2003 F-Super Duty /Excursion Workshop Manual

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1 3//2011 SECTION : Speed Control 2003 F-Super Duty /Excursion Workshop Manual DIAGNOSIS AND TESTING Procedure revision date: 08/01/2006 Speed Control Printable View (331 KB) Refer to Wiring Diagrams Cell 31, Vehicle Speed Control for schematic and connector information. Special Tool(s) 73III Automotive Meter 105-R0057 or equivalent Flex Probe Kit 105-R025B or equivalent Diagnostic Tool, Restraint System (2 req'd) 418-F088 (105-R0012) Principles of Operation The speed control system is designed to maintain a selected vehicle speed between approximately 48 and 200 km/h (30 and 125 mph). The electronic stepper motor (internal to the speed control servo) is controlled by turning the three phases of the motor on and off in sequence. The sequence determines the motor direction (open throttle or closed throttle based on vehicle speed). Whenever the system is engaged and active, a speed control set indicator will be illuminated in the instrument cluster. The brake pedal position (BPP) switch is a normally open switch. When the brake pedal is applied with the speed control system engaged, the BPP switch closes, putting the vehicle speed control in stand-by mode. NOTE: The deactivator switch is provided as an additional safety feature. rmally, when the brake pedal is pressed, the speed control servo will deactivate the speed control system. Under increased brake pedal effort, the deactivator switch, a normally closed switch, will open and remove power to the speed control servo clutch, releasing the throttle independent of the PCM. The clutch pedal position (CPP) switch is incorporated on vehicles equipped with manual transmissions. When the clutch pedal is applied with the vehicle speed control system engaged, the normally closed switch opens and signals the speed control servo to deactivate the speed control. The clockspring provides the electrical interface between the steering column wiring and the speed control switches in the steering wheel. The inputs to the speed control servo are: vehicle speed signal speed control switches brake pedal position (BPP) switch clutch pedal position (CPP) switch (if equipped) deactivator switch The outputs of the speed control servo are: speed control indicator speed control cable controlling the throttle position Inspection and Verification NOTE: If any concerns are noted with the speedometer or horn, address those concerns by referring to their associated sections before continuing speed control diagnosis. NOTE: When in speed control mode, initial depression of the clutch pedal may cause a normal momentary increase of engine rpm. NOTE: If the vehicle is a diesel, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual. 1. Verify the customer concern by operating the speed control system. 2. NOTE: Any aftermarket modifications, including but not limited to those listed below, may cause the speed control to not operate correctly: Any wiring or lamp modifications affecting the brake lamp operation LED brake lamps n-factory installed trailer wiring Radios (speed sensitive, auto mute) Remote starters and alarms Lighting and electrical accessory modifications Visually inspect for obvious signs of mechanical or electrical damage: Visually inspect the speed control actuator and accelerator controls. Visually inspect the speed control cable without removing it to make sure of smooth cable Inspect the speed control cable connection to the throttle body.

2 3//2011 Visually inspect the accelerator cable without removing it to make sure of smooth cable Inspect the accelerator cable connection to the throttle body. Also check for cable interference with the carpet, bulkhead grommet, insulation and instrument panel wiring. Visual Inspection Chart Mechanical Speed control cable Speed control cable not attached to throttle Electrical Central junction box (CJB) fuse(s): 27 (15A) 34 (10A) Speed control switches Brake pedal position (BPP) switch Clutch pedal position (CPP) switch (if equipped) Deactivator switch Speed control servo Circuitry Bulb 3. If the fault is not visually evident, go to the Self-Test Diagnostics. Self-Test Diagnostics WARNING: This test is a key on engine off (KOEO) test only that is conducted in PARK only with the emergency brake fully engaged. NOTE: On vehicles equipped with a manual transmission, the clutch pedal must be released in order to correctly carry out the self-test. On vehicles equipped with an automatic transmission, the transmission selector needs to be in the PARK (P) position. NOTE: Review the following steps before carrying out the self-test diagnostic procedure. NOTE: After entering the diagnostic mode, the module times out if the mandatory switch sequence is not completed within 5 seconds and each button is not pressed within one second of the previous button. If a module time-out occurs (speed control lamp stops flashing part way through the test), the procedure must be re-initiated. The self-test is comprised of 2 parts. The first part is a static check of the speed control electronics module and system. The second part is a dynamic pull-test to check the actuator motor and gear mechanism. To perform the self-test: Connect the scan tool to a power source that is not interrupted when the ignition switch changes positions. With the ignition switch in the RUN position, set the scan tool to monitor the powertrain control module (PCM) throttle position PID while the speed control actuator carries out the self-test. Enter self-test diagnostics by firmly pressing and holding the speed control OFF switch while quickly cycling the ignition switch from RUN-to-OFF-to-RUN, making sure the engine does not start and is not running. The speed control indicator lamp on the instrument panel will flash once to indicate that the speed control module has entered the diagnostic mode. Release the OFF switch. If 5 additional flashes are displayed at this point, a speed control subsystem concern exists. GO to Symptom Chart. NOTE: The module times out if each button is not pressed within one second of the previous button. If a module time out occurs (speed control lamp stops flashing part way through test), the procedure must be re-initiated. Firmly press and release the remaining switches within one second of each other in the following sequence: ON RSM (resume) CST (coast) SET/ACCEL The speed control indicator lamp flashes once after each of the first 4 buttons is successfully pressed. Firmly press and release each switch in the sequence immediately after the light goes out for the previous switch. NOTE: There will be a slight delay from when the last button is pressed and the lamp flashes diagnostic codes. If the self-test will not start or cannot be completed after multiple attempts, GO to Symptom Chart. Follow the list below for diagnostic flash codes, then GO to Symptom Chart. 0 flashes: flash after the last button pressed: suspect circuitry or speed control switch. 1 flash: Static test passed. 2 flashes: The stoplamp switch is damaged, circuit is damaged, or brake pedal is applied. 3 flashes: The speed control deactivator switch is open or the circuit is damaged. 4 flashes: The vehicle speed signal is out of range or circuit is damaged. 5 flashes: Speed control actuator internal failure. NOTE: Monitor the PCM throttle position PID after the last button is pressed. Within 0.25 second after the static test has passed, the speed control actuator carries out a dynamic pull test automatically by actuating the throttle lever from 1 to 10 mm (0.04 to 0.39 inches) of travel from the idle position for 3 seconds and then releasing the throttle. If the PID value does not change and holds steady for 3 seconds, GO to Symptom Chart. During the dynamic throttle pull, observe throttle movement to witness any binding or sticking of the speed control cable, verify the correct connection of the speed control cable to the throttle lever, and make sure that the throttle returns to the idle position. If incorrect connection and/or binding or sticking of the speed control is observed, GO to Symptom Chart. Turn the key to OFF and GO to Symptom Chart. Symptom Chart Symptom Chart Condition Possible Sources Action The speed control is inoperative no flash codes Speed control cable not attached to throttle. Central junction box (CJB) fuse(s): 34 (10A). 27 (15A). Brake pedal position (BPP) switch. Deactivator switch. Speed control switch. Anti-lock brake control module. Powertrain control module (PCM). GO to Pinpoint Test A. The set speed fluctuates GO to Pinpoint Test B.

3 3//2011 The speed control does not disengage when the brakes are applied The speed control does not disengage when the clutch is applied (Super Duty only) The speed control switch is inoperative Flash with last switch pressed and dynamic pull occurs at throttle Flash with last switch pressed, but no dynamic pull occurs at throttle and speed control inoperative Flash code 2 brake pedal position switch circuit failure Anti-lock brake control module. Powertrain control module (PCM). Loose fit or binding between speed control cable and throttle body. Engine controls. Central junction box (CJB) fuse 34 (10A). Brake pedal position (BPP) switch. Deactivator switch. Binding speed control cable. Clutch pedal position (CPP) switch or jumper. Clutch pedal position (CPP) switch. Speed control switch. Speed control cable. Brake pedal position (BPP) switch. Clutch pedal position (CPP) switch or jumper (Super Duty only). Flash code 3 deactivator switch circuit failure Central junction box (CJB) fuse 34 (10A). Deactivator switch. Flash with last switch pressed, dynamic pull occurs at throttle and speed control inoperative The speed control indicator lamp is always on Flash code 4 speed signal circuit failure Anti-lock brake control module. Powertrain control module (PCM). Bulb. Instrument cluster. Anti-lock brake control module. REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual. REPAIR engine as necessary. GO to Pinpoint Test C. GO to Pinpoint Test D. GO to Pinpoint Test E. Test passed. GO to Pinpoint Test F. GO to Pinpoint Test G. GO to Pinpoint Test H. GO to Pinpoint Test I. GO to Pinpoint Test J. GO to Pinpoint Test I. Pinpoint Tests PINPOINT TEST A: THE SPEED CONTROL IS INOPERATIVE NOTE: It is important to use a voltage drop test on some of the tests where specified. Circuits may indicate a good voltage and continuity but may not be capable of carrying sufficient current. A1 CHECK THE SPEED CONTROL CABLE ATTACHMENT TO THE THROTTLE Remove the accelerator control splash shield. Inspect the speed control cable attachment. Check the speed control cable by pulling on the cable and noting the throttle movement. Is the speed control cable OK? A2 CHECK THE VOLTAGE TO THE SPEED CONTROL SERVO Disconnect: Speed Control Servo C122. Measure the voltage between the speed control servo C122 pin 7, circuit 295 (LB/PK), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. GO to A2. REPAIR/RE-ATTACH the speed control cable. TEST the system for normal GO to A3. GO to A4. Is the voltage greater than 10 volts? A3 CHECK THE VOLTAGE DROP ON CIRCUIT 295 (LB/PK) Connect: Speed Control Actuator C122. Measure the voltage drop on the speed control actuator C122-7, circuit 295 (LB/PK). GO to A5.

4 3//2011 Is the voltage drop less than 0.3 volts? A4 CHECK THE SPEED CONTROL SERVO GROUND CIRCUIT 57 (BK) Measure the resistance between the speed control servo C122 pin 10, circuit 57 (BK), harness side and ground. REPAIR the circuit. REPEAT the self-test. REPAIR circuit 295 (LB/PK). TEST the system for normal REPAIR circuit 57 (BK). TEST the system for normal A5 CHECK FOR BRAKE PEDAL POSITION (BPP) SWITCH INPUT WITH NO BRAKES APPLIED Measure the voltage between the speed control servo C122 pin 4, circuit 306 (TN/LB) (Super Duty), circuit 810 (RD/LG) (Excursion), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. GO to A25. GO to A6. Is any voltage present? A6 CHECK THE BRAKE/CLUTCH CIRCUIT Measure the resistance between the speed control servo C122 pin 4, circuit 306 (TN/LB) (Super Duty), circuit 810 (RD/LG) (Excursion), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. GO to A7. GO to A18. A7 CHECK THE DEACTIVATOR SWITCH INPUT TO SPEED CONTROL SERVO Measure the voltage between the speed control servo C122 pin 9, circuit 307 (BK/YE), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. GO to A8. GO to A9. Is the voltage greater than 10 volts? A8 CHECK THE VOLTAGE DROP ON CIRCUIT 307 (BK/YE) Connect: Speed Control Actuator C122. Measure the voltage drop on the speed control actuator C122-9, circuit 307 (BK/YE). Is the voltage drop less than 0.3 volts? A9 CHECK THE DEACTIVATOR SWITCH Disconnect: Deactivator Switch C1025. Measure the resistance between the deactivator switch pins (component side). GO to A11. REPAIR the circuit. REPEAT the self-test. GO to A10. INSTALL a new deactivator switch. REFER to Speed Control Deactivator Switch in this section. TEST the system for normal

5 3//2011 A10 CHECK DEACTIVATOR SWITCH POWER Measure the voltage between the deactivator switch, harness side and ground. REPAIR circuit 307 (BK/YE). TEST the system for normal REPAIR circuit 10 (LG/RD) or circuit 22 (LB/BK). TEST the system for normal Is the voltage greater than 10 volts? A11 CHECK FOR STUCK SPEED CONTROL SWITCH Measure the voltage between the speed control servo C122 pin 5, circuit 151 (LB/BK), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. GO to A20. GO to A12. Is any voltage present? A12 CHECK THE SPEED CONTROL SWITCH OPERATION Measure the voltage between the speed control servo C122 pin 5, circuit 151 (LB/BK), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side, while pressing the speed control switch in the ON position. GO to A15. GO to A13. Is the voltage greater than 10 volts? A13 CHECK CIRCUIT 151 (LB/BK) FOR AN OPEN Disconnect: Clockspring C218a. Measure the resistance between the speed control servo C122 pin 5, circuit 151 (LB/BK), harness side and the clockspring C218a pin 1, circuit 151 (LB/BK) (6 pin) harness side. GO to A14. REPAIR the circuit. TEST the system for normal A14 CHECK THE CLOCKSPRING FOR AN OPEN Remove the driver air bag (if equipped). Refer to Section B. Measure the resistance between the clockspring C218a pin 1 (component side), and the top of clockspring pin 5 (5 pin) (component side). INSTALL a new speed control switch. REFER to Speed Control Servo Switch in this section. INSTALL the driver air bag. REFER to

6 3//2011 Section B. TEST the system for normal INSTALL a new clockspring. REFER to Section B. INSTALL the driver air bag. REFER to Section B. TEST the system for normal Is the resistance less than 1 ohm? A15 CHECK THE SET/ACCEL SWITCH Measure the resistance between the speed control servo C122 pin 5, circuit 151 (LB/BK), harness side and the speed control servo C122 pin 6, circuit 848 (DG/OG), harness side, while pressing the speed control switch SET/ACCEL. GO to A. GO to A16. Is the resistance between 646 and 714 ohms? A16 CHECK CIRCUIT 848 (DG/OG) FOR AN OPEN Measure the resistance between the speed control servo C122 pin 6, circuit 848 (DG/OG), harness side and the clockspring C218a pin 4, circuit 848 (DG/OG) harness side. INSTALL a new speed control switch. REFER to Speed Control Servo Switch in this section. TEST the system for normal REPAIR the circuit. TEST the system for normal A CHECK THE SPEEDOMETER Check the speedometer for correct operation by driving the vehicle. Does the speedometer operate correctly? A18 CHECK CIRCUIT 676 (PK/OG) (MOTORHOME 1203 [BK/BU]) FOR AN OPEN Disconnect: Brake Pedal Position (BPP) Switch C278. Measure the resistance between the BPP switch C278 pin 1, circuit 676 (PK/OG), harness side and ground. GO to A26. REFER to Section GO to A19. REPAIR circuit 676 (PK/OG). TEST the system for normal A19 CHECK THE BRAKE PEDAL POSITION (BPP) SWITCH Remove the BPP switch. Refer to Section Carry out the BPP switch component test. Refer to the Component Test in this section. Is the BPP switch OK? If Excursion, REPAIR circuit 810 (RD/LG) or circuit 306 (TN/LB). TEST the system for normal If Super Duty, GO to A22. A20 CHECK THE SPEED CONTROL SWITCH Remove the driver air bag. Refer to Section B. Connect: Restraint System Diagnostic Tool 418-F088 (105-R0012) or Equivalent. INSTALL a new BPP switch. TEST the system for normal GO to A21.

7 3//2011 Connect the battery. Refer to Section Disconnect: Speed Control Switches. Measure the voltage between the speed control servo C122 pin 5, circuit 151 (LB/BK), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. INSTALL a new speed control switch. REFER to Speed Control Servo Switch in this section. DISCONNECT the battery. REFER to Section INSTALL the driver air bag. REFER to Section B. TEST the system for normal Is voltage present? A21 CHECK CIRCUIT 151 (LB/BK) FOR SHORT TO POWER Disconnect: Clockspring C218a. Measure the voltage between the speed control servo C122 pin 5, circuit 151 (LB/BK), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. INSTALL a new clockspring. REFER to Section B. DISCONNECT the battery. REFER to Section INSTALL the driver air bag. REFER to Section B. TEST the system for normal REPAIR the circuit. DISCONNECT the battery. REFER to Section INSTALL the driver air bag. REFER to Section B. TEST the system for normal Is voltage present? A22 CHECK CIRCUIT 810 (RD/LG) FOR AN OPEN Disconnect: Clutch Pedal Position (CPP) Switch C257. Measure the resistance between the BPP switch C278 pin 2, circuit 810 (RD/LG), harness side and the CPP switch C257 pin 4, circuit 810 (RD/LG), harness side. GO to A23. REPAIR the circuit. TEST the system for normal A23 CHECK CIRCUIT 306 (TN/LB) FOR AN OPEN Measure the resistance between the CPP switch C257 pin 3, circuit 306 (TN/LB), harness side and the speed control servo C122 pin 4, circuit 306 (TN/LB), harness side. GO to A24. REPAIR the circuit. TEST the system for normal A24 CHECK THE CLUTCH PEDAL POSITION (CPP) SWITCH Measure the resistance between the CPP switch (component side) or jumper pin 3 (component side) and the CPP switch (component side) or jumper pin 4 (component side). System is OK. TEST the system for normal INSTALL a new CPP switch or jumper. TEST the system for normal

8 3//2011 A25 CHECK BRAKE PEDAL POSITION (BPP) SWITCH INPUT CIRCUITRY FOR SHORT TO POWER Disconnect: BPP Switch C278. Measure the voltage between the speed control servo C122 pin 4, circuit 306 (TN/LB) (Super Duty), circuit 810 (RD/LG) (Excursion), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. If Excursion, REPAIR circuit 306 (TN/LB) and circuit 810 (RD/LG) as necessary. TEST the system for normal If Super Duty, GO to A30. INSTALL a new BPP switch. REFER to Section TEST the system for normal Is voltage present? A26 CHECK THE VEHICLE SPEED SIGNAL VOLTAGE CAUTION: Make sure the vehicle is secured correctly before attempting to place the transmission range selector lever in DRIVE (D) or in first gear if equipped with a manual transmission. Connect: Speed Control Deactivator Switch C277. Connect: Clockspring C218a. Jack up the drive wheels and chock the other wheels. NOTE: For vehicles with a manual transmission, place the transmission into first gear. Start the vehicle, place the transmission in DRIVE (D), and with the engine at idle, allow the drive wheels to spin. Measure and record the AC voltage between the speed control actuator C122-3, circuit 679 (GY/BK), harness side and ground with the vehicle drive wheels spinning a minimum of 8 km/h (5 mph) and the speedometer registers a speed. GO to A27. GO to A28. Apply the brakes until the drive wheels come to a stop. Place the transmission in PARK (P), fully engage the parking brake and turn the engine off. Is the AC voltage greater than 4.5 volts? A27 CHECK THE VEHICLE SPEED SIGNAL FREQUENCY CAUTION: Make sure the vehicle is secured correctly before attempting to place the transmission range selector lever in DRIVE (D), or in first gear if equipped with a manual transmission. NOTE: For vehicles with a manual transmission, place the transmission into first gear. Start the vehicle, place the transmission in DRIVE (D), and with the engine at idle, allow the drive wheels to spin. Measure and record the frequency between the speed control actuator C122-3, circuit 679 (GY/BK), harness side and ground with the vehicle drive wheels spinning a minimum of 8 km/h (5 mph) and the speedometer registers a speed. Record the speedometer reading. INSTALL a new speed control actuator. REPEAT the self-test. GO to A32. Apply the brakes until the drive wheels come to a stop. Place the transmission in PARK (P), fully engage the parking brake and turn the engine off. Divide the frequency reading by 2.2 to get a mph result and compare this to the reading of the

9 3//2011 speedometer. Does the frequency reading result match the speedometer reading? A28 CHECK THE SPEED CIRCUITRY FOR AN OPEN Disconnect: Anti-lock Brake Control Module C1040a. Measure the resistance between the speed control servo C122 pin 3, circuit 679 (GY/BK), harness side and the anti-lock brake control module C104a pin 16, circuit 679 (GY/BK), harness side. GO to A29. REPAIR the circuit. TEST the system for normal A29 CHECK THE SPEED CONTROL INDICATOR CIRCUITRY FOR AN OPEN Disconnect: Anti-lock Brake Control Module C1040a. Connect a fused (10A) jumper wire between the speed control servo C122 pin 1, circuit 203 (OG/LB), harness side and ground, while observing the speed control indicator. INSTALL a new speed control servo. REFER to Speed Control Servo in this section. TEST the system for normal REFER to Section Is the speed control indicator illuminated? A30 CHECK THE CIRCUIT 306 (TN/LB) FOR SHORT TO POWER Disconnect: Clutch Pedal Position (CPP) Switch C257. Measure the voltage between the speed control servo C122 pin 4, circuit 306 (TN/LB) (Super Duty), circuit 810 (RD/LG) (Excursion), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. REPAIR circuit 306 (TN/LB). TEST the system for normal GO to A31. Is voltage present? A31 CHECK CIRCUIT 810 (RD/LG) FOR SHORT TO POWER Measure the voltage between the CPP switch or jumper C261 pin 3, circuit 810 (RD/LG), harness side and ground. REPAIR circuit 810 (RD/LG). TEST the system for normal INSTALL a new CPP switch or jumper. TEST the system for normal Is voltage present? A32 CHECK FOR CORRECT ANTI-LOCK BRAKE SYSTEM (ABS) MODULE OPERATION Disconnect the ABS module connector. Check for: corrosion damaged pins pushed-out pins Connect the ABS module connector and make sure it seats correctly. Operate the system and verify the concern is still present. Is the concern still presents? INSTALL a new ABS module. REFER to Section REPEAT the self-test. The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector.

10 3//2011 PINPOINT TEST B: THE SET SPEED FLUCTUATES B1 CHECK SPEED CONTROL CABLE/THROTTLE BODY LINKAGE Remove the speed control cable from the speed control servo. Visually inspect the core wire and check the speed control cable by pulling on the cable and noting the throttle movement. Is the speed control cable OK? B2 CHECK THE SPEEDOMETER Check the speedometer for correct operation by driving the vehicle. Does the speedometer fluctuate? B3 CHECK THE VEHICLE SPEED SIGNAL VOLTAGE CAUTION: Make sure the vehicle is secured correctly before attempting to place the transmission range selector lever in DRIVE (D), or in first gear if equipped with a manual transmission. Disconnect: Speed Control Actuator C122. Jack up the drive wheels and chock the other wheels. NOTE: For vehicles with a manual transmission, place the transmission into first gear. Start the vehicle, place the transmission in DRIVE (D), and with the engine at idle, allow the drive wheels to spin. Measure and record the AC voltage between the speed control actuator C122-3, circuit 679 (GY/BK), harness side and ground with the vehicle drive wheels spinning a minimum of 8 km/h (5 mph) and the speedometer registers a speed. GO to B2. INSTALL a new speed control cable or REPAIR the throttle body linkage. REFER to Section TEST the system for normal REFER to Section GO to B3 GO to B4. GO to B5. Apply the brakes until the drive wheels come to a stop. Place the transmission in PARK (P), fully engage the parking brake and turn the engine off. Is the AC voltage greater than 4.5 volts? B4 CHECK THE VEHICLE SPEED SIGNAL FREQUENCY CAUTION: Make sure the vehicle is secured correctly before attempting to place the transmission range selector lever in DRIVE (D), or in first gear if equipped with a manual transmission. NOTE: For vehicles with a manual transmission, place the transmission into first gear. Start the vehicle, place the transmission in DRIVE (D), and with the engine at idle, allow the drive wheels to spin. Measure and record the frequency between the speed control actuator C122-3, circuit 679 (GY/BK), harness side and ground with the vehicle drive wheels spinning a minimum of 8 km/h (5 mph) and the speedometer registers a speed. Record the speedometer reading. INSTALL a new speed control actuator. TEST the system for normal GO to B5. Apply the brakes until the drive wheels come to a stop. Place the transmission in PARK (P), fully engage the parking brake and turn the engine off. Divide the frequency reading by 2.2 to get a mph result and compare this to the reading of the speedometer. Does the frequency reading result match the speedometer reading? B5 CHECK FOR CORRECT ANTI-LOCK BRAKE SYSTEM (ABS) MODULE OPERATION Disconnect the ABS module connector. Check for: corrosion damaged pins pushed-out pins Connect the ABS module connector and make sure it seats correctly. Operate the system and verify the concern is still present. Is the concern still presents? INSTALL a new ABS module. REFER to Section TEST the system for normal The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. PINPOINT TEST C: THE SPEED CONTROL DOES NOT DISENGAGE WHEN THE BRAKES ARE APPLIED C1 MONITOR THE THROTTLE POSITION SENSOR PID Enter the following diagnostic mode on the scan tool: PCM Throttle Position Sensor (TPS) PID. With the vehicle speed above 48 km/h (30 mph) engage the speed control. Monitor the PCM throttle position sensor PID while applying the brake pedal. Does the PCM TPS PID return to base voltage when the brake pedal is applied? The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. TEST the system for normal

11 3//2011 C2 CHECK THE BRAKE PEDAL POSITION (BPP) SWITCH OPERATION Disconnect: Speed Control Servo C122. Measure the voltage between the speed control servo C122 pin 4, circuit 306 (TN/LB) (Super Duty), circuit 810 (RD/LG) (Excursion), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side, while pressing and releasing the brake pedal. GO to C2. GO to C8. GO to C3. Is the voltage greater than 10 volts with the brake pedal pressed and 0 volts with the brake pedal released? C3 CHECK CIRCUIT 22 (LB/BK) FOR AN OPEN Disconnect: Brake Pedal Position (BPP) Switch C278. Measure the voltage between the BPP switch C278 pin 3, circuit 22 (LB/BK), harness side and ground. If Super Duty, GO to C4. If not Super Duty, GO to C7. REPAIR the circuit. TEST the system for normal Is the voltage greater than 10 volts? C4 CHECK CIRCUIT 810 (RD/LG) FOR AN OPEN Disconnect: Clutch Pedal Position (CPP) Switch C257. Measure the resistance between the BPP switch C278 pin 2, circuit 810 (RD/LG), harness side and the CPP switch C257 pin 3, 810 circuit (RD/LG), harness side. GO to C5. REPAIR the circuit. TEST the system for normal C5 CHECK CIRCUIT 306 (TN/LB) FOR AN OPEN Measure the resistance between the CPP switch C257 pin 4, circuit 306 (TN/LB) (Super Duty), circuit 810 (RD/LG) (Excursion), harness side and the speed control servo C122 pin 4, circuit 306 (TN/LB) (Super Duty), circuit 810 (RD/LG) (Excursion), harness side. GO to C6. REPAIR the circuit. TEST the system for normal C6 CHECK THE CLUTCH PEDAL POSITION (CPP) SWITCH Measure the resistance between the CPP switch pin 3 (component side) and the CPP switch pin 4 (component side). INSTALL a new BPP switch. REFER to Section TEST the system for normal INSTALL a new CPP switch or jumper. TEST the system for normal

12 3//2011 C7 CHECK CIRCUIT 810 (RD/LG) FOR AN OPEN (EXCEPT SUPER DUTY) Measure the resistance between the speed control servo C122 pin 4, circuit 810 (RD/LG) (Excursion pin 4, circuit 306 [TN/LB]), harness side and the BPP switch C278 pin 2, circuit 810 (RD/LG), harness side. INSTALL a new BPP switch. REFER to Section TEST the system for normal REPAIR the circuit. TEST the system for normal C8 CHECK THE DEACTIVATOR SWITCH CIRCUITRY Measure the voltage between the speed control servo C122 pin 9, circuit 307 (BK/YE), harness side and ground, while firmly pressing and releasing the brake pedal. INSTALL a new speed control servo. REFER to Speed Control Servo in this section. TEST the system for normal GO to C9. Is the voltage 0 volts with the brake pedal firmly pressed, and greater than 10 volts with the brake pedal released? C9 CHECK THE DEACTIVATOR SWITCH Disconnect: Deactivator Switch C1025. Measure the resistance between the deactivator switch pins (component side) while firmly pressing and releasing the brake pedal. GO to C10. INSTALL a new deactivator switch. REFER to Speed Control Deactivator Switch in this section. TEST the system for normal Is the resistance greater than 10,000 ohms with the brake pedal firmly pressed, and less than 5 ohms with the brake pedal released? C10 CHECK CIRCUIT 307 (BK/YE) FOR AN OPEN Measure the resistance between the speed control servo C122 pin 9, circuit 307 (BK/YE), harness side and the deactivator switch C1025, circuit 307 (BK/YE), harness side. REPAIR circuit 10 (LG/RD). TEST the system for normal REPAIR circuit 307 (BK/YE). TEST the system for normal PINPOINT TEST D: THE SPEED CONTROL DOES NOT DISENGAGE WHEN THE CLUTCH IS APPLIED

13 3//2011 D1 MONITOR THE THROTTLE POSITION SENSOR PID Enter the following diagnostic mode on the scan tool: PCM Throttle Position Sensor (TPS) PID. With the vehicle speed above 48 km/h (30 mph) engage the speed control. Monitor the PCM throttle position sensor PID while pressing the clutch pedal. Does the PCM TPS PID return to base voltage when the clutch pedal is depressed? D2 CHECK THE CLUTCH PEDAL POSITION (CPP) SWITCH CIRCUIT Disconnect: Speed Control Servo C122. Measure the resistance between the speed control servo C122 pin 4, circuit 306 (TN/LB) (Super Duty) 810 (RD/LG) (Excursion), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. The system is operating correctly at this time. The concern may have been caused by a loose or corroded connector. TEST the system for normal GO to D2. GO to D3. GO to Pinpoint Test A. D3 CHECK THE CLUTCH SWITCH OPERATION Measure the resistance between the speed control servo C122 pin 4, circuit 306 (TN/LB) (Super Duty) circuit 810 (RD/LG) (Excursion), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side, while pressing the clutch pedal. INSTALL a new speed control servo. REFER to Speed Control Servo in this section. TEST the system for normal INSTALL a new CPP switch. TEST the system for normal Is the resistance greater than 10,000 ohms? PINPOINT TEST E: THE SPEED CONTROL SWITCH IS INOPERATIVE E1 CHECK THE SPEED CONTROL SWITCH OPERATION Disconnect: Speed Control Servo C122. INSTALL a new speed control servo. REFER to Measure the resistance between the speed control servo C122 pin 5, circuit 151 (LB/BK), harness side and the speed Speed Control Servo in his section. TEST the system control servo C122 pin 6, circuit 848 (DG/OG), harness side, while pressing the speed control switch as follows: for normal Speed Control Switch Resistance Value Coast Between 114 and 126 ohms SET/ACCEL Between 646 and 714 ohms Resume Between 2,090 and 2,310 ohms Off Less than 5 ohms INSTALL a new speed control switch. REFER to Speed Control Servo Switch in this section. TEST the system for normal Are the speed control switch resistance values OK? PINPOINT TEST F: FLASH WITH LAST SWITCH PRESSED, BUT NO DYNAMIC PULL OCCURS AT THROTTLE AND SPEED CONTROL INOPERATIVE F1 CHECK THE SPEED CONTROL CABLE Check the speed control cable for correct attachment at the speed control

14 3//2011 servo and throttle body. Is the speed control cable attached correctly? F2 CHECK FOR A STICKING OR BINDING SPEED CONTROL CABLE Check the speed control cable for sticking or binding. Is the speed control cable OK? GO to F2. RECONNECT the speed control cable. REPEAT the self-test. INSTALL a new speed control servo. REFER to Speed Control Servo in this section. REPEAT the self-test. REPAIR or INSTALL a new speed control cable. REFER to Speed Control Cable in this section. REPEAT the self-test. PINPOINT TEST G: FLASH CODE 2 BRAKE PEDAL POSITION SWITCH CIRCUIT FAILURE G1 CHECK STOPLAMP OPERATION Press and release the brake pedal while observing the stoplamps. Do the stoplamps operate correctly? G2 CHECK CIRCUIT 810 (RD/LG) FOR AN OPEN Disconnect: Speed Control Servo C122. Measure the voltage between the speed control servo C122 pin 4, circuit 810 (RD/LG), (circuit 306 [TN/LB] Super Duty), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side; while pressing the brake pedal. GO to G2. REFER to Section GO to G3. GO to G5. Is the voltage greater than 10 volts? G3 CHECK THE BRAKE CIRCUIT Measure the resistance between the speed control servo C122 pin 4, circuit 306 (TN/LB) (Super Duty), circuit 810 (RD/LG) (Excursion), harness side and the speed control servo C122 pin 10, circuit 57 (BK) harness side. INSTALL a new speed control servo. REFER to Speed Control Servo in this section. REPEAT the self-test. GO to G4. G4 CHECK CIRCUIT 676 (PK/OG) FOR AN OPEN Disconnect: Brake Pedal Position (BPP) Switch C278. Measure the resistance between the BPP switch C278 pin 1, circuit 676 (PK/OG), harness side and ground. INSTALL a new BPP switch. REFER to Section TEST the system for normal REPAIR the circuit. TEST the system for normal G5 CHECK THE BRAKE PEDAL POSITION (BPP) SWITCH Remove the BPP switch. Refer to Section Carry out the BPP switch component test. Refer to the Component Test in this section. Is the BPP switch OK? If Excursion, REPAIR circuit 810 (RD/LG) or circuit 306 (TN/LB). TEST the system for normal If Super Duty, GO to G6. G6 CHECK THE CPP SWITCH OR JUMPER FOR AN OPEN INSTALL a new BPP switch. TEST the system for normal

15 3//2011 Disconnect: CPP Switch C257. Measure the resistance between the CPP switch pin 4 (component side) and the CPP switch pin 3 (component side). GO to G7. INSTALL a new CPP switch. TEST the system for normal G7 CHECK CIRCUIT 306 (TN/LB) FOR AN OPEN Measure the resistance between the speed control servo C122 pin 4, circuit 306 (TN/LB) (Super Duty), circuit 810 (RD/LG) (Excursion), harness side and the CPP switch C257, circuit 306 (TN/LB), harness side. GO to G8. REPAIR circuit 306 (TN/LB). TEST the system for normal G8 CHECK CIRCUIT 810 (RD/LG) FOR AN OPEN Measure the resistance between the BPP switch C278 pin 2, circuit 810 (RD/LG), harness side and the CPP switch or jumper C257 pin 3, circuit 810 (RD/LG), harness side. INSTALL a new speed control servo. REFER to Speed Control Servo in this section. REPEAT the self-test. REPAIR circuit 306 (TN/LB). TEST the system for normal PINPOINT TEST H: FLASH CODE 3 DEACTIVATOR SWITCH CIRCUIT FAILURE H1 CHECK THE DEACTIVATOR SWITCH CIRCUITRY Disconnect: Speed Control Servo C122. Measure the voltage between the speed control servo C122 pin 9, circuit 307 (BK/YE), harness side and the speed control servo C122 pin 10, circuit 57 (BK), harness side. GO to H2. GO to H3. Is the voltage greater than 10 volts? H2 CHECK THE VOLTAGE DROP ON CIRCUIT 307 (BK/YE) Connect: Speed Control Actuator C122. Measure the voltage drop on the speed control actuator C122-7, circuit 810 (RD/LG). Is the voltage drop less than 0.3 volts? H3 CHECK DEACTIVATOR SWITCH POWER Disconnect: Deactivator Switch C1025. Measure the voltage between the deactivator switch C1025, circuit 10 (LG/RD), harness side and ground. INSTALL a new speed control actuator. TEST the system for normal REPAIR the circuit. REPEAT the self-test. GO to H4.

16 3//2011 REPAIR the circuit. REPEAT the self-test. Is the voltage greater than 10 volts? H4 CHECK CIRCUIT 307 (BK/YE) FOR AN OPEN Measure the resistance between the speed control servo C122 pin 9, circuit 307 (BK/YE), harness side and the deactivator switch C1025, circuit 307 (BK/YE), harness side. GO to H5. REPAIR the circuit. REPEAT the self-test. H5 CHECK THE DEACTIVATOR SWITCH Measure the resistance between the deactivator switch pins (component side). INSTALL a new speed control servo. REFER to Speed Control Servo in this section. REPEAT the self-test. INSTALL a new deactivator switch. REFER to Speed Control Deactivator Switch in this section. REPEAT the self-test. PINPOINT TEST I: FLASH WITH LAST SWITCH PRESSED, DYNAMIC PULL OCCURS AT THROTTLE AND SPEED CONTROL INOPERATIVE I1 CHECK THE SPEEDOMETER OPERATION Check the speedometer for correct operation by driving the vehicle. Does the speedometer operate correctly? GO to I2. I2 CHECK CIRCUIT 679 (GY/BK) FOR AN OPEN Disconnect: Speed Control Servo C122. Disconnect: Anti-lock Brake Control Module C1040a. Measure the resistance between the speed control servo C122 pin 3, circuit 679 (GY/BK), harness side and the anti-lock brake control module C104a, circuit 679 (GY/BK), harness side. REFER to Section INSTALL a new speed control servo. REFER to Speed Control Servo in this section. REPEAT the self-test. REPAIR the circuit. REPEAT the self-test. PINPOINT TEST J: THE SPEED CONTROL INDICATOR LAMP IS ALWAYS ON J1 CHECK THE SPEED CONTROL SERVO Disconnect: Speed Control Servo C122. GO to J2.

17 3//2011 Check the speed control indicator lamp. Is the speed control indicator lamp always on? J2 CHECK CIRCUIT 203 (OG/LB) FOR A SHORT TO GROUND Disconnect: Instrument Cluster C220b. Measure the resistance between the speed control servo C122 pin 1, circuit 203 (OG/LB), harness side and ground. INSTALL a new speed control servo. REFER to Speed Control Servo in this section. TEST the system for normal INSTALL a new instrument cluster. REFER to Section TEST the system for normal REPAIR the circuit. TEST the system for normal Is the resistance greater than 10,000 ohms? Component Test Brake Pedal Position (BPP) Switch Use the 73III Automotive Meter or equivalent to check the continuity between the given terminals of the BPP switch C279, component side, using the following table. Pin Circuit Pin Circuit Resistance (Ohms) Position 1 (Brake Pedal Released Position) (PK/OG) or 1203 (BK/LB) Motorhome (RD/LG) Less than (LB/BK) (RD/LG) Greater than 10, (LG/RD) (LG) Greater than 10,000 Position 2 (Brake Pedal Pressed Position) (PK/OG) or 1203 (BK/LB) Motorhome (RD/LG) Greater than 10, (LB/BK) (RD/LG) Less than (LG/RD) (LG) Less than 5 If the resistance is as specified, return to the pinpoint test. Otherwise, install a new BPP switch.

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