ABS/TCS - Default Mode/False DTC's Set/Low Pedal
TSB 09-12-1306/29/09
CHANGE IN BRAKE PEDAL TRAVEL AND/OR
ELECTRONIC STABILITY CONTROL/BRAKE
WARNING LAMP - DTC C1011:1C, C1011:1F OR
C100A:64 - BUILT ON OR BEFORE 5/15/2009
FORD:
2010 Fusion
MERCURY:
2010 Milan
ISSUE
Some 2010 Fusion and Milan Hybrid (HEV) vehicles may experience electronic noise on the main power feed circuit to the Brake Control Module within the 14290 wiring harness. Depending on the frequency and duration of the noise it may generate a false diagnostic trouble code DTC (C011-1C, C1011-1F, or C100A-64) in the Brake Module. This turns off the brake by wire mode, defaulting to direct pedal activation of the brake system, including full vacuum brake assist.
Once the default mode is activated, the Brake and ABS telltales will illuminate and the message center will display the message Check Brake System. The customer may report an extended pedal travel of approximately 1 3/16 of an inch (30 mm). The system will remain in default mode throughout the key cycle. During the subsequent key cycle, if the system recognizes a properly operating Brake Pressure Sensor, brake by wire functionality will return.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Install a brake cutoff pressure sensor jumper harness to overlay the existing 14290 harness.
1. Verify the vehicle ignition is off.
2. Remove the high voltage junction box. Insert a flat-blade screwdriver behind the junction box and push the retainer rearward to release the bracket retainer. Position the high voltage electrical harness block aside. (Figure 1)
3. Remove the upper cowl panel grille and the lower cowl panel following Workshop Manual (WSM), Section 501-02.
4. Disconnect the 3-wire cutoff pressure sensor electrical connector, located to the right of the brake pedal. (Figure 2)
5. Cut off the connector, then fold back and tape the cut wires to the wire harness.
6. Remove and discard the dash panel perforated pad, located left of the brake pedal, exposing the white plastic cowl pass-through plug. (Figure 3)
7. Remove the white plastic plug from the cowl panel and discard. (Figure 4)
8. From the passenger compartment, install the Cutoff Pressure Sensor Jumper through the 1 1/4" (32 mm) opening . Seat the grommet into the opening, with the arrow on the grommet pointing outboard away from the brake pedal. Disregard the UP designation on the grommet.
9. Connect the Cutoff Pressure Sensor Jumper to the cutoff pressure sensor.
10. From the engine compartment, seal the 2 adjacent openings in the cowl using 3M(TM) Strip Caulk-Black part number 08578 or equivalent
11. Route the Cutoff Pressure Sensor Jumper along the ABS harness bundle to the ABS connector. (Figure 5)
12. Raise the vehicle and remove the seven (7) screws and the underbody cover.
13. Disconnect the ABS connector, then release the wire harness pushpin retainer from the support bracket. (Figure 6)
14. Cut the tie strap retaining the wire bundle to the ABS connector.
15. Remove the red terminal lock by pulling it straight outward. (Figure 7)
16. Identify and mark the wires and terminals to be removed. (Figure 8)
a. Cavity 5 - Green wire
b. Cavity 40 - Blue/Brown wire
C. Cavity 41 - Yellow/Blue wire
17. Re-pin the ABS connector using Rotunda terminal removal kit 418-D631 or equivalent.
a. Remove green wire and terminal from cavity 5. Insert Green wire and terminal of the Cutoff Pressure Sensor Jumper into cavity 5.
b. Remove Blue/Brown wire and terminal from cavity 40. Insert Blue/Brown wire and terminal of the Cutoff Pressure Sensor Jumper into cavity 40.
c. Remove Yellow/Blue wire and terminal from cavity 41. Insert Yellow/Blue wire and terminal of the Cutoff Pressure Sensor Jumper into cavity 41.
18. Install the red terminal lock into the ABS connector.
19. Install a new tie strap retaining the wire bundle to the ABS connector.
20. Cut the terminal ends from the removed circuits and tape to the adjacent wire harness.
21. Connect the ABS connector, then secure the wire harness pushpin retainer to the support bracket.
22. Tie strap the Cutoff Pressure Sensor Jumper along the ABS harness bundle with (5) tie straps spaced 7 7/8" to 11.13/16" (20-30 cm) apart, and cut off excess length. (Figure 9)
23. Install the underbody cover.
24. Install the upper and lower cowl panels following (WSM), Section 501-02.
25. Install the high voltage junction box into the retainer.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION DESCRIPTION TIME
091213A 2010 Fusion Hybrid, Milan 1.6 Hrs.
Hybrid: Install A Brake
Cutoff Pressure Sensor
Jumper Harness (Do Not
Use With Any Other Labor
Operations)
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A411 43
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