wheel speed sensor
pins, harness side.
Yes
INSTALL a new wheel speed sensor.
REFER to Wheel Speed Sensor — Front
or Wheel Speed Sensor — Rear in this
section. CLEAR the DTCs. REPEAT the
self-test.
No
• Is the voltage greater than 10 volts? GO to F9.
F9 CHECK FOR CORRECT ABS MODULE OPERATION
correctly. No
Pinpoint Test G: DTC C1277 and C1278 — Steering wheel rotation (in degrees) is sent to the
Steering Wheel Angle 1 and 2 Circuit anti-lock brake system (ABS) module through
Failure/Faulted circuit 1572 (DG) and circuit 1573 (YE). Voltage is
supplied by the ABS module through circuit 1576
Normal Operation
(TN/BK) which is spliced to circuit 1003 (GY/YE).
The steering position sensor monitors the steering Ground is provided by the ABS module through
wheel position when the toothed wheel on the circuit 1577 (RD/LB).
steering shaft passes through its magnetic field.
2005 Aviator, 09/2004

Possible Causes • circuit 1576 (TN/BK) open or short to ground
• circuit 1003 (GY/YE) open or short to ground • circuit 1577 (RD/LB) open, short to ground, or
• circuit 1572 (DG) open, short to ground, or short short to voltage
to voltage • steering position sensor (part of the clockspring)
• circuit 1573 (YE) open, short to ground, or short
to voltage
PINPOINT TEST G: DTC C1277 AND C1278 — STEERING WHEEL ANGLE 1 AND 2 CIRCUIT
FAILURE/FAULTED
G1 CARRY OUT THE CALIBRATION PROCEDURE
• Enter the following diagnostic mode on the diagnostic tool: Clear If DTC C1277 or C1278 is retrieved or the
the DTCs. calibration procedure indicates a fault, GO
• Carry out the steering position sensor calibration procedure to G2.
following the diagnostic tool directions. If any other DTCs are retrieved, GO to the
• Enter the following diagnostic mode on the diagnostic tool: Anti-Lock Brake System (ABS) Module
Retrieve DTCs. Diagnostic Trouble Code (DTC) Index.
• Are any DTCs retrieved or does the calibration procedure
indicate a fault? If sent here from Pinpoint Test Q, GO to
G2.
No
The ABS system is operating correctly.
G2 MONITOR THE STEERING POSITION SENSOR PIDs
• Make sure the steering wheel is centered straight forward. Yes
• Enter the following diagnostic mode on the diagnostic tool: ABS CLEAR the DTCs. DRIVE the vehicle.
Module PIDs. RETRIEVE the DTCs. If DTC C1277 is
• Monitor the ABS module steering position sensor PID while present, INSTALL a new ABS module.
rotating the steering wheel clockwise and counterclockwise. REFER to Anti-Lock Brake System (ABS)
• Are the 2 PID values similar? Module in this section. CALIBRATE the
ABS module. FOLLOW the diagnostic tool
directions for the calibration procedure.
No
If the value is less than 360, GO to G3.
If the value is greater than 360, REFER to
Section 204-00 for alignment concerns,
Section 204-01A or Section 204-01B for a
suspension concerns, or Section 211-04
for steering column concerns. CLEAR the
G3 CHECK CIRCUIT 1003 (GY/YE) FOR AN OPEN
• Disconnect: Steering Position Sensor C226.
(Continued)
2005 Aviator, 09/2004

FAILURE/FAULTED (Continued)
G3 CHECK CIRCUIT 1003 (GY/YE) FOR AN OPEN (Continued)
• Measure the voltage between the steering position sensor
C226-1, circuit 1003 (GY/YE), harness side and ground.
Yes
GO to G4.
No
CALIBRATE the ABS module. FOLLOW
the diagnostic tool directions for the
calibration procedure. REPEAT the
• Is the voltage greater than 10 volts? self-test.
G4 CHECK THE STEERING POSITION SENSOR CIRCUITRY FOR
AN OPEN
harness side and the steering position sensor connector,
Steering Position
Sensor ABS Module
Connector-Pin Connector-Pin Circuit
C226-2 C155-6 1573 (YE)
C226-3 C155-3 1572 (DG)
C226-4 C155-5 1571 (BK)/1577
(RD/LB)
Yes
GO to G5.
No
the DTCs. CALIBRATE the ABS module.
FOLLOW the diagnostic tool directions for
the calibration procedure. REPEAT the
• Are the resistances less than 5 ohms? self-test.
G5 CHECK THE STEERING POSITION SENSOR CIRCUITS FOR A
SHORT TO VOLTAGE
• Measure the voltage between the ABS module connector,
(Continued)
2005 Aviator, 09/2004

FAILURE/FAULTED (Continued)
G5 CHECK THE STEERING POSITION SENSOR CIRCUITS FOR A
SHORT TO VOLTAGE (Continued)
ABS Module Connector-Pin Circuit

C155-6 1573 (YE)
C155-3 1572 (DG)
C155-5 1577 (RD/LB)
Yes
self-test.
No
• Is any voltage present? GO to G6.
G6 CHECK THE STEERING POSITION SENSOR CIRCUITRY FOR A
SHORT TO GROUND
ABS Module Connector-Pin Circuit

C155-6 1573 (YE)
C155-3 1572 (DG)
C155-5 1577 (RD/LB)
Yes
INSTALL a new clockspring. REFER to
Section 501-20B. CLEAR the DTCs.
No
DTCs. CALIBRATE the ABS module.
• Are the resistances greater than 10,000 ohms? self-test.
2005 Aviator, 09/2004

Pinpoint Test H: DTC C1279, C1280, C1281, Possible Causes
C1282, C1516, C1517, C2769, C2770, U1900, • circuit 1574 (DB) open, short to ground
U2023 — Sensor Cluster Fault
• circuit 1575 (WH/BK) open, short to voltage or
The yaw rate sensor, roll rate sensor, lateral • circuit 1878 (WH/BK) open, short to voltage or
accelerometer and longitudinal accelerometer (4WD) ground
are contained in the sensor cluster. The sensor • circuit 1879 (PK/BK) open, short to voltage or
cluster measures the vehicle acceleration, roll rate, ground
and yaw rate, then sends the signal via controller
area network (CAN) communication wires to the • sensor cluster (also called accelerometer)
anti-lock brake system (ABS) module. • ABS module
Voltage is supplied by circuit 1574 (DB). Ground is
provided through circuit 1575 (BK/WH). The CAN
communication is transmitted through circuit 1878
(WH/BK) and circuit 1879 (PK/BK).
PINPOINT TEST H: DTC C1279, C1280, C1281, C1282, C1516, C1517, C2769, C2770, U1900, U2023 —
SENSOR CLUSTER FAULT
NOTE: The yaw rate sensor, lateral accelerometer, roll rate sensor, and longitudinal
accelerometer (4WD) are integral to the sensor cluster.
NOTE: The vehicle must be on level ground, not on a hoist and at a complete standstill. Any
vehicle movement will result in false values for this test.
H1 CARRY OUT THE CALIBRATION PROCEDURE
• Connect the diagnostic tool.
• Clear the DTCs. GO to H2.
• Carry out the yaw rate calibration procedure using the diagnostic No
tool. The anti-lock brake system (ABS) system
• Retrieve the DTCs. is operating correctly. The condition may
• Are any DTCs retrieved or does the calibration procedure have been caused by an incomplete or
indicate a fault? inaccurate calibration.
H2 CHECK THE ABS MODULE YAW RATE PID
• Enter the following diagnostic mode on the diagnostic tool: ABS Yes
Module PID. GO to H3.
• Monitor the ABS module yaw rate PID. No
• Is the ABS module yaw rate PID value between -0.05 and CHECK the mounting of the sensor
0.05? cluster. If OK, INSTALL a new sensor
cluster. REFER to Accelerometer in this
section. CLEAR the DTCs. CALIBRATE
the ABS module. FOLLOW the diagnostic
tool directions for the calibration
procedure. REPEAT the self-test.
H3 CHECK THE ABS MODULE LATERAL ACCELERATION PID
Module PID. If equipped with 4WD, GO to H4.
• NOTE: The vehicle must be on level ground and at a complete If equipped with 2WD, GO to H5.
standstill. Any vehicle movement will result in false values for
this test. No
Monitor the ABS module lateral acceleration PID. CHECK the mounting of the sensor
• Is the ABS module lateral acceleration PID value between -7 cluster. If OK, INSTALL a new sensor
and 7? cluster. REFER to Accelerometer in this
(Continued)
2005 Aviator, 09/2004

SENSOR CLUSTER FAULT (Continued)
H4 CHECK THE ABS MODULE LONGITUDINAL ACCELERATION
PID
• Monitor the ABS module longitudinal acceleration PID. No
• Is the ABS module longitudinal acceleration PID value CHECK the mounting of the sensor
between -4 and 4? cluster. If OK, INSTALL a new sensor
H5 CHECK THE ABS MODULE ROLL RATE PID
• Monitor the ABS module roll rate PID. No
• Is the ABS module roll rate PID value between -0.05 and CHECK the mounting of the sensor
0.05? cluster. If OK, INSTALL a new sensor
H6 CHECK THE SENSOR CLUSTER CIRCUITRY FOR AN OPEN
• Disconnect: Sensor Cluster C3179.
harness side and the sensor cluster connector, harness side as
follows:
Sensor
ABS Module Cluster
Connector-Pin Circuit Connector-Pin Circuit
C155-7 1576 (TN/BK) C3179-3 1574 (DB)
C155-5 1577 (RD/LB) C3179-5 1575 (BK/WH)
C155-25 1879 (PK/BK) C3179-1 3125 (RD/YE)
C155-29 1878 (WH/BK) C3179-2 3126 (TN/YE)
Yes
GO to H7.
No
H7 CHECK THE SENSOR CLUSTER CIRCUITRY FOR A SHORT TO
VOLTAGE
(Continued)
2005 Aviator, 09/2004

VOLTAGE (Continued)
• Measure the voltage between the sensor cluster connector,
Sensor Cluster Connector-Pin Circuit

C3179-3 1574 (DB)
C3179-5 1575 (BK/WH)
C3179-1 3125 (RD/YE)
C3179-2 3126 (TN/YE)
Yes
self-test.
No
• Is any voltage present? GO to H8.
GROUND
• Measure the resistance between the sensor cluster connector,
Sensor Cluster Connector-Pin Circuit

C3179-3 1574 (DB)
C3179-5 1575 (BK/WH)
C3179-1 3125 (RD/YE)
C3179-2 3126 (TN/YE)
Yes
GO to H9.
No
(Continued)
2005 Aviator, 09/2004

H9 CHECK THE VOLTAGE FROM THE ABS MODULE
• Measure the voltage between the sensor cluster C3179-3, circuit
1574 (DB), harness side and the sensor cluster C3179-5, circuit
1575 (BK/WH), harness side.
Yes
INSTALL a new sensor cluster. REFER to
Accelerometer in this section. CLEAR the
self-test.
No
• Is the voltage greater than 10 volts? GO to H10.
H10 CHECK FOR CORRECT ABS MODULE OPERATION
correctly. No
Pinpoint Test I: DTC C1285 — Booster Possible Causes

Solenoid Circuit Failure • circuit 1582 (LG/RD) open, short to voltage or
The active brake booster has internal solenoids that • circuit 1583 (BN/WH) open, short to voltage or
assist driver brake applications or can apply the ground
brakes when needed if the driver loses control. • active brake booster
Voltage is supplied by circuit 1582 (LG/RD). • anti-lock brake system (ABS) module
Ground is provided through circuit 1583 (BN/WH).
2005 Aviator, 09/2004

PINPOINT TEST I: DTC C1285 — BOOSTER SOLENOID CIRCUIT FAILURE
I1 CARRY OUT THE CALIBRATION PROCEDURE
• Enter the following diagnostic mode on the diagnostic tool: Clear If DTC C1285 is retrieved, or the brake
DTC. booster portion of the calibration
• Carry out the active brake booster calibration procedure using procedure indicates a failure, GO to I2.
the diagnostic tool. If any other DTC is retrieved, GO to the
• Enter the following diagnostic mode on the diagnostic tool: Anti-Lock Brake System (ABS) Module
Retrieve DTCs. Diagnostic Trouble Code (DTC) Index.
indicate a fault? No
The ABS system is operating correctly.
I2 CHECK THE BRAKE BOOSTER SOLENOID
• Disconnect: Active Brake Booster C149.
• Measure the resistance between the active brake booster
C149-3, circuit 1583 (BN/WH), component side and the active
brake booster C149-4, circuit 1582 (LG/RD), component side.
Yes
GO to I3.
No
INSTALL a new active brake booster.
• Is the resistance between 1 and 2 ohms? self-test.
I3 CHECK CIRCUIT 1582 (LG/RD) AND CIRCUIT 1583 (BN/WH)
FOR AN OPEN
circuit 1582 (LG/RD), harness side and the active brake booster
C149-4, circuit 1582 (LG/RD), harness side, and between the
ABS module C155-31, circuit 1583 (BN/WH), harness side and
the active brake booster C149-3, circuit 1583 (BN/WH).
Yes
GO to I4.
No
(Continued)
2005 Aviator, 09/2004

PINPOINT TEST I: DTC C1285 — BOOSTER SOLENOID CIRCUIT FAILURE (Continued)
I4 CHECK CIRCUITS 1582 (LG/RD) AND 1583 (BN/WH) FOR A
SHORT TO GROUND
C149-4, circuit 1582 (LG/RD), harness side and ground, and
between the active brake booster C149-3 circuit 1583 (BN/WH),
harness side and ground.
Yes
GO to I5.
No
I5 CHECK CIRCUITS 1582 (LG/RD) AND 1583 (BN/WH) FOR A
SHORT TO VOLTAGE
• Measure the voltage between the active brake booster C149-4,
circuit 1582 (LG/RD), harness side and ground, and between the
active brake booster C149-3 circuit 1583 (BN/WH), harness side
and ground.
Yes
self-test.
No
• Is any voltage present? GO to I6.
I6 CHECK THE ACTIVE BRAKE BOOSTER SOLENOID FOR
CORRECT OPERATION
• Connect: Active Brake Booster C149.
• Start the engine and wait approximately 1 minute to create
vacuum in the brake booster and then place the ignition switch
in the OFF position.
(Continued)
2005 Aviator, 09/2004

PINPOINT TEST I: DTC C1285 — BOOSTER SOLENOID CIRCUIT FAILURE (Continued)
I6 CHECK THE ACTIVE BRAKE BOOSTER SOLENOID FOR
CORRECT OPERATION (Continued)
• Connect a fused (10A) jumper wire between the ABS module
C155-31, circuit 1583 (BN/WH), harness side and ground .
• While observing the brake pedal for movement, connect a fused

(10A) jumper wire for approximately 2 seconds between the ABS
module C155-17, circuit 1582 (LG/RD), harness side and the
positive battery post.
Yes
GO to I7.
No
• Does the brake pedal move? REPEAT the self-test.
I7 CHECK FOR CORRECT ABS MODULE OPERATION
correctly. No
Pinpoint Test J: DTC C1287 — Brake Possible Causes

Booster Pedal Force Switch Circuit Failure • circuit 1579 (OG/RD) open or short to ground
Normal Operation • circuit 1580 (WH/LG) open, short to voltage, or
The active brake booster has a normally open and a short to ground
normally closed pedal force switch that operates • circuit 1581 (PK/LB) open, short to voltage, or
according to driver brake applications. short to ground
The normally open pedal force switch circuit is • active brake booster
1581 (PK/LB). The normally closed pedal force • ABS module
switch circuit is 1580 (WH/LG).
2005 Aviator, 09/2004

PINPOINT TEST J: DTC C1287 — BRAKE BOOSTER PEDAL FORCE SWITCH CIRCUIT FAILURE
J1 CARRY OUT THE CALIBRATION PROCEDURE
• Enter the following diagnostic mode on the diagnostic tool: Clear If DTC C1287 is retrieved or the
DTCs. calibration procedure indicates a fault, GO
• Carry out the active brake booster calibration procedure using to J2.
the diagnostic tool. If any other DTC, GO to the Anti-Lock
• Enter the following diagnostic mode on the diagnostic tool: Brake System (ABS) Module Diagnostic
Retrieve the DTCs. Trouble Code (DTC) Index.
indicate a fault? No
The system is operating correctly.
J2 CHECK THE NORMALLY CLOSED RELEASE SWITCH
• Disconnect: Active Brake Booster C149.
C149-2, circuit 1580 (WH/LG), component side and the active
brake booster C149-5, circuit 1579 (OG/RD), component side
while pressing and releasing the brake pedal.
Yes
GO to J3.
No
• Is the resistance less than 5 ohms with the brake pedal FOLLOW the diagnostic tool directions for
released and greater than 10,000 ohms with the brake pedal the calibration procedure. REPEAT the
applied? self-test.
J3 CHECK THE NORMALLY OPEN RELEASE SWITCH
C149-1, circuit 1581 (PK/LB), component side and the active
brake booster C149-5, circuit 1579 (OG/RD), component side
while pressing and releasing the brake pedal.
Yes
GO to J4.
No
• Is the resistance greater than 10,000 ohms with the brake FOLLOW the diagnostic tool directions for
pedal released and less than 5 ohms with the brake pedal the calibration procedure. REPEAT the
applied? self-test.
(Continued)
2005 Aviator, 09/2004

(Continued)
J4 CHECK THE ACTIVE BRAKE BOOSTER CIRCUITRY FOR A
SHORT
connector pins, harness side as follows:
Active Brake Booster

Connector-Pin Circuit
C149-1 1581 (PK/LB)
C149-2 1580 (WH/LG)
C149-5 1579 (OG/RD)
Yes
GO to J5.
No
• Are the resistances greater than 10,000 ohms? REPEAT the self-test.
SHORT TO VOLTAGE
• Measure the voltage between the active brake booster
connector, harness side and ground as follows:

C149-1 1581 (PK/LB)
C149-2 1580 (WH/LG)
C149-5 1579 (OG/RD)
Yes
No
• Is voltage present? GO to J6.
(Continued)
2005 Aviator, 09/2004

(Continued)
SHORT TO GROUND

C149-1 1581 (PK/LB)
C149-2 1580 (WH/LG)
C149-5 1579 (OG/RD)
Yes
GO to J7.
No
J7 CHECK THE BRAKE BOOSTER CIRCUITRY FOR AN OPEN
harness side and the active brake booster connector, harness
side as follows:
Active Brake
ABS Module Booster
C155-27 C149-1 1581 (PK/LB)
C155-28 C149-5 1579 (OG/RD)
C155-30 C149-2 1580 (WH/LG)
Yes
GO to J8.
No
(Continued)
2005 Aviator, 09/2004

(Continued)
J8 CHECK FOR CORRECT ABS MODULE OPERATION
correctly. No
Pinpoint Test K: DTC C1288 and C1440 — Possible Causes

Brake Pressure Transducer Input Circuit • circuit 3600 (RD/WH) open, short to voltage, or
Failure
short to ground
Normal Operation • circuit 3601 (WH/RD) open, short to voltage, or
The primary brake pressure transducer sends current short to ground
to the anti-lock brake system (ABS) module • circuit 3603 (RD) open, short to voltage, or short
proportional to the driver’s brake pedal application. to ground
Reference voltage is supplied by circuit 3601 • primary brake pressure transducer
(WH/RD). Ground is provided through circuit 3603 • ABS module
(RD). The transducer current is supplied by circuit
3600 (RD/WH).
PINPOINT TEST K: DTC C1288 AND C1440 — BRAKE PRESSURE TRANSDUCER INPUT CIRCUIT
FAILURE
K1 CHECK FOR DTCS
• Check the recorded results from the ABS module self-test. REPAIR these DTCs first. REFER to the
• Is DTC C1287, C1483, B2734, B2736, B2737, B2738, or B2740 appropriate pinpoint test for each DTC
present? retrieved.
No
GO to K2.
K2 CHECK THE PRIMARY BRAKE PRESSURE TRANSDUCER
CIRCUITRY FOR A SHORT TO VOLTAGE
• Disconnect: Primary Brake Pressure Transducer C147.
• Measure the voltage between the primary brake pressure
transducer connector, harness side and ground as follows:
Primary Brake Pressure

Transducer Connector-Pin Circuit
C147-1 3603 (RD)
C147-2 3600 (RD/WH)
C147-3 3601 (WH/RD)
(Continued)
2005 Aviator, 09/2004

FAILURE (Continued)
CIRCUITRY FOR A SHORT TO VOLTAGE (Continued)
Yes
No
• Is any voltage present? GO to K3.
CIRCUITRY FOR A SHORT TO GROUND
• Measure the resistance between the primary brake pressure
transducer connector, harness side and ground as follows:

C147-1 3603 (RD)
C147-2 3600 (RD/WH)
C147-3 3601 (WH/RD)
Yes
GO to K4.
No
CIRCUITRY FOR A SHORT
• Measure the resistance between the primary brake pressure
transducer connector pins, harness side as follows:
(Continued)
2005 Aviator, 09/2004

FAILURE (Continued)
CIRCUITRY FOR A SHORT (Continued)

C147-1 3603 (RD)
C147-2 3600 (RD/WH)
C147-3 3601 (WH/RD)
Yes
GO to K5.
No
CIRCUITRY FOR AN OPEN
harness side and the primary brake pressure transducer
connector, harness side as follows:
Primary Brake
Pressure
ABS Module Transducer
C155-19 C147-1 3603 (RD)
C155-20 C147-2 3600 (RD/WH)
C155-18 C147-3 3601 (WH/RD)
Yes
GO to K6.
No
• Are the resistances less than 5 ohms? the DTCs. REPEAT the self-test.
(Continued)
2005 Aviator, 09/2004

FAILURE (Continued)
K6 CHECK THE ABS MODULE OUTPUT
• Measure the voltage between the primary brake pressure
transducer C147-3, circuit 3601 (WH/RD), harness side and the
primary brake pressure transducer C147-1, circuit 3603 (RD),
harness side.
Yes
GO to K7.
No
• Is the voltage approximately 5 volts? GO to K8.
OUTPUT
• Connect: Primary Brake Pressure Transducer C147.
• Remove pin 20, circuit 3600 (RD/WH) from the ABS module
connector.
• Measure the voltage between the ABS module C155-20, circuit GO to K8.
3600 (RD/WH), harness side and ground while pressing and No
releasing the brake pedal. INSTALL a new primary brake pressure
• Is the voltage between 0.35 and 0.65 volt with the brake transducer. REFER to Section 206-06.
pedal released and between 0.65 and 4.5 volts with the CLEAR the DTCs. CALIBRATE the ABS
brake pedal pressed? module. REPEAT the self-test.
K8 CHECK FOR CORRECT ABS MODULE OPERATION
correctly. No
Pinpoint Test L: DTC C1730 — Reference Reference voltage is supplied to the primary brake
Voltage Out Of Range (+5 V) pressure transducer through circuit 3601 (WH/RD),
and to the brake pedal travel sensor through circuit
Normal Operation
3010 (TN). The reference voltage circuits return to
The 5-volt reference voltage is supplied by the the ABS module through circuit 3603 (RD) for the
anti-lock brake system (ABS) module to the primary primary brake pressure transducer, and through
brake pressure transducer and the brake pedal travel circuit 3011 (BK/OG) for the brake pedal travel
sensor. sensor.
Possible Causes
• circuit 3601 (WH/RD) short to voltage or short
ground
2005 Aviator, 09/2004

• circuit 3010 (TN) short to voltage or short to • master cylinder
ground • primary brake pressure transducer
• ABS module • brake pedal travel sensor
PINPOINT TEST L: DTC C1730 — REFERENCE VOLTAGE OUT OF RANGE (+5 V)
L1 CHECK CIRCUIT 3601 (WH/RD) AND CIRCUIT 3010 (TN) FOR
SHORTS TO VOLTAGE
• Disconnect: Brake Pedal Travel Sensor C148.
3601 (WH/RD), harness side and ground; and between the ABS
module C155-26, circuit 3010 (TN), harness side and ground.
Yes
self-test.
No
• Is any voltage present? GO to L2.
L2 CHECK CIRCUIT 3601 (WH/RD) AND CIRCUIT 3010 (TN) FOR A
SHORT TO GROUND
circuit 3601 (WH/RD), harness side and ground; and between
the ABS module C155-26, circuit 3010 (TN), harness side and
ground.
Yes
GO to L3.
No
L3 CHECK THE PRIMARY BRAKE PRESSURE TRANSDUCER
(Continued)
2005 Aviator, 09/2004

PINPOINT TEST L: DTC C1730 — REFERENCE VOLTAGE OUT OF RANGE (+5 V) (Continued)
L3 CHECK THE PRIMARY BRAKE PRESSURE TRANSDUCER
(Continued)
circuit 3601 (WH/RD), harness side and the ABS module
C155-19, circuit 3603 (RD), harness side.
Yes
GO to L4.
No
INSTALL a new brake pressure
transducer. REFER to Section 206-06.
CLEAR the DTCs. CALIBRATE the ABS
module. FOLLOW the diagnostic tool
• Is the resistance between 1 and 2 ohms? REPEAT the self-test.
L4 CHECK THE BRAKE PEDAL TRAVEL SENSOR
circuit 3010 (TN), harness side and the ABS module C155-24,
circuit 3011 (BK/OG), harness side.
Yes
GO to L5.
No
INSTALL a new brake pedal travel sensor.
CLEAR the DTCs. CALIBRATE the ABS
module. FOLLOW the diagnostic tool
• Is the resistance between 1 and 2 ohms? REPEAT the self-test.
L5 CHECK FOR CORRECT ABS MODULE OPERATION
correctly. No
2005 Aviator, 09/2004

Pinpoint Test M: DTC C1960 — Driver Brake Voltage is supplied by circuit 810 (RD/LG).
Apply Circuit Fault
Possible Causes
Normal Operation • circuit 810 (RD/LG) short to voltage or short to
The 12 volt driver brake apply (DBA) signal is sent ground
from the anti-lock brake system (ABS) module • ABS module
during brake application to the trailer tow relay (if
equipped).
PINPOINT TEST M: DTC C1960 — DRIVER BRAKE APPLY CIRCUIT FAULT
M1 CHECK FOR OTHER DTCs
• Check the recorded results from the anti-lock brake system GO to the Anti-Lock Brake System (ABS)
(ABS) module self-test: Module Diagnostic Trouble Code (DTC)
• Are any other DTCs retrieved? Index and repair those DTCs before
continuing.
No
GO to M2.
M2 CHECK CIRCUIT 810 (RD/LG) FOR A SHORT TO VOLTAGE
810 (RD/LG) and ground.
Yes
No
• Is any voltage present? GO to M3.
M3 CHECK CIRCUIT 810 (RD/LG) FOR A SHORT TO GROUND
(Continued)
2005 Aviator, 09/2004

PINPOINT TEST M: DTC C1960 — DRIVER BRAKE APPLY CIRCUIT FAULT (Continued)
M3 CHECK CIRCUIT 810 (RD/LG) FOR A SHORT TO GROUND
(Continued)
circuit 810 (RD/LG) and ground.
Yes
GO to M4.
No
• Is the resistance greater than 10,000 ohms? REPEAT the self-test.
M4 CHECK FOR CORRECT ABS MODULE OPERATION
correctly. No
Pinpoint Test N: DTC B2734, B2736, B2737, Possible Causes

B2738, B2740 — Pedal Travel Sensor Fault • circuit 3010 (TN) open, short to voltage, or short
Normal Operation to ground
The brake pedal travel sensor sends current to the • circuit 3011 (BK/OG) open, short to voltage, or
anti-lock brake system (ABS) module proportional short to ground
to the brake pedal position. • circuit 3012 (WH) open, short to voltage, or short
Reference voltage is supplied by circuit 3010 (TN). to ground
Ground is provided through circuit 3011 (BK/OG). • brake pedal travel sensor
The sensor signal is supplied by circuit 3012 (WH). • ABS module
PINPOINT TEST N: DTC B2734, B2736, B2737, B2738, B2740 — PEDAL TRAVEL SENSOR FAULT
N1 CHECK THE BRAKE PEDAL TRAVEL SENSOR CIRCUITRY FOR
A SHORT TO VOLTAGE
• Measure the voltage between the brake pedal travel sensor
(Continued)
2005 Aviator, 09/2004

(Continued)
A SHORT TO VOLTAGE (Continued)
Brake Pedal Travel Sensor

C148-1 3010 (TN)
C148-2 3011 (BK/OG)
C148-3 3012 (WH)
Yes
No
• Is any voltage present? GO to N2.
A SHORT TO GROUND
• Measure the resistance between the brake pedal travel sensor

C148-1 3010 (TN)
C148-2 3011 (BK/OG)
C148-3 3012 (WH)
Yes
GO to N3.
No
(Continued)
2005 Aviator, 09/2004

(Continued)
A SHORT
• Measure the resistance between the brake pedal travel sensor
connector pins, harness side as follows:

C148-1 3010 (TN)
C148-2 3011 (BK/OG)
C148-3 3012 (WH)
Yes
GO to N4.
No
AN OPEN
harness side and the brake pedal travel sensor connector,
Brake Pedal Travel

ABS Module Sensor
C155-26 C148-1 3010 (TN)
C155-24 C148-2 3011 (BK/OG)
C155-40 C148-3 3012 (WH)
Yes
GO to N5.
No
• Are the resistances less than 5 ohms? the DTCs. REPEAT the self-test.
(Continued)
2005 Aviator, 09/2004

(Continued)
N5 CHECK THE ABS MODULE OUTPUT
• Measure the voltage between the brake pedal travel sensor
C147-3, circuit 3601 (WH/RD), harness side and the brake pedal
travel sensor C147-1, circuit 3603 (RD), harness side.
Yes
GO to N6.
No
• Is the voltage approximately 5 volts? GO to N7.
N6 CHECK THE BRAKE PEDAL TRAVEL SENSOR OUTPUT
• Connect: Brake Pedal Travel Sensor C147.
• Remove pin 20, circuit 3600 (RD/WH) from the ABS module
connector.
• Measure the voltage between the ABS module C155-20, circuit Yes
3600 (RD/WH), harness side and ground while pressing and GO to N7.
releasing the brake pedal. No
• Is the voltage between 0.35 and 0.65 volt with the brake INSTALL a new brake pedal travel sensor.
pedal released and between 0.65 and 4.5 volts with the CLEAR the DTCs. CALIBRATE the ABS
brake pedal pressed? module. REPEAT the self-test.
N7 CHECK FOR CORRECT ABS MODULE OPERATION
correctly. No
Pinpoint Test O: Stability Assist Cannot Be Voltage is supplied to the traction control switch
Disabled through circuit 1003 (GY/YE). The signal from the
traction control switch is sent to the ABS module
Normal Operation
through circuit 959 (GY).
Engine torque modulation is achieved by regulating
Possible Causes
fuel and spark to the cylinders. The stability assist
system operates using the anti-lock brake system • circuit 959 (GY) open or short to voltage
(ABS) module to interact with the powertrain • traction control switch
control module (PCM) to reduce engine torque if
one or both rear wheels lose traction and begin to • ABS module
spin during acceleration.
2005 Aviator, 09/2004

PINPOINT TEST O: THE STABILITY ASSIST CANNOT BE DISABLED
O1 CHECK THE TRACTION CONTROL SWITCH
• Disconnect: Traction Control Switch C280.
• Turn the traction control switch to the OFF position.
• Measure the resistance between the traction control switch
C280-5, circuit 1003 (GY/YE), component side and C280-1,
circuit 959 (GY) component side.
Yes
GO to O2.
No
INSTALL a new traction control switch.
REFER to Traction Control Switch in this
section. TEST the system for normal
• Is the resistance greater than 10,000 ohms? operation.
O2 CHECK CIRCUIT 959 (GY) FOR A SHORT TO VOLTAGE
959 (GY), harness side and ground.
Yes
REPAIR the circuit. TEST the system for
normal operation.
No
• Is any voltage present? GO to O3.
O3 CHECK CIRCUIT 960 (BK/LB) FOR A SHORT TO GROUND
(Continued)
2005 Aviator, 09/2004

PINPOINT TEST O: THE STABILITY ASSIST CANNOT BE DISABLED (Continued)
O3 CHECK CIRCUIT 960 (BK/LB) FOR A SHORT TO GROUND
(Continued)
circuit 960 (BK/LB), harness side and ground.
Yes
GO to O4.
No
• Is the resistance greater than 10,000 ohms? normal operation.
O4 CHECK FOR CORRECT ABS MODULE OPERATION
correctly. No
Pinpoint Test P: DTC C1998 — Module Possible Causes

Calibration Not Complete • anti-lock brake system (ABS) module
Normal Operation • sensor cluster
The stability assist system needs to be calibrate • steering position sensor
whenever a component specific to the system is
disconnected or a new component is installed.
PINPOINT TEST P: DTC C1998 — MODULE CALIBRATION NOT COMPLETE
NOTE: The stability assist lamp flashes when a system calibration is required. Calibration is
required after certain DTCs are cleared.
NOTE: Make sure the vehicle is not on a hoist and is sitting on level ground before
performing the stability assist module calibration.
P1 CHECK FOR DTCs
• Key in ON position. GO to the appropriate pinpoint test for the
• Check the recorded results from the smart junction box (SJB) DTC.
self-test: Some of the pinpoint tests recommend
• Is any other DTC retrieved with C1998? anti-lock brake system (ABS) module
calibration prior to any further diagnostics;
in this case, GO to P2.
No
GO to P2.
(Continued)
2005 Aviator, 09/2004

PINPOINT TEST P: DTC C1998 — MODULE CALIBRATION NOT COMPLETE (Continued)
P2 ABS MODULE CALIBRATION
• Start the engine. GO to P3.
• NOTE: Be sure to rotate the steering wheel lock-to-lock during No
the calibration of the ABS system. GO to P4.
Carry out the ABS module calibration per the diagnostic tool
instructions. Some concerns will cause the calibration
• Did the calibration complete for all of the stability assist to not complete. If sent here from another
sensors and did the stability assist lamp turn off? pinpoint test, RETURN to that pinpoint test
for further diagnostics.
P3 CLEAR DTC C1998
NOTE: Clear DTC C1998 after completing the calibration. Yes
• Connect the diagnostic tool. TEST DRIVE the vehicle. REPEAT the
• Key in ON position. self-test.
• Clear the DTC. If sent here from another pinpoint test,
• Did the DTC clear? RETURN to that pinpoint test for further
diagnostics.
No
GO to P4.
P4 MONITOR THE STEERING POSITION SENSOR PIDS
• Monitor the ABS module steering position sensor PIDS while Yes
rotating the steering wheel clockwise and counterclockwise. GO to Pinpoint Test H.
• Are the 2 steering position sensor PID values switching as No
the wheel rotates? GO to Pinpoint Test G.
Pinpoint Test Q: The Traction Control Switch Possible Causes

Indicator Is Never/Always On • circuit 1003 (GY/YE) open
Normal Operation • circuit 960 (BK/LB) open, short to voltage, or
Circuit 1003 (GY/YE) provides voltage to the short to ground
traction control switch. Ground for the traction • traction control switch
control switch indicator lamp is provided and • ABS module
controlled by the anti-lock brake system (ABS)
module through circuit 960 (BK/LB).
PINPOINT TEST Q: THE TRACTION CONTROL SWITCH INDICATOR IS NEVER/ALWAYS ON
Q1 DETERMINE THE CONDITION
• Observe the traction control switch indicator. GO to Q2.
• Is the OFF indicator on the traction control switch No
illuminated? GO to Q4.
Q2 CHECK THE ABS MODULE
• Disconnect: ABS Module C155. Yes
• Key in ON position. GO to Q3.
• Does the OFF indicator on the traction control switch No
continue to illuminate? GO to Q7.
Q3 CHECK CIRCUIT 960 (BK/LB) FOR A SHORT TO GROUND
(Continued)
2005 Aviator, 09/2004

PINPOINT TEST Q: THE TRACTION CONTROL SWITCH INDICATOR IS NEVER/ALWAYS ON (Continued)
Q3 CHECK CIRCUIT 960 (BK/LB) FOR A SHORT TO GROUND
(Continued)
C280-6, circuit 960 (BK/LB), harness side and ground.
Yes
section. TEST the system for normal
operation.
No
• Is the resistance greater than 10,000 ohms? normal operation.
Q4 CHECK CIRCUIT 1003 (GY/YE) FOR AN OPEN
• Measure the voltage between the traction control switch C280-5,
circuit 1003 (GY/YE), harness side and ground.
Yes
GO to Q5.
No
• Is the voltage greater than 10 volts? normal operation.
Q5 CHECK CIRCUIT 960 (BK/LB) FOR AN OPEN
C280-6, circuit 960 (BK/LB), harness side and the ABS module
C155-13, circuit 960 (BK/LB), harness side.
Yes
GO to Q6.
No
• Is the resistance less than 5 ohms? normal operation.
(Continued)
2005 Aviator, 09/2004

PINPOINT TEST Q: THE TRACTION CONTROL SWITCH INDICATOR IS NEVER/ALWAYS ON (Continued)
Q6 CHECK THE TRACTION CONTROL SWITCH
• Connect: Traction Control Switch C280.
• Connect a fused (5A) jumper wire between the ABS module
C155-13, circuit 960 (BK/LB), harness side and ground.
Yes
GO to Q7.
No
• Is the OFF indicator on the traction control switch section. TEST the system for normal
illuminated? operation.
Q7 CHECK FOR CORRECT ABS MODULE OPERATION
correctly. No
2005 Aviator, 09/2004


Accelerometer 3. Disconnect the accelerometer electrical
connector.
4. Remove the accelerometer electrical harness

retainer and position aside.
Item Part Number Description

1 2C011 Accelerometer electrical
connector
2 W700101-S Accelerometer bracket nuts (2
required)
3 3C187 Accelerometer
NOTE: When installing a new accelerometer, the

anti-lock brake system (ABS) module must be
configured (using vehicle as-built data) and
calibrated. Follow the diagnostic tool directions for
the calibration procedures. For module
configuration, refer to Section 418-01.
1. Remove the floor console. For additional

2. Remove the heater duct.

5. Remove the 2 accelerometer nuts and the 6. To install, reverse the removal procedure.
accelerometer.
• To install, tighten to 7 Nm (62 lb-in).
2005 Aviator, 09/2004


Module
Item Part Number Description CAUTION: Electronic modules are

1 2M101 ABS module screws (3 sensitive to electrical charges. The ABS module
required) can be damaged if exposed to these charges.
2 2C219 ABS module
NOTE: When installing a new ABS module, it
Removal and Installation must be configured (using vehicle as-built data) and
calibrated. Follow the diagnostic tool directions for
the calibration procedures. For module
WARNING: Brake fluid contains configuration, refer to Section 418-01.
with eyes. Wash hands thoroughly after 1. Remove the hydraulic control unit (HCU). For
handling. If brake fluid contacts eyes, flush eyes additional information, refer to Hydraulic
with running water for 15 minutes. Get medical Control Unit (HCU) in this section.


2. Remove the 3 screws and the ABS module. 3. To install, reverse the removal procedure.
2005 Aviator, 09/2004


Hydraulic Control Unit (HCU)
Material
Item Specification
PM-1 (Canada CPM-1)

2005 Aviator, 09/2004

Item Part Number Description 2. With the vehicle in NEUTRAL, position it on a
1 14398 Anti-lock brake system (ABS) hoist. For additional information, refer to
module electrical connector Section 100-02.
2 — Brake line-to-HCU nuts
(M12-1) (part of 2C296) 3. Disconnect the ABS electrical connector.
3 — Brake line-to-brake line nuts
(part of 2C296) 4. NOTE: The brake lines must be installed in the
same location as removed.
4 W803826-S HCU bracket-to-frame nuts (3
required) Remove the 2 brake line-to-HCU nuts and
5 2C215 HCU assembly position the brake lines aside.
6 (part of 2C296) Brake line-to-HCU nuts • To install, tighten to 23 Nm (17 lb-ft).
(M10-1)
7 W520101 Bracket-to-brake line holder 5. NOTE: The brake lines must be installed in the
nuts (2 required) same location as removed.
8 2C296 Brake line holder assembly Remove the 4 brake line-to-brake line nuts.
9 (part of 2C304) Bracket-to-HCU bolts (3 • To install, tighten to 18 Nm (13 lb-ft).
required)
10 2C304 HCU Bracket 6. Remove the 3 HCU bracket-to-frame nuts.
7. Remove the HCU assembly.
polyglycol ethers and polyglycols. Avoid contact 8. NOTE: The brake lines must be installed in the
with eyes. Wash hands thoroughly after same location as removed.
handling. If brake fluid contacts eyes, flush eyes Remove the 4 brake line-to-HCU nuts.
attention if irritation persists. If taken • To install, tighten to 18 Nm (13 lb-ft).
medical attention immediately. Failure to follow 9. Remove the 2 bracket-to-brake line holder nuts
these instruction may result in personal injury. and the brake line holder assembly.
painted and plastic surfaces. If brake fluid is 10. Remove the bracket-to-HCU bolts and the HCU
spilled onto a painted or plastic surface, bracket.
immediately wash it with water. • To install, tighten to 17 Nm (13 lb-ft).
NOTE: The 4-channel anti-lock brake system 11. To install, reverse the removal procedure.
(ABS) with stability assist shown, 3-channel ABS is
similar. • Bleed the brake system. For additional
1. Remove the battery tray. For additional
2005 Aviator, 09/2004


Traction Control Switch
Item Part Number Description 2. Remove the center console. For additional
1 14B079 Harness connector information, refer to Section 501-12.
2 — Traction control switch 3. Disconnect the traction control switch
connector.
4. Remove the traction control switch.
1. Disconnect the battery. For additional
information, refer to Section 414-00. 5. To install, reverse the removal procedure.


Wheel Speed Sensor — Front

Item Part Number Description 2. Remove the front brake disc. For additional
1 14398 Wheel speed sensor electrical information, refer to Section 206-03.
connector
3. Disconnect the wheel speed sensor electrical
2 — Wheel speed sensor harness
retainer (part of 2C190) (3 connector.
required)
3 — Wheel speed sensor harness 4. Remove the 3 wheel speed sensor harness
pin-type retainer (part of retainers.
2C190) (2 required)
4 — Wheel speed sensor bolt (part 5. Remove the 2 wheel speed sensor harness
of 2C204) pin-type retainers.
5 2C204 Wheel speed sensor
6. Remove the wheel speed sensor bolt.
Removal and Installation • To install, tighten to 17 Nm (13 lb-ft).
1. With the vehicle in NEUTRAL, position it on a 7. Remove the wheel speed sensor and the
hoist. For additional information, refer to harness.
Section 100-02.
2005 Aviator, 09/2004


Wheel Speed Sensor — Rear
Item Part Number Description 2. Disconnect the wheel speed sensor electrical
1 14407 Wheel speed sensor electrical connector.
connector
3. Disconnect the 3 wheel speed sensor harness
2 — Wheel speed sensor harness
pin-type retainer (part of pin-type retainers.
2C190) (3 required)
3 W500212-S Wheel speed sensor bolt 4. Remove the wheel speed sensor bolt.
4 2C381 Wheel speed sensor • To install, tighten to 27 Nm (20 lb-ft).
Removal and Installation 5. Remove the wheel speed sensor and harness
assembly.
1. With the vehicle in NEUTRAL, position it on a 6. To install, reverse the removal procedure.
Section 100-02.


Brake Pressure Transducer
Item Part Number Description 1. Disconnect the brake pressure transducer

1 14398 Brake pressure transducer electrical connector.
electrical connector
2. Remove the brake pressure transducer.
2 2A032 Brake pressure transducer



• Bleed the brake system. For additional
2005 Aviator, 09/2004

Brake System

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Brake System

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206-00-1 Brake System — General Information 206-00-1

Copyright  2004, Ford Motor Company

DESCRIPTION AND OPERATION

Copyright  2004, Ford Motor Company

2005 Aviator, 09/2004

DIAGNOSIS AND TESTING

Worldwide Diagnostic System WARNING: Brake fluid contains

Copyright  2004, Ford Motor Company

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Connector Circuit Reference

Driver Seat Module (DSM) C341d

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Driver Seat Module (DSM) C341e

Pin Number(s) Circuit Designation/Description Normal Condition/Measurement

Driver Seat Module (DSM) C341f

Pin Number(s) Circuit Designation/Description Normal Condition/Measurement

2005 Aviator, 09/2004

Pin Number(s) Circuit Designation/Description Normal Condition/Measurement

Adjustable Brake Pedal Motor C2003

Pin Number(s) Circuit Designation/Description Normal Condition/Measurement

2005 Aviator, 09/2004

Pin Number(s) Circuit Designation/Description Normal Condition/Measurement

Adjustable Brake Pedal Switch C2235

Pin Number(s) Circuit Designation/Description Normal Condition/Measurement

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Pins Switch Position Resistance Value

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Potentiometer Pins Resistance Value

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Pinpoint Test C: DTCS B1987, B1988, and • adjustable pedal switch

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Pinpoint Test E: Vibration When Brakes Are

2005 Aviator, 09/2004

• CAUTION: Do not use a bench lathe to machine the

• CAUTION: Do not use a bench lathe to machine the

Component Tests 2. With the transmission in NEUTRAL, stop the

2005 Aviator, 09/2004

2005 Aviator, 09/2004

Copyright  2004, Ford Motor Company

2005 Aviator, 09/2004

Master Cylinder Bleeding

CAUTION: Do not allow the brake master

CAUTION: Brake fluid is harmful to

Copyright  2004, Ford Motor Company

5. Repeat the previous 3 steps until there are no

NOTE: This procedure is required only when a new

1. Connect the diagnostic tool and follow the ABS

2. Use the caliper bleed procedure to bleed the

2005 Aviator, 09/2004

Copyright  2004, Ford Motor Company