1999-2010 Ford F-250 F-350 Service & Repair Manual

1999 ACCESSORIES & EQUIPMENT Cruise Control Systems - F250-F550 Super Duty Pickups DESCRIPTION Cruise control system consists of speed control switches (ON, OFF, SET/ACCEL, COAST and RESUME), speed control servo/actuator assembly, brake pedal position switch, clutch pedal position switch, deactivator switch (brake pressure switch) and related wiring. OPERATION ENGAGING & DISENGAGING SYSTEM System is operational at speeds greater than 30 MPH. When ON and SET/ACCEL switches have been pressed, vehicle speed will be maintained until new speed is set, brake or clutch pedal is depressed, or OFF switch is pressed. To increase or decrease set speed, hold SET/ACCEL or COAST switch until desired speed is reached, then release switch. Tap SET/ACCEL or COAST switch for one MPH incremental increase or decrease in speed. ADJUSTMENTS ACTUATOR CABLE Adjustment procedure not available from manufacturer. If there is a problem with high idle due to not enough NOTE: This article includes Cab & Chassis. WARNING: Vehicles are equipped with air bag supplemental restraint system. Before attempting any repairs involving steering column, instrument panel or related components, see SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM in FORD MOTOR CO. - AIR BAG RESTRAINT SYSTEMS article. CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES -- FORD MOTOR CO. article in GENERAL INFORMATION before disconnecting battery. NOTE: On 7.3L diesel, all speed control functions are controlled by the Powertrain Control Module (PCM). See SELF - DIAGNOSTICS -- 7.3L DIESEL article in ENGINE PERFORMANCE for diagnostic procedures. For diesel engine cruise control system wiring diagrams, see WIRING DIAGRAMS .

length in actuator cable, check for proper cable installation. See ACTUATOR CABLE under REMOVAL & INSTALLATION. TROUBLE SHOOTING Perform complete visual inspection of system. Repair as necessary. Ensure speedometer and horn are operating properly. If there are any problems with speedometer or horn, repair those first. See appropriate ANALOG INSTRUMENT PANELS article and/or STEERING COLUMN SWITCHES article. If Malfunction Indicator Light (MIL) is lit or flashes, check Powertrain Control Module (PCM) for stored Diagnostic Trouble Codes (DTCs). See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE for diagnostic procedures. SYSTEM TESTS SPEED CONTROL SERVO/ACTUATOR ASSEMBLY CONNECTOR TERMINAL IDENTIFICATION The following test procedures reference various terminals on speed control servo/actuator assembly connector. For terminal number, circuit description and wire color, see SPEED CONTROL SERVO/ACTUATOR ASSEMBLY CONNECTOR TERMINAL IDENTIFICATION table. See Fig. 1 . SPEED CONTROL SERVO/ACTUATOR ASSEMBLY CONNECTOR TERMINAL IDENTIFICATION WARNING: Deactivate air bag system before performing any service operation involving steering column components. See appropriate AIR BAG RESTRAINT SYSTEMS article. Do not apply electrical power to any component on steering column without first deactivating air bag system. Air bag may deploy. CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. Terminal No. Circuit Description Wire Color 1 Not Used Not Used 2 Not Used Not Used 3 Vehicle Speed Input GRY/BLK 4 Brake/Clutch Position Switch Input TAN/LT BLU 5 Speed Control Switch Input LT BLU/BLK 6 Speed Control Switch Return DK GRN/ORG 7 Vehicle Power LT BLU/PNK 8 Not Used Not Used

Fig. 1: Identifying Speed Control Servo/Actuator Assembly Connector Terminals SPEED CONTROL INOPERATIVE 1. Turn ignition switch to LOCK position. Remove accelerator control splash shield. Inspect speed control actuator cable attachment. Pull on actuator cable and note throttle movement. If actuator cable is okay, go to next step. If cable is not okay, reattach or replace actuator cable. See ACTUATOR CABLE under REMOVAL & INSTALLATION. 2. Disconnect speed control servo/actuator assembly 10-pin connector located at right side of engine compartment near starter motor relay. Turn ignition switch to RUN position. Measure voltage between speed control servo/actuator assembly connector terminals No. 7 (Light Blue/Pink wire) and No. 10 (Black wire). See Fig. 1 . If battery voltage does not exist, go to next step. If battery voltage exists, go to step 5 . 3. Turn ignition switch to LOCK position. Check fuse junction panel fuse No. 28 (10-amp). If fuse is okay, go to next step. If fuse is blown, replace fuse. Test system. If fuse blows again, repair short to ground in Light Blue/Pink wire. 4. Measure resistance between speed control servo/actuator assembly connector terminal No. 10 (Black wire) and ground. See Fig. 1 . If resistance is less than 5 ohms, repair open in Light Blue/Pink wire. If resistance is 5 ohms or more, repair open in Black wire. 5. Turn ignition switch to LOCK position. Measure voltage between speed control servo/actuator assembly connector terminals No. 4 (Tan/Light Blue wire) and No. 10 (Black wire). See Fig. 1 . If battery voltage exists, replace brake pedal position switch. If battery voltage does not exist, go to next step. 6. Measure resistance between speed control servo/actuator assembly connector terminals No. 4 (Tan/Light Blue wire) and No. 10 (Black wire). If resistance is less than 5 ohms, go to next step. If resistance is 5 9 Brake Pressure Input BLK/YEL 10 Ground BLK NOTE: Ensure horn operates properly before performing this test. Repair as necessary. See WIRING DIAGRAMS in appropriate STEERING COLUMN SWITCHES article.

ohms or more, go to step 16 . 7. Measure voltage between speed control servo/actuator assembly connector terminals No. 9 (Black/Yellow wire) and No. 10 (Black wire). If battery voltage exists, go to step 10 . If battery voltage does not exist, go to next step. 8. Disconnect deactivator switch (brake pressure switch) 2-pin connector located at brake master cylinder. Measure resistance between switch terminals. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, replace switch. 9. Measure voltage between deactivator switch connector Light Green/Red wire terminal and ground. If battery voltage exists, repair open in Black/Yellow wire. If battery voltage does not exist, repair open in Light Green/Red wire. See WIRING DIAGRAMS . 10. Measure voltage between speed control servo/actuator assembly connector terminals No. 5 (Light Blue/Black wire) and No. 10 (Black wire). See Fig. 1 . If battery voltage exists, go to step 17 . If battery voltage does not exist, go to next step. 11. Measure voltage between speed control servo/actuator assembly harness connector terminals No. 5 (Light Blue/Black wire) and No. 10 (Black wire) while pressing speed control actuator ON switch. If battery voltage exists, go to step 14 . If battery voltage does not exist, go to next step. 12. Disconnect speed control/horn switch assembly 6-pin connector in steering wheel. Measure resistance in Light Blue/Black wire between speed control servo/actuator assembly connector terminal No. 5 and speed control/horn switch assembly connector terminal No. 1. See Fig. 1 and Fig. 2 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Light Blue/Black wire. 13. Remove driver's air bag. See appropriate AIR BAG RESTRAINT article. Disconnect speed control switches connector. Measure resistance between speed control/horn clockspring connector terminal No. 1 and top of speed control/horn clockspring terminal No. 5. See Fig. 3 . If resistance is less than one ohm, replace speed control actuator switch. See SPEED CONTROL SWITCHES under REMOVAL & INSTALLATION. If resistance is one ohm or more, replace speed control/horn clockspring. See CLOCKSPRING under REMOVAL & INSTALLATION. 14. With SET/ACCEL switch pressed, measure resistance between speed control servo/actuator assembly connector terminals No. 5 (Light Blue/Black wire) and No. 6 (Dark Green/Orange wire). See Fig. 1 . If resistance is 612-748 ohms, go to next step. If resistance is not 612-748 ohms, replace speed control actuator switch. See SPEED CONTROL SWITCHES under REMOVAL & INSTALLATION. 15. Drive vehicle and observe speedometer. If speedometer operates properly, repair open in Gray/Black wire. See WIRING DIAGRAMS . If speedometer does not operate properly, repair speedometer as necessary. See appropriate ANALOG INSTRUMENT PANELS article for diagnostic procedures. 16. Disconnect Brake Pedal Position (BPP) switch 5-pin connector. Measure resistance between BPP switch connector Pink/Orange wire terminal and ground. If resistance is less than 5 ohms, go to step 19 . If resistance is 5 ohms or more, repair open in Pink/Orange wire. 17. Turn ignition switch to LOCK position. Disconnect speed control/horn switch assembly 6-pin connector. Turn ignition switch to RUN position. Measure voltage between speed control servo/actuator assembly connector terminals No. 5 (Light Blue/Black wire) and No. 10 (Black wire). See Fig. 1 . If battery voltage exists, go to next step. If battery voltage does not exist, replace speed control actuator switches. See SPEED CONTROL SWITCHES under REMOVAL & INSTALLATION. 18. Turn ignition switch to LOCK position. Disconnect speed control/horn switch assembly 6-pin connector. Turn ignition switch to RUN position. Measure voltage between speed control servo/actuator assembly connector terminals No. 5 (Light Blue/Black wire) and No. 10 (Black wire). If voltage exists, repair short

to power in Light Blue/Black wire. If no voltage exists, replace clockspring. See CLOCKSPRING under REMOVAL & INSTALLATION. 19. Turn ignition switch to RUN position. Measure voltage between BPP switch connector Light Blue/Black wire terminal and ground. If battery voltage exists, go to next step. If battery voltage does not exist, repair open in Light Blue/Black wire. 20. Disconnect Clutch Pedal Position (CPP) switch (M/T) or jumper (A/T) 6-pin connector. Measure resistance of Red/Light Green wire between BPP switch connector and CPP switch (jumper on A/T) connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Red/Light Green wire. 21. Measure resistance of Tan/Light Blue wire between CPP switch (jumper on A/T) connector and speed control servo/actuator assembly connector terminal No. 4. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Tan/Light Blue wire. 22. Measure resistance between CPP switch (jumper on A/T) terminals No. 3 and 4 (center terminals). If resistance is less than 5 ohms, replace BPP switch. If resistance is 5 ohms or more, replace CPP switch or jumper. Fig. 2: Identifying Speed Control/Horn Switch Assembly Connector Terminals (Female Side Shown) Courtesy of FORD MOTOR CO.

Fig. 3: Testing Speed Control/Horn Clockspring Resistance Courtesy of FORD MOTOR CO. SET SPEED FLUCTUATES 1. Turn ignition switch to LOCK position. Remove speed control actuator cable from speed control servo/actuator assembly. Inspect core wire and check actuator cable by pulling on cable and noting throttle movement. If actuator cable is okay, go to next step. If actuator cable is faulty, replace actuator cable and/or repair throttle body linkage as necessary. 2. Drive vehicle and observe speedometer operation. If speedometer fluctuates, repair speedometer as necessary. See appropriate ANALOG INSTRUMENT CLUSTER article for further diagnosis. If speedometer is steady, replace speed control servo/actuator assembly. See SPEED CONTROL SERVO/ACTUATOR ASSEMBLY under REMOVAL & INSTALLATION. CRUISE DOES NOT TURN OFF WHEN BRAKES ARE APPLIED 1. Disconnect speed control servo/actuator assembly 10-pin connector, located at right side of engine compartment near starter motor relay. Measure voltage between speed control servo/actuator assembly connector terminals No. 4 (Tan/Light Blue wire) and No. 10 (Black wire) while pressing and releasing brake pedal. See Fig. 1 . Battery voltage should exist when brake pedal is pressed and no voltage should exist when brake pedal is released. If voltage is as specified, go to step 7 . If voltage is not as specified, go to next step. 2. Check fuse junction panel fuse No. 15 (5-amp). If fuse is okay, go to next step. If fuse is blown, replace fuse. Test system. If fuse blows again, repair short to ground. See WIRING DIAGRAMS .

3. Turn ignition switch to LOCK position. Disconnect Brake Pedal Position (BPP) switch 5-pin connector. Turn ignition switch to RUN position. Measure voltage between BPP switch connector Light Blue/Black wire terminal and ground. If battery voltage exists, go to next step. If battery voltage does not exist, repair open in Light Blue/Black wire. 4. Disconnect Clutch Pedal Position (CPP) switch (M/T) or jumper (A/T) 6-pin connector. Measure resistance of Red/Light Green wire between BPP switch connector and CPP switch (jumper on A/T) connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Red/Light Green wire. 5. Measure resistance of Tan/Light Blue wire between CPP switch (jumper A/T) connector and speed control servo/actuator assembly connector terminal No. 4. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Tan/Light Blue wire. 6. Measure resistance between CPP switch (jumper A/T) terminal No. 3 and 4 (center terminals). If resistance is less than 5 ohms, replace BPP switch. If resistance is 5 ohms or more, replace CPP switch or jumper. 7. Measure voltage between speed control servo/actuator assembly connector terminal No. 9 (Black/Yellow wire) and ground while firmly pressing and releasing brake pedal. See Fig. 1 . No voltage should exist with brake pedal firmly pressed and battery voltage should exist with brake released. If voltage is as specified, replace speed control servo/actuator assembly. See SPEED CONTROL SERVO/ACTUATOR ASSEMBLY under REMOVAL & INSTALLATION. If voltage is not as specified, go to next step. 8. Disconnect deactivator switch (brake pressure switch) 2-pin connector located at front of master cylinder. Connect jumper wire between deactivator switch connector terminals. Measure voltage between speed control servo/actuator assembly connector terminals No. 9 (Black/Yellow wire) and No. 10 (Black wire). See Fig. 1 . If battery voltage exists, replace deactivator switch. If battery voltage does not exist, go to next step. 9. Measure resistance of Black/Yellow wire between deactivator switch connector and speed control servo/actuator assembly connector terminal No. 9. If resistance is less than 5 ohms, repair open in Light Green/Red wire. If resistance is 5 ohms or more, repair open in Black/Yellow wire. CRUISE DOES NOT TURN OFF WHEN CLUTCH PEDAL IS APPLIED 1. Turn ignition switch to LOCK position. Disconnect speed control servo/actuator assembly 10-pin connector, located at right side of engine compartment near starter motor relay. Measure resistance between speed control servo/actuator assembly connector terminals No. 4 (Tan/Light Blue wire) and No. 10 (Black wire). See Fig. 1 . If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, go to SPEED CONTROL INOPERATIVE . 2. Measure resistance between speed control servo/actuator assembly connector terminals No. 4 (Tan/Light Blue wire) and No. 10 (Black wire) while depressing clutch pedal. If resistance is more than 10 k/ohms, replace speed control servo/actuator assembly. See SPEED CONTROL SERVO/ACTUATOR ASSEMBLY under REMOVAL & INSTALLATION. If resistance is 10 k/ohms or less, replace CPP switch. COAST FUNCTION INOPERATIVE Turn ignition switch to LOCK position. Disconnect speed control servo/actuator assembly 10-pin connector,

located at right side of engine compartment near starter motor relay. Measure resistance between speed control servo/actuator assembly connector terminals No. 5 (Light Blue/Black wire) and No. 6 (Dark Green/Orange wire) while rotating steering wheel from stop to stop with COAST switch depressed. See Fig. 1 . If resistance is 108-132 ohms, replace speed control servo/actuator assembly. See SPEED CONTROL SERVO/ACTUATOR ASSEMBLY under REMOVAL & INSTALLATION. If resistance is not 108-132 ohms, replace speed control switches. See SPEED CONTROL SWITCHES under REMOVAL & INSTALLATION. SET/ACCEL FUNCTION INOPERATIVE Turn ignition switch to LOCK position. Disconnect speed control servo/actuator assembly 10-pin connector, located at right side of engine compartment near starter motor relay. Measure resistance between speed control servo/actuator assembly connector terminals No. 5 (Light Blue/Black wire) and No. 6 (Dark Green/Orange wire) while rotating steering wheel from stop to stop with SET/ACCEL switch depressed. See Fig. 1 . If resistance is 612-748 ohms, replace speed control servo/actuator assembly. See SPEED CONTROL SERVO/ACTUATOR ASSEMBLY under REMOVAL & INSTALLATION. If resistance is not 612-748 ohms, replace speed control switches. See SPEED CONTROL SWITCHES under REMOVAL & INSTALLATION. RESUME FUNCTION INOPERATIVE Turn ignition switch to LOCK position. Disconnect speed control servo/actuator assembly 10-pin connector, located at right side of engine compartment near starter motor relay. Measure resistance between speed control servo/actuator assembly connector terminals No. 5 (Light Blue/Black wire) and No. 6 (Dark Green/Orange wire) while rotating steering wheel from stop to stop with RESUME switch depressed. See Fig. 1 . If resistance is 1980-2420 ohms, replace speed control servo/actuator assembly. See SPEED CONTROL SERVO/ACTUATOR ASSEMBLY under REMOVAL & INSTALLATION. If resistance is not 1980-2420 ohms, replace speed control switches. See SPEED CONTROL SWITCHES under REMOVAL & INSTALLATION. SPEED CONTROL WILL NOT TURN OFF WITH OFF SWITCH Turn ignition switch to LOCK position. Disconnect speed control servo/actuator assembly 10-pin connector, located at right side of engine compartment near starter motor relay. Measure resistance between speed control servo/actuator assembly connector terminals No. 5 (Light Blue/Black wire) and No. 6 (Dark Green/Orange wire) while rotating steering wheel from stop to stop with OFF switch depressed. See Fig. 1 . If resistance is less than 5 ohms, replace speed control servo/actuator assembly. See SPEED CONTROL SERVO/ACTUATOR ASSEMBLY under REMOVAL & INSTALLATION. If resistance is 5 ohms or more, replace speed control switches. See SPEED CONTROL SWITCHES under REMOVAL & INSTALLATION. REMOVAL & INSTALLATION CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN

ACTUATOR CABLE Removal Remove air cleaner outlet tube. Remove accelerator control splash shield. Disconnect actuator cable from throttle body cam and bracket. Push in locking arm on actuator cable cap and rotate cap counterclockwise to remove. Disconnect actuator cable core wire end from servo pulley. Installation Gently compress servo spring and insert cable slug into servo pulley slot. Make sure rubber seal is fully seated onto actuator cable cap. Release compressed spring while aligning actuator cable cap tabs with slots in servo housing. Rotate actuator cable cap until locking arm engages. Connect actuator cable to throttle body cam. Position cable in bracket. Install accelerator control splash shield. Install air cleaner outlet tube. CLOCKSPRING Removal & Installation 1. Remove steering wheel. See STEERING WHEEL . Apply 2 strips of masking tape across air bag sliding contact to prevent clockspring rotation. 2. Twist and remove tilt wheel handle and shank. Remove lower steering column shroud. Turn ignition switch to RUN position. Using a punch, push upward on lock cylinder release tab while pulling out lock cylinder. 3. Remove upper steering column shroud. Remove key-in-ignition warning indicator switch. Turn instrument panel steering column cover retaining clips counterclockwise to release. Remove instrument panel steering column cover. 4. Disconnect clockspring electrical connectors. Remove 3 retaining clips and remove clockspring. To install, reverse removal procedure. Remove anti-rotation tab on new clockspring. DEACTIVATOR (BRAKE PRESSURE) SWITCH Removal & Installation Deactivator switch is located on master cylinder. Disconnect electrical connector. Unscrew switch. To install, reverse removal procedure. Bleed brake system. See appropriate DISC & DRUM article in BRAKES. SPEED CONTROL SERVO/ACTUATOR ASSEMBLY Removal & Installation. PROCEDURES -- FORD MOTOR CO. article in GENERAL INFORMATION before disconnecting battery. NOTE: Incorrect wrapping of actuator cable around servo pulley may result in high idle condition.

Remove actuator cable. See ACTUATOR CABLE . Disconnect electrical connector. Remove servo and bracket. To install, reverse removal procedure. Tighten bolts/screws to 72-89 INCH lbs. (8-10 N.m). SPEED CONTROL SWITCHES Removal & Installation 1. Disconnect battery ground cable. Disconnect auxiliary power sources, if any. Wait one minute for air bag diagnostic monitor module energy reserves to deplete. 2. Remove 2 back cover plugs and bolts holding driver's air bag module. Remove driver's air bag module. Release 4 speed control switch clips and remove speed control switches. Disconnect electrical connector. To install, reverse removal procedure. STEERING WHEEL Removal & Installation 1. Disconnect battery ground cable. Disconnect auxiliary power sources, if any. Wait one minute for air bag diagnostic monitor module energy reserves to deplete. Make sure wheels are straight ahead. 2. Remove 2 back cover plugs and bolts holding driver's air bag module. Remove driver's air bag module. Remove and discard steering wheel retaining bolt. 3. Use 2-jaw puller to remove steering wheel. Remove steering wheel while routing wires from air bag sliding contact through steering wheel. To install, reverse removal procedure. Use new steering wheel bolt. Tighten to 23-32 ft. lbs. (31-44 N.m). WIRING DIAGRAMS WARNING: Observe all air bag service precautions. Disable air bag system. See SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEMS in appropriate AIR BAG RESTRAINT SYSTEMS article.

1999-2010 Ford F-250 F-350 Service & Repair Manual

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