intermittent ABS warning light 2000

[phil-l]

Further update:

I've been spending time with the ABS system on my 2000 LX. And I've seen improvement!

- I removed and cleaned each ABS wheel sensor. All were in good shape; some dirt on each, but not too bad.

- I checked the connector at each ABS wheel sensor, made sure it was clean, and added some fresh dielectric grease. I carefully checked the wires leading to each sensor: No pinched or stretched areas.

- I bled the entire brake system, using the two person "pump-the-pedal" method.

- THE ITEM I THINK MADE THE MOST DIFFERENCE FOR ME: I discovered that the tab locking the connector to the ABS module was loose! This is the module that (for my 2000) is on the bottom of the van, underneath the driver's seat. So I completely removed the connector, carefully cleaned it with a quality contact cleaning spray, and firmly re-seated it.

While it hasn't been long enough to claim victory, I haven't seen the infamous intermittent ABS warning light since I've competed these steps.

I highly recommend checking the connector to the ABS module. You'll need to crawl under the van and remove a plastic shield (4 fasteners). But it's actually pretty easy to do. The locking tab is immediately below the wire bundle that exits the connector. The tab slides toward the rear of the van. The connector is fairly large: It includes about 20 small signal pins, and four larger blades for power. I'm theorizing that this connector sees a lot of vibration, water and dirt - and can benefit from cleaning.

[truckmsl]

phil-l,

How about an update? I was busy last weekend working on my taurus, and wasn't able to check out my ABS connector. Hopefully you're on to something there.

[phil-l]

My ABS system is still behaving. I hope we're on to something here!

I even more firmly believe the connector to the ABS module has been the source of my problems. It appears to be fairly well designed - but I believe the connection can become marginal over time. I'm particularly suspicious of the low-voltage signal portions of the connector (note that the connector includes both small signal "pin" connections and larger power-style "spade" connections). For example, the wheel sensor voltages are pretty small - on the order of 1 volt. It wouldn't take much electrical "noise" on such a circuit to throw an ABS error. And it also wouldn't be surprising that such an error would only appear periodically - and might disappear as soon as the van is re-started (which is exactly the symptoms I've been seeing).

Of course, I need some more time to verify that the problem doesn't return.

I plan to get under the van and take some pictures to share what I've done.

[catvents]

Originally Posted by phil-l

My ABS system is still behaving. I hope we're on to something here!

I even more firmly believe the connector to the ABS module has been the source of my problems. It appears to be fairly well designed - but I believe the connection can become marginal over time. I'm particularly suspicious of the low-voltage signal portions of the connector (note that the connector includes both small signal "pin" connections and larger power-style "spade" connections). For example, the wheel sensor voltages are pretty small - on the order of 1 volt. It wouldn't take much electrical "noise" on such a circuit to throw an ABS error. And it also wouldn't be surprising that such an error would only appear periodically - and might disappear as soon as the van is re-started (which is exactly the symptoms I've been seeing).

Of course, I need some more time to verify that the problem doesn't return.

I plan to get under the van and take some pictures to share what I've done.

We were always waiting for a miracle solution for this endless problem; maybe you have found it. Anyway this is the next weekend project for me, and just believe that this could be the right solution for this. Nothing or almost nothing happened during the winter time or during rain ( probably because of moisture or humidity) but happen all the time when it is dry and hot. I can't wait to see the result

[aviacionlight]

Hi, someone can helpme??????? i have the abs and brake light on on my windstar 2001 i do almost everything and this weekend gone check the abs module connector hope that works.

I just need to know the voltage on the wire conected to the parking brake switch, i checkit and reads 1.06 volts it is correct? have more than 6 months with the lights problem and is driving me crazy.

Anyone with hanes manual?

Thanks

[phil-l]

The ABS light is unrelated to the parking brake switch.

The *red* brake light on the dashboard will light if either:

- the parking brake is engaged
or
- a problem is detected in the hydraulic brake system, such as (most commonly) low fluid, or unbalanced hydraulic pressure in the system (which would indicate other problems with brake lines or the master cylinder).

The *amber* ABS light on the dashboard only indicates a problem with the anti-lock portion of the brake system. The ABS module is *only* responsible for pulsing the brakes when it detects wheel slip during a stop (i.e., the brakes will still nominally work if the ABS module fails - but there will be no pulsing if a wheel slips during a stop).

[Ian Szgatti]

I work in a shop and am currently working on a windstar that has ABS troubles... first thing tommorow morning I'm going to clean the connector. This van came in with an obvious broken TONER RING... (in case some of you don't know its the gear looking ring that induces the signal to the ABS mod.) I ordered an installed a new shaft and figured on solving the problem. I was surprised to find out the problem still exsisted... not only were the symptoms still present, this van doesn't throw an ABS warning light.

I will say this, I scanned the ABS computer, and got some codes from it, there were at least six, but the one that most stood out to me was... brake warning light short to ground... I have a feeling the poster who cleaned the corrosion and dirt from the terminals actually adressed the source...
Like I said, i'll be doing the same thing in the morning and let you know what happens. Lets remember that sometimes similar symptoms arise from different problems... but by the time I do this I will have eliminated other possibilities.

[phil-l]

Ian -

Please let us know how it works out.

To clarify, note that the work I outlined earlier was done solely to address an intermittent ABS light: It came on about once every 2 weeks - and went away as soon as the van was re-started. If you have an ABS light that is on whenever the van is running, you likely have a problem that goes beyond a dirty connector. Get the chassis codes read and address the error properly.

That said, it appears that intermittent ABS lights on this era of Windstar are common - and maddeningly difficult to get rid of. As I gain confidence that what I've done has solved my problem (Still no ABS light!!!), I'll be sharing more details and pictures.

[aviacionlight]

Originally Posted by Ian Szgatti

I work in a shop and am currently working on a windstar that has ABS troubles... first thing tommorow morning I'm going to clean the connector. This van came in with an obvious broken TONER RING... (in case some of you don't know its the gear looking ring that induces the signal to the ABS mod.) I ordered an installed a new shaft and figured on solving the problem. I was surprised to find out the problem still exsisted... not only were the symptoms still present, this van doesn't throw an ABS warning light.

I will say this, I scanned the ABS computer, and got some codes from it, there were at least six, but the one that most stood out to me was... brake warning light short to ground... I have a feeling the poster who cleaned the corrosion and dirt from the terminals actually adressed the source...
Like I said, i'll be doing the same thing in the morning and let you know what happens. Lets remember that sometimes similar symptoms arise from different problems... but by the time I do this I will have eliminated other possibilities.

Ian any update? it works?
Please letus Know.

[knl25]

Tried what Phil described but did not work in my case. My ABS light is still on intermittently. My scantool can access the abs module but did not detect any code.

[phil-l]

knl25 -

As it turns out, all of my effort to clean ABS connections didn't end up making a real difference. The intermittent light came back, and began to show up more frequently over time.

However, your comment comes at a fortuitous moment. After nearly 2000 miles *without* a return of my infamous, annoying intermittent ABS light, I believe I can finally claim victory: I solved the problem on my van.

The solution isn't trivial: I replaced the electronic portion of the ABS controller (the unit underneath the van, under the driver's position). I purchased a new unit from Ford (approx $325), and replaced it *without* opening the brake hydraulic system (no bleeding, etc.). This does require some effort and there are a few tricks to avoid problems.

I took lots of pictures, and have been planning a nice write-up of what I did. I need to finish it up and post it here!

[garync1]

Originally Posted by knl25

Tried what Phil described but did not work in my case. My ABS light is still on intermittently. My scantool can access the abs module but did not detect any code.

My scan tool can also access some ABS codes but not on some ABS with DTC codes. The cheapest I found for the ABS type scanner that will allow to bleed ABS system totally is around 1,000 bucks. Yes the module Phil I speaks of is a common problem on the Windstars My problem is ABS and Brake light came on at the same time. I did some cleaning of some of the ABS electrics and have not had any more issues at this point. I think the heat played a roll here in NC this year because we had a lot of days that never got below 90 degrees and a few of those days hit 100 +. After it started cooling down I have had no transmission problems or ABS problems.. Go figure.. Now after the cool down and the plug wires were changed fuel millage increased and performance is back to normal. Now its not the bomb I thought it was going to end up being this year. 103,000 + miles and going strong.." Knock -ON -Wood".

[69cuda340s]

Anyone have any other ideas on the intermittent ABS light problem? What about the ground TSB?

[LTDzak]

Bringing this one back from the dead - anyone (Phil?) know what kind of fastener is used to attach the ABS module to the ABS HCU (Hydraulic control unit)? A yard sold me a low mileage used module, but the screws were so corroded they included the HCU itself. Trying to get these apart and not clear whether they're allen head, Phillips or what. Don't want to start in on the unit in the car until I can get donar apart.

[LTDzak]

Answering my own post, these are T-15 (or possibly T-18) Torx head screws. Although I won't be taking pictures, will post some notes when done.

Note the post on this page indicates that software needs to be read off the old module and downloaded to the new module. I *think* this is for Windstars having traction control. Neither mine nor the donar car had traction control, so am going to wing it.

LTDzak