Brake Pressure Sensor Replacement

Cruise Control Repair for 1997 to 2003 F-150 Pickups

One of, if not the most common repair for a malfunctioning cruise control system (cruise control works intermittently, deactivates when hitting bumps in the road, or does not work at all) on the 1997 to 2003 F-150 is a pressure sensor located on the brake master cylinder. The sensor is designed to recognize when the brake pedal is depressed and deactivate the cruise control system. In at least some vehicles produced during these model years, the brake pressure sensor was recalled and replaced if it was found to be leaking - since not all sensors leaked, many were not replaced under the recall. The brake pressure sensor tends to be the root cause of cruise control system related problems for many Ford vehicles (not just F-150 trucks) between 1997 and 2003 model years.

Applicable Model Years: 1997 - 2003 Ford F-150
Brake Repair Kit: Ford part # SW-6350 (1L1Z-9F924-AA)

 

The body of an original brake pressure sensor will be orange/red in color, while the updated replacement part is black. If your cruise control is not functioning or working intermittently and you've identified that your vehicle is equipped with the flawed sensor, replacing it is not a total loss if it does not repair your cruise control related issues. As previously stated, the brake pressure sensor is responsible for many cruise control related driveability issues, but not all.

Click any thumbnail to view high resolution fullsize image w/ addition details (where applicable)

brake pressure sensor location

• Disconnect the negative battery cable.

• Locate the brake pressure sensor on the end (furthest from firewall) of the brake master cylinder assembly.

Removing brake pressure sensor

• Release both retaining clips on the brake pressure sensor electrical connector, then pull upwards to remove the connector.

• Thoroughly clean the circumference of the sensor where it inserts into the brake master cylinder in order to reduce the chance of debris contaminating the brake fluid once the sensor is removed.

Brake pressure sensor closeup

• Place a clean rag underneath the sensor to soak up any fluid that is lost when the old sensor is removed.

Note - when you remove the old sensor, have the replacement sensor within reach so that you can quickly (within a few seconds) install it. If the new sensor is quickly installed, you will lose little, if any brake fluid (the brake fluid will not run out rapidly) and there will be no need to bleed the brake system.

• The original sensor requires a 15 mm open end wrench or crowfoot for removal (a 9/16" actually fit more snug for us). The replacement sensor requires a 7/8 open end wrench or crowfoot.

New brake pressure sensor with harness

• Replace the brake pressure sensor. Snug the new sensor down, do not overtighten.

• The updated brake pressure sensor from Ford includes a harness adapter; the connector on the new sensor differs from that of the original sensor. If you are replacing an updated sensor, you should still install the new harness adapter for good measure.

New brake pressure sensor installed

• Finally, install the harness adapter. Pump the brake pedal several times, then check for leaks. Test drive the vehicle at low speeds (< 25 mph) and test for both proper brake function and any fluid leaks. Finally, road test the vehicle and check for cruise control operation and leaks.