ABS Codes Were Pulled

We had been having the ABS and Brake lights come on every once in a while; maybe once a week. So I flushed the brake fluid, cleaned all sensors, put dielectric grease in the connectors, unplugged ABS control unit connector and put dielectric grease in that connection, and checked all wheel bearings for slack. Then we drove it 200 miles on vacation, no light. Then lights come on once during vacation while there and restarting the van made the lights go out. Drove home no light. Then two days ago the lights came on so we tried restarting the van. After restarting the van a few times they kept coming back on.

So I took the van to the shop and they pulled the ABS codes:

1194, 1198, 1210 and maybe some others.

They said all the codes indicate "dump valve circuit failure". The machanic says the ABS system is detecting malfunctioning valves in the ABS unit. He said different valves were reporting failures, not just one valve. He said his shop can not fix it and I would have to take it to the dealer. He also said there could be some dirt hung up in there causing the valves to stick and it may work its way out. I might flush the brakes again.

The shop hooked an analyzer to the ABS system and drove the van and verified ALL wheel sensors are working perfectly.

The light did not come on when taking the van in. It did not come on during their test drive. And since my wife picked it up today they have not come back on.

Anyone have any suggestions because I don't think I have seen the last of those lights.

The dealer....and maybe some shops will have the ABS test controller that will work the ABS valves.......this....along with flushing out the old brake fluid....replacing with new brake fluid may clean the unit.
Otherwise......you could be looking at replacing the unit...unless they find a electrical issue....which it sounds like you have covered the connectors pretty well.

Take note that if the brake fluid level in the master cylinder is even slightly low.....like the bottom side of the "FULL" line.....the ABS and brake lights will come on.

Check the pressure switch that is located on the bottom of the master cylinder......it is known to leak.......can cause a fire.....can cause cruise control to not work.
The pressure switch is cheap and easy to change.....if your FORD dealership has one in stock......they are in high demand.

Thanks for the advice.

The fluid is at the full line but it never hurts to bring that up because others can benefit from that advice. I keep the brake pressure switch disconnected because we don't use the cruise control and the van is kept in a garage attached to the house (fire hazzard). The van has always been garage kept since new. The van has zero rust or corrosion anywhere and all the wire harnesses look to be in perfect shape. While anything is possible I think its unlikely its a ground or wire harness issue given the condition of this van.

A guy I work with, who was a mechanic at a dealership for 10 years, told me to apply the brakes hard on a slick surface, like a wet road, to excercise the ABS valves. He said only do it when the lights are out. Because if the lights are ON the ABS is deactivated and the vehicle will skid instead of excercising the valves.

I have an automotive brake system pressure-bleeder so I may try flushing with that. When I flushed the brakes recently I just pumped the pedal and refilled the master cylinder; I did not run the master cylinder low. I pushed a full quart of fluid through the system and it was coming out clean on all four corners.

If the light keeps coming on I'll call Ford dealers and ask about an ABS Test Controller. Chances are some will know what one is and some won't.

Any other suggestions are welcome, thanks, Bill

Now what Wiswind was saying is you cannot fully bleed your brakes. You need an ABS scan tool that is able to actuate the ABS pump when you bleed them. This will allow full bleeding of the brakes and ABS system. The shop that did the trouble shooting for you with there scan tool may be able to do this for you.. I will say bleed the system with your pump as best you can. It should not hurt and will allow a even better flush if you take to the shop. What I do on newer cars now is every oil change I take my vac pump and take all old fluid out and replace with new. Keeps the fluid fresher longer. But of course I can only get out whats in the reservoir. Now with what you have found out along with others who have posted makes me wonder if Ford knows what going on. i think they may be replacing ABS modules because they feel all the codes can't be true. If your brake fluid gets nasty it can cause an issue with the ABS system..

After rereading your above post the dump valve circuit failure would to me point toward the ABS Module. DARN!!!

Its looking like the ABS Module which was the last thing I wanted it to be. Lights came on again tonight when running an errand. But restarting the van made them go out. Its looking like either sticky valves or bad ABS Module. What ever it is it is happening more often. The shop did say they could flush the system but they didn't say anything about flushing or actuating the ABS valves. They told me all they can do is pull the codes and do a basic fluid flush.

I'll flush it again but use a pressure bleeder next time. If that does not work I may take it to Ford and have them take a look and give an estimate.

Now with what you have found out along with others who have posted makes me wonder if Ford knows what going on. i think they may be replacing ABS modules because they feel all the codes can't be true.

Hard to believe I could get a "dump valve circuit failure" on all four wheels but that is what the codes are saying. What is the chance that all the valves are sticking on a 75,000 mile garage kept van?

I am having trouble with mine doing the same thing. Mine does it on hot days more than cold.. Thats what led me to think it had to be electrical.. Which would point to the Module. During the winter these lights have not been coming on. Right now I trying to get the break down of the FORD Abs system for these vans. Everyone differs on how they put these units in but they are mostly the same. Just some use different ways to control the hydraulic units and valves. Some use more than others and some have double pumps. So it makes working on these things a almost dealer option. Score one for the dealers.. Funny thing is now is a car buyers dream. Just saw a 2007 Hummer H3 on carmax here in Fayetteville NC for 23,000 bucks.. Also saw a Honda Accord for the same price. LOL Now if you want fuel MPG's you will have to pay SUV prices. Don't you just love or Country.. Good luck and keep us posted.. Thanks,Gary

If you scroll down and look at "Problem #2" it talks about the ABS unit failing in the warm weather:

http://www.fordwindstarrecall.info/

If you scroll down and look at "Problem #2" it talks about the ABS unit failing in the warm weather:

http://www.fordwindstarrecall.info/

WOW!! That site must had been posted not to long ago. I have found the complaints on the site above a while back. As far as Hwy safety site and complaints. The site about the ABS warning lights I had not seen.. Makes my findings more understanding to me.. I knew the warm weather had something to do with it. So I guess in my future my module will need to be replaced.. The bad thing is if they had not upgraded the part it will most likely happen again.. As far as my brake pressure switch, I never had an issue with it.. Everything there looks ok. I will try to take some pictures of my units and post on what I can see. Thanks for posting the web site. Great Info!!!

ALL my wire harnesses and electrical connections are in like new condition and my brake pressure switch has never leaked. Sounds to me like I have the ABS Control Module expansion problem causing the intermittent codes to be thrown.

I think I will jump on the band wagon and file a complaint with NHTSA.

Is it true only the dealer can replace the ABS Control Module? I might replace it if I can do it myself but I don't want to pay for the dealer labor.

some time ago had abs codes on my 98 pulled by my mechanic and on inspection found the toothed ring that signals the abs sensor was cracked. replaced it and all is well. some of the same symptoms as yours, acts up more on hot days (expansion). just my 2 cents.........