AU Ford Falcon - SPUD Project



12V Accessory Power Source (Cigarette Lighter) information on the 12V accessory plug (cigarette lighter socket). Applies to EA/EB/ED/EF/EL/AU/BA/BF Falcons and SX/SY Territory models Antilock Braking System (ABS) Antilock Braking System (ABS) information Air Conditioner Controls - Series 1 air Conditioner controls repair information (Series 1 only) Accessory plug Information on the Mobile Office pack accessory plug. Also relevant to the BA/BF/FG Falcons and SX/SY/SZ Territorys Alternator alternator information Body Control Module (BCM) Body Control Model (BCM) information Digital Clock Information on the basic clock available on all low models Brake Switch brake switch replacement Reading Vehicle Identification Plate (Build Plate) Codes - How to read Vehicle Identification Plate A.K.A. build plate codes Crankshaft Angle Sensor basic information on the Crankshaft Angle Sensor, or CAS. Cabin Fuse Panel in-depth information on the continuity and functionality of the interior cabin fuse box PCM Catch Codes Centre Console Buttons accessory buttons (e.g. TCS, ABS, ANT.) information and pinouts Manufacturer Specific Instructions - CodeEzy Keyfob cloning instructions using a CodeEzy branded universal keyfob (Smartlock only) Common Faults common faults Credits Credits DTCs DTC (A.K.A Diagnostic Trouble Codes), and other relevant ECU/PCM Information Door Lock Actuators repair and replacement information for the door lock actuators. Also relevant for BA/BF Falcons and SX/SY Territorys Interior Driver Buttons information on driver-side console buttons (Lock/Boot/Fuel) Engine Number engine number information and location Exterior Door Handles Information on the replacement of the exterior door handles. Also relevant to the BA/BF Falcons and SX/SY Territorys Factory Specifications Factory Specifications fuel filter replacement Fuel Injectors fuel injector diagnosis and replacement Fuel Pressure Regulator Fuel Pressure Regulator replacement steps. applicable to BA/BF/FG/FGX Falcons and SX/SY/SZ Territory models (I6 only) Fuses & Relays fuse information and minimum viable fuses, including diagrams and parts tables Headlight Switches headlight switch controls information and pinouts Head Unit Head Unit information Idle Speed Controller (ISC) Idle Speed Controller Information Ignition Coil Pack ignition coil pack information, including replacement and testing information Instrument Cluster instrument cluster information and special functions Interior Mirror information and removal and replacement information for the interior mirror. Also relevant to the BA/BF/FG Falcons and SX/SY/SZ Territorys Manufacturer Specific Instructions - KEYDIY keyfob cloning instructions using a KEYDIY branded keyfob and programmer Central Locking Keyfobs central locking and Central Locking keyfob information Component lifespans - Educated guess lifespans for common maintenance components. Likely partially useful for various models of vehicle Miscellaneous Notes - Uncategorized notes not requiring a dedicated page PCM PCM (ECU equivalent) location and general information PCV PCV information and replacement instructions Parts Sharing - (partial) list of shared parts from Ford Falcons XA/XB/XC/XD/XE/XF/XG/XH/EA/EB/EF/EL/AU/BA/BF/FG/FGX, and Ford Territory SX/SY/SZ Premium Audio System Premium Audio Information Rear Lights Connector tail light/rear light assembly plug information Relays - General Information types of relays (general information) Manufacturer Specific Instructions - Remocon Keyfob cloning instructions using a Remocon branded keyfob and programmer (Smartlock only) Roof Racks roof rack installation methods and information Seatbelts replacement and repair instructions for seatbelts and B-Pillar Seatbelt trims. Partially useful for the BA/BF Falcons and SX/SY Territory models Series Information Series specifics information Sparkplugs spark plugs information and replacement instructions Speakers Speaker installation and wiring information. Partially applies to BA-BF Falcons and SX-SY Territory models Speedometer Reading Calculator interactive calculator for changing of speedometer reading based on transmission driven gear, diff ratio, and wheel size. Changing Differential Ratios and Tyre Sizes calculations required for changing of speedometer reading based on transmission driven gear, diff ratio, and wheel size. Steering Wheel Controls steering wheel Cruise Control and Media Control assembly information, pinout, and 3D printable model Thermo Fan Thermo fan removal instructions Thermostat thermostat replacement instructions PCM Relearn PCM Relearn procedure Reading the Tickford Vehicle Engineering (TVE) Plates - How to read the Tickford Vehicle Engineering (TVE) Plates Trailer Auxiliary plug towbar trailer connector information, including instructions on how to wire a custom trailer plug (if required). Partially applicable to BA-BF Falcons and SX-SZ Territorys Tyre Size Calculator Generic Tyre Size Calculator Reading the Vehicle Identification Number (VIN) Plate how to read and decode the VIN number and engine number Ford Falcon AU VIN Decoder Ford Falcon AU Interactive VIN Decoder Verification Letters how to get an official Ford Verification Letter. Will work with other similar models Wheels & Tyres information on the tyre sizes and brake dust covers. also includes general information on calculating tyre size from a tyre size Sedan audio upgrade - 6x9” Speakers


Brake Switch

Brake Switch

If you find that your brake lights are not turning on when you expect, or you find the cruise control is not disengaging when pressing the brake pedal, you may find that you have a faulty brake switch. The brake switch is the electrical component that tells the car that you have pressed the brakes, as without it the car only mechanically activates the brake booster.

The brakes will not fail due to a brake switch failure. If you find any symptoms with your brakes mechanically then there is a problem with the brake system itself

Plug Information

Unfortunately, the connector used for the brake switch is a OEM connector seemingly made by Ford. Thankfully, this connector is quite common across Fords from America between 1969 and 2006. The most common of these models appears to be the Ford Mustang, which had this connector for the same functionality between 1971 and 2004. Alternatively, the blades are a standard size and could be adapted to directly if required.

eBay Brake Switch Connector

Image of a brake switch loom, taken from an eBay listing

Diagnosis

Diagnosis for this part is simple. Start the vehicle and put your foot lightly on the brake pedal, in any gear. Have another person check for brake light funtionality

Alternatively, 2-3 standard red bricks can be wedged into place to force the brake pedal down, however this is a last resort option if no one else is available

Replacement

Follow the below steps to replace your brake switch:

These steps are easiest completed with the driver seat removed, but can be done from the side of the car or by laying upside-down on the front-drivers seat, depending on your flexibility

  1. Find and remove the yellow retaining pin from the end of the brake pedal shaft, located on the passenger-side of the brake pedal lever, towards the top.

    Brake Switch Yellow Pin

    Yellow retaining pin on brake pedal shaft. Note picture was taken after replacement due to space constraints.

  2. If present, remove the small green plastic ring from the brake lever pin by pulling it from the brake pedal shaft.

    This ring should be present, but in older models, they could potentially break or not be reinstalled if the switch was replaced previously

  3. Remove the brake switch by pulling the passenger side section (with the complete hole) over the top of the shaft, and then pulling the driver side section (the semi-circle opening) of the switch away from the shaft. The switch sits around the brake booster level, with the closed end to the left of and the open end on the right of the lever.

    Alternatively you can pull the brake booster lever off of the brake pedal shaft all at once, however this was found to be inefficient

    Brake booster lever

    Picture of the brake booster lever, after the brake switch has been removed

    Brake switch closed side

    The closed side of the factory brake switch. This is the section that will need to be pulled over the shaft

    Brake switch open side

    The open side of the factory brake switch. This is the section that can be pulled away from the brake pedal shaft once the closed side is removed

  4. Unplug the electrical connector by pulling up on the retaining tab on the loom end connector

    Brake switch electrical connector

    Picture of the factory brake switch connector. The clip on the brake switch itself is reinforced from underneath, necessitating removal by moving the retaining clip of the loom end connector instead.

  5. Reverse all previous steps to reinstall, ensuring that the switch has:
    • The open side on the driver side of the brake booster lever
    • The closed side on the passenger side of the brake booster lever
    • Been secured in using the green plastic ring and retaining pin
    • Is electrically connected to the loom

    Brake switch installation layout

    Picture of the switch after installation. Note the pin, green ring, and location of the brake booster lever

  6. Done

Page printed from The AU Falcon SPUD Project, visit https://digi-ron.github.io/AU-Falcon-SPUD-Project/ for more!