Ford Excursion :: Brake Intermittent - Hard Pedal And Pulsing Feeling Randomly


Apr 23, 2014

I'm having an issue with my brakes. It was very intermittent, but seems to be happening a little more often lately. 99% of the time they work fine.

I'll try to describe. (vaguely) It will sometimes feel like the ABS is engaging, get a very hard pedal and some pulsing feeling. Sometimes just the pulsing without the hard pedal. It will happen at random times. Today it did it in the driveway going 5 MPH. No reason the ABS should think of kicking in.

I feel confident to rule out anything downstream at the wheels. I am leaning towards the master cylinder, but maybe that's wishful thinking. Afraid it also could be something sticking in the ABS which I assume is $$$.

Brake fluid is 18 months old with maybe 20k on it.

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First issue is that I have developed a hard start. It started last Saturday, and went from sporadically starting hard, to starting hard every time. I have 146,000 miles on her. She cranks strong, but will not turn over the first time, sometimes takes 2, 3, or 4 times. (Foot on gas pedal) I don't know if it's an issue of not getting enough fuel or what. Occasionally, even after she starts, it's very rough (shaking the whole vehicle, and acting like she wants to die) until I rev the engine and she smoothes out. After she smoothes out, there is no problem with wanting to drive, she's strong. If I kill the ignition, and start up immediately, she starts the first time, it's only after 10 minutes or so of being off.

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Got stuck in the sand pits today. While trying to get out by going forward and back. I always get the front end starts bouncing hard. I always let off. Is this wheel hop or axle wrap?

Whatever it's called. How do I minimize this. It's a shame to have all that power and not be able to lay it down.

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So... here's the short version of the things I've checked so far:

1. no brake lights when pedal depressed.

2. running lights work fine

3. turn signals work fine

4. hazards work fine

5. brake lights DO illuminate when I press the brake button on my trailer brake controller

6. checked power to the green with red tracer wire going to the brake light switch on the pedal. 12 v present continuously

7. checked power to light green wire. 12 v present when pedal is depressed. 0 v when pedal is released.

8. checked power to tail lights (wish I had tried the trailer brake controller sooner, this step would have been unnecessary). voltage present (I think 10-12 v) when the running lights were turned on. 0 v when brake pedal depressed. I suspect now that I would have 12 v when squeezing my trailer brake controller button.

I was pretty convinced it was the brake switch at the pedal. But since I'm seeing the voltage pass through the light green wire when depressed.... I know the wiring to the lights are good because they work when pressing the trailer brake controller button.

So... Do I need to dig into the multifunction switch that I've been reading about? Does the power go from the pedal switch to the multifunction, then to the trailer brake controller? I'm really hoping that I don't have to dig into the column to check that multifunction switch!

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This may be my only chance to do a step-by-step ...

Tools Required : Fingers (preferably attached to hands)

Step One : Check diver side floorboard for cleanliness (people are going to see it in the pics)

Don't worry about passenger side. There will be no pics of it.

Step Two (fingers required for steps two through seven and ten) : Vacuum driver floorboard since there will be pictures made of it.

Step Three : Remove old, worn out brake pedal cover.

Step Four : Remove aftermarket brake pedal cover from ridiculously oversized Amazon box that's still in the passenger side floorboard.

Step Five : Take a picture of the old and new covers together to make fun of the old one.

Step Six : Install new brake pedal cover.

Step Seven : Remove new brake pedal cover and re-install right side up..

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