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