2011 FORD E150 brakes

Procedure for adjusting GAIN:
The GAIN setting is used to set the TBC for the specific towing
condition and should be changed as towing conditions change. Changes
to towing conditions include trailer load, vehicle load, road conditions
and weather.
The GAIN should be set to provide the maximum trailer braking
assistance while ensuring the trailer wheels do not lock when braking;
locked trailer wheels may lead to trailer instability.
Note:This should only be performed in a traffic-free environment at
speeds of approximately 20–25 mph (30–40 km/h).
1. Make sure the trailer brakes are in good working condition,
functioning normally and properly adjusted. See your trailer dealer if
necessary.
2. Hook up the trailer and make the electrical connections according to
the trailer manufacturer’s instructions.
3. When a trailer with electric brakes is plugged in, theTRAILER
CONNECTEDmessage displays in the instrument cluster message
center.
4. Use the GAIN adjustment (+/-) buttons to increase or decrease the
GAIN setting to the desired starting point. A GAIN setting of 6.0 is a
good starting point for heavier loads.
5. In a traffic-free environment, tow the trailer on a dry, level surface at
a speed of 20–25 mph (30–40 km/h) and squeeze the manual control
lever completely.
6. If the trailer wheels lock up (indicated by squealing tires), reduce the
GAIN setting; if the trailer wheels turn freely, increase the GAIN setting.
Repeat Steps 5 and 6 until the GAIN setting is at a point just below
trailer wheel lock-up. If towing a heavier trailer, trailer wheel lock-up
may not be attainable even with the maximum GAIN setting of 10.
Explanation of instrument cluster warning messages:
The TBC interacts with the instrument cluster message center to display
the following messages:
TRAILER BRAKE MODULE FAULT:This message is displayed and
accompanied by a single chime, in response to faults sensed by the TBC.
In the event this message is seen, please contact your authorized dealer
as soon as possible for diagnosis and repair. The TBC may still function,
but performance may be degraded.
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WIRING FAULT ON TRAILER:This message is displayed when a
Short circuit on the electric brake output wirehas occurred. If the
WIRING FAULT ON TRAILERmessage is displayed and accompanied
by a single chime, with no trailer connected, the problem is with the
vehicle wiring from the TBC to the 7–pin connector at the bumper. If the
message is only displayed with a trailer connected, the problem is related
to the trailer wiring; consult your trailer dealer for assistance. This can
be a short to ground (i.e., chaffed wire) or a short to voltage (i.e., pulled
pin on trailer emergency break-away battery) or trailer brakes drawing
too much current.
Note:Your TBC can be diagnosed by your authorized dealer to
determine exactly which trailer fault has occurred; however, if the fault
is with the trailer this diagnosis isnotcovered under your Ford
warranty.
Points to Remember:
•Remember to adjust gain setting before using the TBC for the first
time.
•Readjust gain setting on the TBC (according to procedure above)
whenever road, weather and trailer or vehicle loading conditions
change from those that existed when the gain was initially set.
•The sliding lever on the TBC should be used only for manual
activation of trailer brakes to assist with proper adjustment of the
GAIN. Misuse, such as application during trailer sway, could cause
instability of trailer and/or tow vehicle.
•Avoid towing in adverse weather conditions. The TBC does not
provide anti-lock control of the trailer wheels. Trailer wheels can lock
up on slippery surfaces, resulting in reduced stability of trailer and
tow vehicle.
•The TBC is equipped with a feature which reduces output at vehicle
speeds below 11 mph (18 km/h) so trailer and vehicle braking is not
jerky or harsh. This feature is only available when applying the brakes
using the vehicle’s brake pedal, not the TBC.
•The TBC interacts with the brake system of the vehicle, including
ABS, in order to reduce the likelihood of trailer wheel lock-up;
therefore, if these systems are not functioning properly, the TBC may
not function at full performance.
•Your vehicle’s brake system and the trailer brake system work
independently of each other; changing the GAIN setting on the TBC
does not affect the operation of your vehicle’s brakes whether a trailer
is attached or not.
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•When the vehicle is turned off, the TBC output is disabled and the
display is shut down; turning the ignition from off to on awakens the
TBC module.
•The TBC is only a factory- or dealer-installed item; Ford is not
responsible for warranty or performance of the TBC due to misuse or
customer installation.
•Do not attempt removal of the TBC without consulting the
Workshop Manual; damage to the unit may result.
Trailer lamps
Trailer lamps are required on most towed vehicles. Make sure all running
lights, brake lights, turn signals and hazard lights are working. Contact
your authorized dealer or trailer rental agency for proper instructions
and equipment for hooking-up trailer lamps.
Driving while you tow
When towing a trailer:
•Do not drive faster than 70 mph (113 km/h) during the first 500 miles
(800 km) of trailer towing and don’t make full-throttle starts.
•Turn off the speed control. The speed control may shut off
automatically when you are towing on long, steep grades.
•Consider turning overdrive off (4–speed transmissions) or using the
tow/haul feature (5–speed transmissions) to eliminate excessive
shifting and assist in transmission cooling. For additional information,
refer toAutomatic transmission operationin theDrivingchapter.
•Allow more distance for stopping with a trailer attached; anticipate
stops and brake gradually.
When descending long, steep downhill grades, always use a lower gear to
provide engine braking to save wear on brakes. Use D (Overdrive OFF)
on moderately steep hills, 2 (Second) on steep hills, and 1 (First) on
very steep hills.Do not apply your brakes continuously, as they
may overheat and become less effective.
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•Be sure that the engine block heater, heater cord and extension cord
are solidly connected. A poor connection can cause the cord to
become very hot and may result in an electrical shock or fire. Be sure
to check for heat anywhere in the electrical hookup once the system
has been operating for approximately a half hour.
•Finally, have the engine block heater system checked during your fall
tune-up to be sure it’s in good working order.
How to use the engine block heater
Ensure the receptacle terminals are clean and dry prior to use. To clean
them, use a dry cloth.
Depending on the type of factory installed equipment, your engine block
heater system may consume anywhere between 400 watts or 1000 watts
of power per hour. Your factory installed block heater system does not
have a thermostat; however, maximum temperature is attained after
approximately three hours of operation. Block heater operation longer
than three hours will not improve system performance and will
unnecessarily use additional electricity.
Make sure system is unplugged and properly stowed before driving the
vehicle. While not in use, make sure the protective cover seals the
prongs of the engine block heater cord plug.
BRAKES
Occasional brake noise is normal. If a metal-to-metal, continuous grinding
or continuous squeal sound is present, the brake linings may be worn-out
and should be inspected by an authorized dealer. If the vehicle has
continuous vibration or shudder in the steering wheel while braking, the
vehicle should be inspected by an authorized dealer.
Refer toWarning lights and
chimesin theInstrument Cluster
chapter for information on the brake
system warning light.
Four-wheel anti-lock brake system (ABS)
Your vehicle is equipped with an anti-lock braking system (ABS). This
system helps you maintain steering control during emergency stops by
keeping the brakes from locking. Noise from the ABS pump motor and
brake pedal pulsation may be observed during ABS braking and the
brake pedal may suddenly travel a little farther as soon as ABS braking is
done and normal brake operation resumes. These are normal
characteristics of the ABS and should be no reason for concern.
P!
BRAKE
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The parking brake is not recommended to stop a moving vehicle.
However, if the normal brakes fail, the parking brake can be used to stop
your vehicle in an emergency. Since the parking brake applies only the
rear brakes, the vehicle’s stopping distance will increase greatly and the
handling of your vehicle will be adversely affected.
TRACTION CONTROL (IF EQUIPPED)
Your vehicle may be equipped with a traction control system (TCS). This
system helps you maintain the stability and steerability of your vehicle,
especially on slippery road surfaces such as snow or ice-covered roads
and gravel roads. The system will allow your vehicle to make better use
of available traction in these conditions.
During TCS operation, the traction
control active light will flash and the
engine will not “rev-up” when you
press further on the accelerator.
This is normal system behavior and
should be no reason for concern.
WARNING:Aggressive driving in any road conditions can cause
you to lose control of your vehicle increasing the risk of severe
personal injury or property damage. The occurrence of a traction
control event is an indication that at least some of the tires have
exceeded their ability to grip the road. This may lead to an increased
risk of loss of vehicle control, vehicle rollover, personal injury and
death. If you experience a severe road event, SLOW DOWN.
The TCS switch, located on the
center console, has a TCS OFF light
that illuminates steadily in the
instrument cluster when the system
is off. The TCS will automatically
turn on every time the ignition is
turned off and on. The TCS should
normally be left on.
If you should become stuck in snow or ice or on a very slippery road
surface, try switching the TCS off. This may allow excess wheel spin to
“dig” the vehicle out and enable a successful “rocking” maneuver.
Remember to switch the TCS back on once the vehicle is no longer
stuck.
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•If the driving condition is severe and your foot is not on the brake, the
brake pedal may move as the systems applies higher brake forces. You
may also hear a whoosh of air from under the instrument panel during
this severe condition.
•The brake pedal may feel stiffer than usual.
Traction control system (TCS)
Traction control is a driver aid feature that helps your vehicle maintain
traction of the wheels, typically when driving on slippery and/or hilly
road surfaces, by detecting and controlling wheel spin.
Excessive wheel spin is controlled in two ways, which may work
separately or in tandem; engine traction control and brake traction
control. Engine traction control works to limit drive-wheel spin by
momentarily reducing engine power. Brake traction control works to limit
wheel spin by momentarily applying the brakes to the wheel that is
slipping. Traction control is most active at low speeds.
During traction control events, the stability control light in the
instrument cluster will flash.
If the TCS is activated excessively in a short period of time, the braking
portion of the system may become temporarily disabled to allow the
brakes to cool down. In this situation, TCS will use only engine power
reduction or transfer to help control the wheels from over-spinning.
When the brakes have cooled down, the system will regain all features.
Anti-lock braking, RSC, and ESC are not affected by this condition and
will continue to function during the cool-down period.
The engine traction control and brake traction control system may be
deactivated in certain situations. SeeSwitching off AdvanceTracwith
RSC.
Electronic stability control (ESC)
Electronic stability control (ESC) may enhance your vehicle’s directional
stability during adverse maneuvers, for example when cornering severely
or avoiding objects in the roadway. ESC operates by applying brakes to
one or more of the wheels individually and, if necessary, reducing engine
power if the system detects that the vehicle is about to skid or slide
laterally.
During ESC events, the stability control light in the instrument cluster
will flash.
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Certain adverse driving maneuvers may activate the ESC system, which
include but are not limited to:
•Taking a turn too fast
•Maneuvering quickly to avoid an accident, pedestrian or obstacle
•Driving over a patch of ice or other slippery surfaces
•Changing lanes on a snow-rutted road
•Entering a snow-free road from a snow-covered side street, or vice
versa
•Entering a paved road from a gravel road, or vice versa
•Cornering while towing a heavily loaded trailer (refer toTrailer
towingin theTires, Wheels and Loadingchapter).
Roll Stability Control™ (RSC)
Roll Stability Control™ (RSC) may help to maintain roll stability of the
vehicle during adverse maneuvers. RSCoperates by detecting the
vehicle’s roll motion and the rate at which it changes and by applying the
brakes to one or more wheels individually.
During an event that activates the RSC, the stability control light in the
instrument cluster will flash.
Certain adverse driving maneuvers may activate the RSCsystem, which
include:
•Emergency lane-change
•Taking a turn too fast
•Quick maneuvering to avoid an accident, pedestrian or obstacle
Switching off AdvanceTracwith RSC
If the vehicle is stuck in snow, mud or sand, and seems to lose engine
power, switching off certain features of the AdvanceTracwith RSC
system may be beneficial because the wheels are allowed to spin. This
will restore full engine power and will enhance momentum through the
obstacle. To switch off the AdvanceTracwith RSCsystem partially,
press the TCS OFF button below 20 mph (32 km/h). Full features of the
AdvanceTracwith RSCsystem can be restored by pressing the TCS
OFF button again or if the vehicle is above 20 mph (32 km/h) or by
turning off and restarting the engine.
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If the fuse is not blown and the brake lamps are working properly, the
following procedure will allow you to move the gearshift lever from P
(Park):
1. Apply the parking brake, and turn
the ignition to the on position.
2. Use a screwdriver to remove the
lower trim panel under the steering
column. Make sure to not disturb
the wires on the electrical
connector.
3. Locate the brake-shift interlock
solenoid underneath the steering
column.
4. Pull back on the solenoid, and at
the same time, shift the
transmission into N (Neutral).
5. Start the vehicle.
See your authorized dealer as
soon as possible if this procedure is used.
WARNING:Do not drive your vehicle until you verify that the
brake lamps are working.
WARNING:When doing this procedure, you will be taking the
vehicle out of park which means the vehicle can roll freely. To
avoid unwanted vehicle movement, always fully set the parking brake
prior to doing this procedure. Use wheel chocks if appropriate.
WARNING:If the parking brake is fully released, but the brake
warning lamp remains illuminated, the brakes may not be
working properly. See your authorized dealer.
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