Another Intermittent ABS Light

Brake fluid is maxed out and I've got the new sensor in, still experiencing the intermittent light.

So, next step is to inspect the sensors right? Other than to check that they are correctly in place, wiring looks good, and cleaned up with brake fluid, what else can be done at this point?

If I'm able to pull the Codes (autozone might have the tool), will that help narrow the problem? Will it pinpoint a bad sensor or just tell me all are bad?

If you can get the codes, they should tell you which sensor is causing the problem.
It may require a more advanced reader than the generic OBDII reader that the auto part stores and many of us have.

However, the avenue that you are following is exactly what I would do.

So, a trip to the dealer for the code reading? Problem is, the light may not be on, would their reader hold the code? It would not surprise me if they would want $200 to pull the codes...

I think I've read some posts among the hundreds about this issue that some have changed the sensor reported as the problem and did not solve the light issue.

A good repair shop should be able to read the codes, not just the dealer.
It is a good starting point.

I would suggest that you jack up and pull off each wheel. I'd do a thorough cleaning with a tooth brush of the abs exciter wheel (toothed wheel on the hub) and the pick up. Also examine the wires leading to the sensor. The exciter will pick up all sorts of road gunk and that can lead to a bad reading. This cleaning should be done by hand so that it'd really thorough.

I've heard many stories of the flakey abs light being "solved" by driving in a heavy rain for a few hours. This leads me to believe the sensors just needed cleaning. Before you go and dump $$ at a dealer, do some general cleaning yourself.

Piper

I had a similar problem but mine was correlated with weather. When the weather was damp the light usually came on. When I was cleaning battery terminals, I spilt some water on the ABS power module below and the ABS light came on right after (it was ok when I pull the car out from garage). What I did was to pull out the connectors attached to the power module and pushed back in a few times. The light never came back since. This may not help you but you could be lucky as I was.

A few years ago I had the ABS/Trac light on my '99. The leaking brake switch was replaced ... no effect. I inspected/cleaned all wheel sensors ... no effect. Couldn't tell any difference in general braking performance, but just to be on safe side I had the code read at dealership. $300+ later I had a new ABS brake control module to install beneath floorpan ..near drivers area. No problem afterwards ... for a few years.

Now the light is back on warm days. Cold or rainy days there is no light. I found some websites that covered this issue. (Now when I Google, I no longer find them.) Seems that there are printed board circuits in the module that overheat and distort ... and then overheat even more until they self destruct.

Someday I intend to open up the module and see if there is anything I can fix. Hate to pay out that $300+ again.

that recall/abs issue is here. http://www.fordwindstarrecall.info/#problem1

Yep, that's it! Thanks!

While I had the car up on the lift, I sprayed down the toothed ABS gear on the front wheels (could not see the rear, must be in the drum?) with brake cleaner and scrubbed with a metal toothbrush. I also sprayed the area where the sensor was. Note that if you tackle this, it is a good idea to have a flashlight, as it is hard to see the sensor end that reads the tooth travel. Anyway, I sprayed the assembly thoroughly and it otherwise did not look damaged. So far, its been about 5 days with no problem, though it was an intermittent issue and I'm not claiming victory yet, so far so good with the cleaning.