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Anti-Lock Control

Refer to Wiring Diagrams Cell 42, Speed Control for schematic and connector information.

Inspection and Verification

NOTE: Check the integrity of all connectors and their associated harnesses. Be sure to check for the following:

� Frayed wires.

� Loose or damaged connectors.

� Damaged wire harness.

� Dirt or foreign matter in connections.

� Warning indicator bulb(s).

System Pre-Check

NOTE: Perform this procedure first. Failure to do so can result in incorrect diagnosis of a problem, wasted time, and improper replacement of components.

The system pre-check screens a vehicle for relatively simple diagnostic repairs, such as loose connectors, blown fuses, etc. However, the system pre-check also prepares the vehicle for further diagnostics. In addition, warning indicator concerns are diagnosed in this test.

NOTE: The anti-lock brake control module is commonly referred to as the RABS II module. This repair procedure is written for REAR ABS II (RABS II) systems. The RABS II system is standard for Econoline vehicles, except E-Super Duty.

The RABS II uses the instrument panel yellow ABS warning indicator and under some conditions the red BRAKE warning indicator to alert the driver to a system malfunction. Both warning indicators must be working properly to assist in diagnosis. The steps below must be followed prior to beginning the RABS II diagnostic procedure.

Vehicle Setup

WARNING: Place blocks behind the rear wheels (1007) and in front of the front wheels to prevent the vehicle from moving while the system pre-check is being done.

Drive the vehicle to a level area, and place the shift lever in PARK for automatic transmissions (7003). Turn the ignition off, set the parking brake and turn on the running lamps. Place blocks behind the rear wheels and in front of the front wheels.

Release the parking brake.

Warning Indicator Lamp

The red BRAKE warning indicator is constantly monitored by the anti-lock brake control module. If the red BRAKE warning indicator illuminates, the anti-lock brake control module will disable the RABS II system and turn on the yellow ABS warning indicator. For this reason, diagnosing and resolving any base brake concerns illuminating the red BRAKE warning indicator will, in most cases, resolve a perceived RABS II concern.

Red BRAKE Warning Indicator Self Check

The red BRAKE warning indicator is used to indicate a low fluid level condition or parking brake applied condition. To check this warning indicator, insert the key in the ignition switch (11572) and turn it to the START position. The warning indicator should illuminate with the key in the START position. If it fails to illuminate, go to Symptom Chart.

Allow the key to spring back from the START position to the RUN position. At this time, the red BRAKE warning indicator should turn off. If it does not turn off, recheck the parking brake switch to make sure that it is fully disengaged. In the event that the red BRAKE warning indicator remains on, go to Symptom Chart.

Yellow ABS Warning Indicator Self Check

The yellow ABS warning indicator is used to indicate a malfunction and a deactivation of the RABS II. To check this indicator, first go to Red BRAKE Warning Indicator Self Check.

Allow the key to spring back from the START position to the RUN position. The yellow ABS warning indicator should perform a self check by illuminating for approximately two seconds and then turning off. If it turns back on and does not flash, then a system concern has been detected. Refer to Diagnostic Trouble Codes, Retrieving to obtain diagnostic trouble codes. If yellow ABS indicator fails to illuminate, go to Symptom Chart.

Diagnostic Trouble Codes (DTC), Retrieving

CAUTION: Care must be taken to connect only the black/orange stripe wire to ground. Connecting the mating connector wire to ground will result in a blown fuse.

NOTE: Verify the ignition switch is in the RUN position (engine does not need to be running). Next, locate the black RABS II diagnostic connector C208. The diagnostic connector C208 has

SECTION 206-09A: Anti-Lock Control — Rear 1998 E-Series Workshop Manual

DIAGNOSIS AND TESTING Procedure revision date: 02/08/2000

Special Tool(s)

73 Digital Multimeter or equivalent 105-R0051

321998 E-Series Workshop Manual

5/23/2011http://www.fordtechservice.dealerconnection.com/pubs/content/~WSWM/~MUS~LEN/21...

two mating halves, one of which has a BK/O wire connected to it. Disconnect the two halves.

Attach one end of a jumper wire to the BK/O wire side of the diagnostic connector C208. Ground the opposite end of the jumper wire until the ABS light begins to flash. Grounding this wire will start the yellow ABS warning indicator flashing. If grounding this wire does not start the yellow ABS warning indicator flashing, go to Symptom Chart.

The code consists of a number of short flashes and ends with a long flash. Count the short flashes and include the following long flash in the count to obtain the code number. For example, three short flashes followed by one long flash indicates Diagnostic Trouble Code 4. The code will continue to repeat itself until the key is turned off. It is recommended that the code be verified by reading it several times. This code will be used later for system repair instructions. It should be written down for future use. A Diagnostic Trouble Code 16 is obtained when the anti-lock brake control module detects normal system operation.

Diagnostic Trouble Codes, Erasing

The last step of the system pre-check always includes clearing the keep-alive memory (KAM). Turn off the ignition while the diagnostic connector C208 halves are separated as described in the procedures for retrieving the diagnostic trouble code. The diagnostic connector C208 must be re-assembled to provide KAM power to the anti-lock brake control module.

If a valid code has been obtained, go to the appropriate pinpoint test for that code, otherwise go to the Symptom Chart section below.

Symptom Chart

NOTE: Code 16 is always present, unless a system concern has been detected and a DTC has been stored. This code should be used by the technician to verify that the RAB system is OK. Code 16 will be output by the RABS module when the technician grounds circuit 571 (BK/O), or the RABS keep-alive memory fuse has blown.

Please note that both the red BRAKE warning indicator self-check and test drive are required prior to performing the tests in this section. Failure to perform these procedures will greatly diminish the effectiveness of the diagnosis.

Symptom Chart

Condition Possible Sources Action

� The Red BRAKE Warning Indicator Does Not Self-Check

� Red BRAKE warning indicator bulb. � Fuse. � Circuitry. � Resistor/diode element. � Unseated brake fluid level warning switch connector C149. � Defective ignition prove-out switch.

� GO to Pinpoint Test A.

� The Red BRAKE Warning Indicator Stays On When the Ignition Switch Is in RUN

� Circuitry. � Damaged parking brake switch.

� GO to Pinpoint Test B.

� The Yellow ABS Warning Indicator Does Not Self-Check

� Fuse. � Circuitry. � Yellow ABS warning indicator. � Harness connector not fully seated with anti-lock brake control

module. � Anti-lock brake control module. � Incorrect anti-lock brake control module type (RABS I instead of

RABS II).

� GO to Pinpoint Test C.

� The Yellow ABS Warning Indicator Self-Checks OK but Automatically Begins Flashing

� Anti-lock brake control module. � Circuitry. � Keep-alive memory (KAM) Fuse 11.

� GO to Pinpoint Test D.

� The Yellow ABS Warning Indicator Self-Checks OK, but No Diagnostic Trouble Codes Are Retrieved When the Diagnostics Are Started

� Circuitry. � Incorrect anti-lock brake control module type (RABS I instead of

RABS II). � Anti-lock brake control module.

� GO to Pinpoint Test E.

� DTC 2 — Open RABS II Isolation Solenoid Circuit

� Anti-lock brake control module or RABS valve connectors not fully seated.

� Terminal backout in the anti-lock brake control module and/or RABS valve harness connector.

� Bulkhead connector (between engine compartment and instrument panel) terminal backout or loose connection.

� Circuitry. � RABS valve. � Anti-lock brake control module.

� GO to Pinpoint Test F.

� DTC 3 — Open RABS II Dump Solenoid Circuit





� GO to Pinpoint Test G.

� DTC 4 — Open/Grounded RABS Valve Reset Circuit





� GO to Pinpoint Test H.

� DTC 6 — Erratic Rear Anti-Lock Brake Sensor Circuit

� Anti-lock brake control module or RABS sensor connectors not fully seated.

� Terminal backout in the anti-lock brake control module connector. � Bulkhead connector (between engine compartment and

instrument panel) terminal backout or loose connection. � Circuitry. � RABS sensor. � Damaged rear brake anti-lock sensor ring.

� GO to Pinpoint Test J.

� DTC 7 — No Isolation Solenoid During Self-Check


� GO to Pinpoint Test K.

� DTC 8 — No Dump Solenoid During Self- � Circuitry. � GO to Pinpoint Test L.



Check � Bulkhead connector between engine compartment and instrument panel terminals shorted.

� RABS valve. � Anti-lock brake control module.

� DTC 9 — High Speed Sensor Resistance � Terminal backout in the anti-lock brake control module connector. � Anti-lock brake control module or RABS sensor connectors not

fully seated. � Circuitry. � Rear anti-lock brake sensor. � Anti-lock brake control module.

� GO to Pinpoint Test M.

� DTC 10 — Low Speed Sensor Resistance � Circuitry. � Rear anti-lock brake sensor. � Anti-lock brake control module.

� GO to Pinpoint Test N.

� DTC 11 — Brake Pedal Position (BPP) Switch Always Closed

� Terminal backout in the anti-lock brake control module harness connector.

� Stoplamps. � Circuitry. � Brake pedal position (BPP) switch. � Anti-lock brake control module.

� GO to Pinpoint Test P.

� DTC 12 — Loss of Hydraulic Brake Fluid When ABS Is Activated

� Low master cylinder fill level. � Fluid leaks in vehicle brake system. � Worn or damaged brake fluid level warning switch. � Master cylinder float that sticks in the bottom of brake master

cylinder reservoir (2K478) or does not float. � Diode/resistor element. � Damaged ignition switch. � Circuitry. � Damaged anti-lock brake control module.

� GO to Pinpoint Test Q.

� DTC 13 — RABS II Module Failure � Anti-lock brake control module. � GO to Pinpoint Test R.

� DTC 16 — RAB System OK � No system faults detected. � STOP. Rear anti-lock brake system functioning properly.

� Intermittent Problem Suspected � Intermittent connections at speed sensor, RABS valve, anti-lock brake control module.

� Circuitry. � Anti-lock brake control module.

� GO to Pinpoint Test S.

� Unwarranted RABS Activity � Metal chips on rear anti-lock brake sensor pole piece. � GO to Pinpoint Test J.

� Intermittent open rear anti-lock brake sensor circuit at intermediate connections especially bulkhead.

� GO to Pinpoint Test S.

� Circuitry. � INSPECT wiring harness from rear axle assembly to frame side rail for chafing or rub marks.

� Rear brake adjustment too tight. � ADJUST as necessary.

� Brake linings are grabby. � REPAIR and/or REPLACE as necessary.

� One or Both Wheels Lock Up � Damaged RABS valve reset switch. � GO to Pinpoint Test H.

� Hydraulically inoperative RABS valve. � GO to Pinpoint Test H.

� RABS sensor air gap too large. � GO to Pinpoint Test J.

� RABS sensor/rear anti-lock brake sensor indicator does not produce sufficient output.

� REFER to Pinpoint Test J.

� Brake related concern: damp or contaminated rear brake shoe linings, stuck/leaking rear wheel cylinder or overadjusted rear brake drums.

� REPAIR and/or REPLACE as necessary.

� Hung-up parking brake. � REFER to Section 206-05.

� Brake pedal position switch input to anti-lock brake control module not present.

� GO to Pinpoint Test P.

� Stoplamps inoperative. � REFER to Section 417-01.

� Soft/Hard Brake Pedal � Leaky dump valve (soft pedal). � GO to Pinpoint Test H.

� Leaky isolation valve during RABS stop (soft pedal). � GO to Pinpoint Test K.

� Stoplight switch always on while driving. � GO to Pinpoint Test P.

� Hydraulic leak in rear brake tube or rear brake hose, fitting, brake master cylinder, rear wheel cylinder, or front disc brake caliper.

� REPAIR as necessary.

� Air in brake system. � BLEED the system. REFER to Section 206-00.

� Brake related concern: little or no vacuum boost, stuck or inoperative rear wheel cylinder or front disc brake caliper, or pinched or crimped rear brake tube or rear brake hose.


� Lack of Deceleration During Medium/Hard Brake Applications

� Leaky dump valve. � GO to Pinpoint Test H.

� Stuck shut isolation valve. � GO to Pinpoint Test H.

� Circuitry. � GO to Pinpoint Test J.

� Metal chips on rear anti-lock brake sensor. � GO to Pinpoint Test J.

� Borderline high rear anti-lock brake sensor to rear anti-lock brake sensor indicator air gap, excessive rear anti-lock brake sensor indicator radial runout, damaged or missing rear anti-lock brake sensor indicator teeth.

� GO to Pinpoint Test J.

� Hydraulic leak in brake line tubing or rear brake hose, fitting, brake master cylinder, rear wheel cylinder, or front disc brake caliper.


� Air in brake system. � BLEED the system. REFER to Section 206-00.

� Brake related concern: little or no vacuum boost, stuck or inoperative wheel cylinder or caliper, pinched or crimped rear brake hose or brake line tubing, or ineffective brake shoe or pad linings.




Pinpoint Tests

PINPOINT TEST A: THE RED BRAKE WARNING INDICATOR DOES NOT SELF-CHECK

CONDITIONS DETAILS/RESULTS/ACTIONS

A1 CHECK THE RED BRAKE WARNING INDICATOR/FUSE

Engage the parking brake.

� Does the red BRAKE warning indicator illuminate?

Yes RELEASE the parking brake. GO to A2 .

No REFER to Section 413-01A.

A2 CHECK THE DIODE RESISTOR ELEMENT AND CIRCUIT 531 (DG/Y)

Brake Fluid Level Warning Switch C149

Connect a jumper wire between brake fluid level warning switch C149-3, circuit 531 (DG/Y), and ground.


Yes GO to A3.

No REPAIR circuit 531 (DG/Y) and/or diode resistor element. REPEAT the system pre-check.

A3 CHECK THE BRAKE FLUID LEVEL WARNING SWITCH

NOTE: Check for corroded or unseated pins before repairing and/or replacing the brake fluid level warning switch.

Connect a jumper wire between brake fluid level warning switch C149-3, circuit 531 (DG/Y), and brake fluid level warning switch C149-2, circuit 512 (T/LG).



� Does the red BRAKE warning indicator lamp illuminate?

Yes REPLACE the brake fluid level warning switch. REPEAT the system pre-check.

No GO to A4.

A4 CHECK CIRCUIT 512 (T/LG) FOR AN OPEN

Anti-Lock Brake Control Module C217

Measure the resistance between anti-lock brake control module C217-2, circuit 512 (T/LG), and brake fluid level warning switch C149-2, circuit 512 (T/LG).

� Is the resistance less than 5 ohms?

Yes GO to A5.

No REPAIR circuit 512 (T/LG). REPEAT the system pre-check.

A5 CHECK THE IGNITION SWITCH

Ignition Switch C240

Measure the resistance between ignition switch terminal P1, and ground, while in the START position.


Yes GO to A6.

No REPLACE the ignition switch. REPEAT the system pre-check.

A6 CHECK CIRCUIT 531 (DG/Y) FOR AN OPEN

Measure the resistance between brake warning switch C149-3, circuit 531 (DG/Y), and ignition switch C240-P1, circuit 531 (DG/Y).



PINPOINT TEST B: THE RED BRAKE WARNING INDICATOR STAYS ON WHEN THE IGNITION SWITCH IS IN RUN


Yes REPLACE the anti-lock brake control module. REPEAT system pre-check.

No REPAIR circuit 531 (DG/Y). REPEAT the system pre-check.


B1 CHECK THE WARNING INDICATOR LAMPS

Disengage the parking brake.

� Do both the red BRAKE warning indicator and the yellow ABS warning indicator illuminate?

Yes RETRIEVE the codes. GO to Symptom Chart.

No GO to B2.

B2 CHECK THE PARKING BRAKE SWITCH

Parking Brake Switch C243


Yes GO to B3.

No REPLACE the parking brake switch. REPEAT the system pre-check.

B3 CHECK THE ANTI-LOCK BRAKE CONTROL MODULE



PINPOINT TEST C: THE YELLOW ABS WARNING INDICATOR DOES NOT SELF-CHECK



Yes REFER to Section 413-01A.

No REPLACE the anti-lock brake control module. REPEAT the system pre-check.


C1 CHECK THE FUSE JUNCTION PANEL FUSE 2 (15A)

Fuse Junction Panel Fuse 2 (15A)

� Is the fuse OK?

Yes GO to C2.

No REPLACE the failed fuse. TEST the system for normal operation. If the fuse fails again, CHECK for short to ground. REPAIR as necessary. REPEAT the system pre-check.

C2 CHECK ANTI-LOCK BRAKE CONTROL MODULE GROUND

NOTE: When checking resistance in the RABS system, always disconnect the battery to starter relay cable. Improper resistance can occur with the vehicle battery connected.


Disconnect the battery ground cable. On vehicles equipped with dual batteries, refer to Section 414-01.

Measure the resistance between anti-lock brake control module C217-4, circuit 530 (LG/Y), and ground.


Yes RECONNECT the battery ground cable. On vehicles equipped with dual batteries, refer to Section 414-01. GO to C3 .



PINPOINT TEST D: THE YELLOW ABS WARNING INDICATOR SELF-CHECKS OK BUT AUTOMATICALLY BEGINS FLASHING

No REPAIR circuit 530 (LG/Y). REPEAT the system pre-check.

C3 CHECK VOLTAGE TO THE YELLOW ABS WARNING INDICATOR

Measure the voltage between anti-lock brake control module C217-7, circuit 603 (DG), and ground.

� Is the voltage greater than 10 volts?

Yes REPLACE the anti-lock brake control module. REPEAT the system pre-check.

No GO to C4.

C4 CHECK CIRCUIT 603 (DG) FOR AN OPEN

Instrument Cluster C225

Measure the resistance between anti-lock brake control module C217-7, circuit 603 (DG), and instrument cluster C225-8, circuit 603 (DG).


Yes REPAIR and/or REPLACE the instrument cluster. REPEAT the system pre-check.

No REPAIR circuit 603 (DG). REPEAT the system pre-check.


D1 OBSERVE THE YELLOW ABS WARNING INDICATOR LAMP FOR FLASH SEQUENCE

NOTE: A diagnostic trouble code (DTC) will appear as one or more short pulses followed by one long pulse.

Observe the yellow ABS warning indicator lamp.

� Is the flash sequence a DTC?

Yes GO to the Symptom Chart for diagnosis of the DTC.



No GO to D2.

D2 CHECK FUSE JUNCTION PANEL FUSE 11 (15A)

Fuse Junction Panel Fuse 11 (15A)

� Is the fuse OK?

Yes GO to D3.

No REPLACE the failed fuse. TEST the system for normal operation. If the fuse fails again, CHECK for short to ground. REPAIR as necessary. REPEAT the system pre-check.

D3 CHECK VOLTAGE TO THE ANTI-LOCK BRAKE CONTROL MODULE


Measure the voltage between anti-lock brake control module C217-1, circuit 601 (LB/PK), and ground; and between anti-lock brake control module C217-9, circuit 601 (LB/PK), and ground, while shaking the wiring harness.

� Is the voltage steady and greater than 10 volts?

Yes GO to D4.

No REPAIR circuit 601 (LB/PK). REPEAT the system pre-check.

D4 CHECK THE ANTI-LOCK BRAKE CONTROL MODULE GROUND

Disconnect the battery ground cable. On vehicles equipped with dual batteries, refer to Section 414-01.

Measure the resistance between anti-lock brake control module C217-4, circuit 530 (LG/Y), and ground, while shaking the wiring harness.



PINPOINT TEST E: THE YELLOW ABS WARNING INDICATOR SELF CHECKS OK BUT NO DIAGNOSTIC TROUBLE CODES ARE RETRIEVED WHEN THE DIAGNOSTICS ARE STARTED

� Is the resistance steady and less than 5 ohms?


No REPAIR circuit 530 (LG/Y). REPEAT the system pre-check.


E1 CHECK THE BRAKE PEDAL POSITION (BPP) SWITCH

Depress the brake pedal (2455).

� Do the stoplamps function properly?

Yes GO to E2.

No REFER to Section 417-01.

E2 CHECK THE BRAKE PEDAL POSITION (BPP) SWITCH INPUT TO THE ANTI-LOCK BRAKE CONTROL MODULE


Depress the brake pedal.



Measure the voltage between anti-lock brake control module C217-11, circuit 511 (LG), and ground.


Yes GO to E3.

No REPAIR circuit 511 (LG). REPEAT the system pre-check.

E3 CHECK VOLTAGE TO THE ANTI-LOCK BRAKE CONTROL MODULE

Measure the voltage between anti-lock brake control module C217-1, circuit 601 (LB/PK), and ground; and between anti-lock brake control module C217-9, circuit 601 (LB/PK), and ground.

� Are the voltages greater than 10 volts?

Yes GO to E4.

No REPAIR circuit 601 (LB/PK). REPEAT the system pre-check.

E4 CHECK CIRCUIT 603 (DG) FOR A SHORT TO GROUND

Observe the yellow ABS warning indicator.

� Is the yellow ABS warning indicator on continuously?

Yes REPAIR circuit 603 (DG). REPEAT the system pre-check.

No GO to E5.

E5 CHECK THE KEEP-ALIVE MEMORY (KAM) CIRCUIT 571 (BK/O)



PINPOINT TEST F: DIAGNOSTIC TROUBLE CODE (DTC) 2 — OPEN RABS II ISOLATION SOLENOID CIRCUIT

Diagnostic Test Connector C208

Measure the resistance between anti-lock brake control module C217-12, circuit 571 (BK/O), and diagnostic test connector C208M, circuit 571 (BK/O).



No REPAIR circuit 571 (BK/O). REPEAT the system pre-check.


F1 DETERMINE IF THE FAULT IS HARD OR INTERMITTENT



� Does the yellow ABS warning indicator illuminate?

Yes GO to F2.

No Intermittent fault. GO to Pinpoint Test S.

F2 CHECK CIRCUIT 599 (PK/LG) FOR AN OPEN

RABS Valve C153


Measure the resistance between anti-lock brake control module C217-13, circuit 599 (PK/LG), and RABS valve C153-4, circuit 599 (PK/LG).



PINPOINT TEST G: DIAGNOSTIC TROUBLE CODE (DTC) 3 — OPEN RABS II DUMP SOLENOID CIRCUIT


Yes GO to F3.

No REPAIR circuit 599 (PK/LG). REPEAT the system pre-check.

F3 CHECK THE RESISTANCE OF THE RABS VALVE ISOLATION SOLENOID

Measure the resistance between the RABS valve terminals 3 and 4.

� Is the resistance between 2.7 and 6.6 ohms?


No REPLACE the RABS valve. REPEAT the system pre-check.


G1 DETERMINE IF THE FAULT IS HARD OR INTERMITTENT



� Does the yellow ABS warning indicator lamp illuminate?

Yes



PINPOINT TEST H: DIAGNOSTIC TROUBLE CODE (DTC) 4 — OPEN/GROUNDED RABS VALVE RESET CIRCUIT

Hard fault. GO to G2 .


G2 CHECK CIRCUIT 664 (Y/LG) FOR AN OPEN

RABS Valve C153


Measure the resistance between anti-lock brake control module C217-14, circuit 664 (Y/LG), and RABS valve C153-1, circuit 664 (Y/LG); and between anti-lock brake control module C217-8, circuit 664 (Y/LG), and RABS valve C153-1, circuit 664 (Y/LG).

� Are the resistances less than 5 ohms?

Yes GO to G3.

No REPAIR circuit 664 (Y/LG). REPEAT the system pre-check.

G3 CHECK THE RESISTANCE OF THE RABS DUMP VALVE SOLENOID


� Is resistance between 0.9 and 3.3 ohms?




H1 DETERMINE IF THE FAULT IS HARD OR INTERMITTENT





� Do the yellow ABS and red BRAKE warning indicators illuminate?

Yes GO to H2.


H2 CHECK CIRCUIT 535 (LB/R) FOR AN OPEN

RABS Valve C153


Measure the resistance between anti-lock brake control module C217-6, circuit 535 (LB/R), and RABS valve C153-2, circuit 535 (LB/R).


Yes GO to H3.

No REPAIR circuit 535 (LB/R). REPEAT the system pre-check.

H3 CHECK CIRCUIT 57 (BK) FOR AN OPEN

Measure the resistance between RABS valve C153-3, circuit 57 (BK), and ground.




Yes GO to H4.

No REPAIR circuit 57 (BK). REPEAT the system pre-check.

H4 CHECK CIRCUIT 535 (LB/R) FOR A SHORT TO GROUND

Measure the resistance between anti-lock brake control module C217-6, circuit 535 (LB/R), and ground.

� Is the resistance greater than 10,000 ohms?

Yes GO to H5.

No REPAIR circuit 535 (LB/R). REPEAT the system pre-check.

H5 CHECK THE RABS VALVE RESET SWITCH

Measure the resistance between RABS valve terminal 2 and ground.




PINPOINT TEST J: DIAGNOSTIC TROUBLE CODE (DTC) 6 — ERRATIC REAR ANTI-LOCK BRAKE SENSOR CIRCUIT




J1 DETERMINE IF THE FAULT IS HARD OR INTERMITTENT




Yes GO to J2.


J2 VERIFY INTEGRITY OF REAR ANTI-LOCK BRAKE SENSOR WIRE ROUTING

Inspect the wire routing.

� Are the wires secure, undamaged, and properly routed?

Yes GO to J3.

No REPAIR as necessary. REPEAT the system pre-check.

J3 CHECK THE REAR ANTI-LOCK BRAKE SENSOR RESISTANCE


Measure the resistance between anti-lock brake control module C217-3, circuit 519 (LG/BK), and anti-lock brake control module C217-10, circuit 523 (R/PK), while shaking the wire harness.

� Is the resistance steady and between 800-3500 ohms?

Yes GO to J4.

No GO to J8.

J4 CHECK THE REAR ANTI-LOCK BRAKE SENSOR CIRCUIT FOR A SHORT TO GROUND

Measure the resistance between anti-lock brake control module C217-3, circuit 519 (LG/BK), and ground; and between anti-lock brake control module C217-10, circuit 523 (R/PK), and ground.



� Are the resistances greater than 10,000 ohms?

Yes GO to J5.

No GO to J10.

J5 CHECK FOR METAL SHAVINGS ON THE REAR ANTI-LOCK BRAKE SENSOR MAGNET POLE

Remove the rear anti-lock brake sensor from the rear differential case (4204) and inspect for metal shavings and chips on the rear anti-lock brake sensor pole piece.

� Are metal shavings/chips present?

Yes DRAIN and CLEAN the rear differential case. GO to J6 .

No GO to J7.

J6 CHECK REAR ANTI-LOCK BRAKE SENSOR OUTPUT


Raise and support the vehicle on a hoist so that all wheels are clear of the ground.

Turn the wheels at 8 km/h (5 mph).

Measure the voltage between anti-lock brake control module C217-3, circuit 519 (LG/BK), and anti-lock brake control module C217-10, circuit 523 (R/PK).



� Is the voltage steady and approximately 650 milli-VAC RMS?

Yes GO to J7.

No REPLACE the rear anti-lock brake sensor. REPEAT the system pre-check.

J7 CHECK THE REAR ANTI-LOCK BRAKE SENSOR RING TEETH

Remove the differential case cover.

Carefully inspect each tooth on the rear anti-lock brake sensor indicator.

� Are any teeth missing or damaged?

Yes REPLACE the rear anti-lock brake sensor indicator. REPEAT the system pre-check.


J8 CHECK THE REAR ANTI-LOCK BRAKE SENSOR FOR AN OPEN

Rear Anti-Lock Brake Sensor C415

Measure the resistance between the rear anti-lock brake sensor terminals.

� Is the resistance between 800 and 3500 ohms?

Yes GO to J9.


J9 CHECK CIRCUIT 519 (LG/BK) FOR AN OPEN

Measure the resistance between anti-lock brake control module C217-3, circuit 519 (LG/BK), and rear anti-lock



PINPOINT TEST K: DIAGNOSTIC TROUBLE CODE (DTC) 7 — NO ISOLATION SOLENOID DURING SELF-CHECK

brake sensor C415, circuit 519 (LG/BK).


Yes REPAIR circuit 523 (R/PK). REPEAT the system pre-check.

No REPAIR circuit 519 (LG/BK). REPEAT the system pre-check.

J10 CHECK THE REAR ANTI-LOCK BRAKE SENSOR FOR SHORT TO GROUND


Measure the resistance between the rear anti-lock brake sensor terminal, and ground.


Yes GO to J11.


J11 CHECK CIRCUIT 519 (LG/BK) FOR SHORT TO GROUND

Measure the resistance between anti-lock brake control module C217-3, circuit 519 (LG/BK), and ground.





K1 DETERMINE IF THE FAULT IS HARD OR INTERMITTENT





� Does the yellow ABS warning indicator lamp illuminate?

Yes GO to K2.


K2 CHECK RABS ISOLATION VALVE

Brake Pressure Regulator Valve C153

Check the resistance between C153, component side, circuit 599 (PK/LG) and C153, component side, circuit 57 (BK).


Yes GO to K3.

No INSTALL a new brake pressure regulator valve. REPEAT the system pre-check.

K3 CHECK CIRCUIT 599 (PK/LG) FOR AN OPEN

Check the resistance between C217, pin 13, circuit 599 (PK/LG), and C153, circuit 599 (PK/LG).


Yes GO to K4.

No REPAIR circuit 599 (PK/LG). REPEAT the system pre-check.

K4 CHECK CIRCUIT 57 (BK) FOR AN OPEN

Check the resistance between C153, circuit 57 (BK) and ground.




PINPOINT TEST L: DIAGNOSTIC TROUBLE CODE 8 — NO DUMP SOLENOID DURING SELF-CHECK

Yes INSTALL a new RABS valve. REPEAT the system pre-check.

No REPAIR circuit 57 (BK). REPEAT the system pre-check.


L1 DETERMINE IF THE FAULT IS HARD OR INTERMITTENT




Yes Hard fault. GO to L2 .


L2 CHECK CIRCUIT 664 (Y/LG) AND RABS DUMP VALVE SOLENOID FOR SHORT TO GROUND


Measure the resistance between anti-lock brake control module C217-8, circuit 664 (Y/LG), and anti-lock brake control module circuit 664 (Y/LG), and ground.

� Are the resistances between 1-3 ohms?


No GO to L3.



PINPOINT TEST M: DIAGNOSTIC TROUBLE CODE (DTC) 9 — HIGH SPEED SENSOR RESISTANCE

L3 CHECK THE RABS VALVE DUMP SOLENOID

RABS Valve C153


� Is the resistance 3-6 ohms?

Yes REPAIR circuit 664 (Y/LG). REPEAT the system pre-check.



M1 DETERMINE IF THE FAULT IS HARD OR INTERMITTENT




Yes GO to M2.


M2 VERIFY THE INTEGRITY OF THE REAR ANTI-LOCK BRAKE SENSOR WIRE ROUTING

Inspect the wire routing.

� Are the wires secure, undamaged, and properly routed?

Yes GO to M3.

No REPAIR as necessary. REPEAT the system pre-check.

M3 CHECK THE REAR ANTI-LOCK BRAKE SENSOR RESISTANCE


Measure the resistance between anti-lock brake control module C217-3, circuit 519 (LG/BK), and anti-lock brake



control module C217-10, circuit 523 (R/PK), while shaking the wire harness.

� Is the resistance steady and between 800-3500 ohms?

Yes GO to M4.

No GO to M5.

M4 CHECK THE REAR ANTI-LOCK BRAKE SENSOR CIRCUIT FOR A SHORT TO GROUND




No GO to M7.

M5 CHECK THE REAR ANTI-LOCK BRAKE SENSOR FOR AN OPEN


Measure the resistance between the rear anti-lock brake control sensor terminals.


Yes GO to M6.

No REPLACE the anti-lock brake sensor. REPEAT the system pre-check.

M6 CHECK CIRCUIT 519 (LG/BK) FOR AN OPEN

Measure the resistance between anti-lock brake control module C217-3, circuit 519 (LG/BK), and rear anti-lock



PINPOINT TEST N: DIAGNOSTIC TROUBLE CODE (DTC) 10 — LOW SPEED SENSOR RESISTANCE

brake sensor C415, circuit 519 (LG/BK).




M7 CHECK THE REAR ANTI-LOCK BRAKE SENSOR FOR SHORT TO GROUND


Measure the resistance between the rear anti-lock brake sensor terminal, and ground.


Yes GO to M8.


M8 CHECK CIRCUIT 519 (LG/BK) FOR SHORT TO GROUND

Measure the resistance between the anti-lock brake control module C217-3, circuit 519 (LG/BK), and ground.





N1 DETERMINE IF THE FAULT IS HARD OR INTERMITTENT






Yes GO to N2.


N2 CHECK CIRCUITS 519 (LG/BK) AND 523 (R/PK) FOR A SHORT



Measure the resistance between anti-lock brake control module C217-3, circuit 519 (LG/BK), and anti-lock brake control module circuit 523 (R/PK).


Yes GO to N3.

No REPAIR the short between circuits 519 (LG/PK) and 523 (R/PK). REPEAT the system pre-check.

N3 CHECK CIRCUITS 523 (R/PK) AND 519 (LG/BK) FOR SHORT TO GROUND





PINPOINT TEST P: DIAGNOSTIC TROUBLE CODE (DTC) 11 — BRAKE PEDAL POSITION (BPP) SWITCH ALWAYS CLOSED

Yes GO to N4.

No REPAIR circuit 523 (R/PK) and/or 519 (LG/BK). REPEAT the system pre-check.

N4 CHECK THE REAR ANTI-LOCK BRAKE SENSOR RESISTANCE

Measure the resistance between the rear anti-lock brake sensor terminals.

� Is the resistance between 800-3500 ohms?

Yes GO to N5.


N5 CHECK THE REAR ANTI-LOCK BRAKE SENSOR FOR A SHORT TO GROUND

Measure the resistance between rear anti-lock brake sensor terminal, and ground.


Yes REPLACE the rear anti-lock brake sensor. REPEAT the system pre-check.



P1 CHECK STOPLAMP OPERATION

Depress the brake pedal. Observe the stoplamps.

� Do the stoplamps function correctly?

Yes GO to P2.

No REFER to Section 417-01.

P2 CHECK CIRCUIT 511 (LG) FOR AN OPEN



PINPOINT TEST Q: DIAGNOSTIC TROUBLE CODE (DTC) 12 — LOSS OF HYDRAULIC BRAKE FLUID WHEN ABS IS ACTIVATED



Measure the voltage between anti-lock brake control module C217-11, circuit 511 (LG), and ground.



No REPAIR circuit 511 (LG). REPEAT the system pre-check.


Q1 DETERMINE IF THE FAULT IS HARD OR INTERMITTENT




Yes GO to Q2.


Q2 CHECK THE BRAKE FLUID LEVEL

Check the brake fluid level in the brake master cylinder reservoir.

� Is the fluid level OK?

Yes GO to Q3.



No CHECK for leaks in the brake system. REPAIR as necessary. FILL the brake master cylinder reservoir to the specified level. REPEAT the system pre-check.

Q3 CHECK CIRCUIT 531 (DG/Y) FOR SHORT TO GROUND

Brake Fluid Level Switch C149

Measure the resistance between brake fluid level switch C149-3, circuit 531 (DG/Y), and ground.


Yes GO to Q4.

No GO to Q6.

Q4 CHECK THE DIODE/RESISTOR ELEMENT

Engage the parking brake.



Yes GO to Q5.

No REPLACE the resistor/diode element. REPEAT the system pre-check.

Q5 CHECK CIRCUIT 512 (T/LG) FOR SHORT TO GROUND


Measure the resistance between brake fluid level switch C149-2, circuit 512 (T/LG), and ground.



PINPOINT TEST R: DIAGNOSTIC TROUBLE CODE (DTC) 13 — RABS II MODULE FAILURE


Yes RECONNECT the brake fluid level switch. GO to Q7 .

No REPAIR circuit 512 (T/LG). REPEAT the system pre-check.

Q6 CHECK THE IGNITION SWITCH

Ignition Switch C240



Yes REPLACE the ignition switch. REPEAT the system pre-check.

No REPAIR circuit 531 (DG/Y). REPEAT the system pre-check.

Q7 CHECK THE BRAKE FLUID LEVEL SWITCH

Measure the resistance between anti-lock brake control module C217-2, circuit 512 (T/LG), and ground.

� Is the resistance 5 ohms or less?

Yes REPLACE the brake fluid level switch. REPEAT the system pre-check.



R1 CHECK THE KEEP-ALIVE MEMORY (KAM) FUSE

Observe the yellow ABS warning indicator proveout.

� Does the yellow ABS warning indicator prove out normally?



PINPOINT TEST S: INTERMITTENT PROBLEM DIAGNOSIS

Yes GO to R2.

No REPLACE the KAM fuse junction panel fuse 11 (15A). If the fuse fails again, CHECK for short to ground. REPAIR as necessary. REPEAT the system pre-check.

R2 CHECK LOW SPEED ABS STOP

NOTE: Wetting down the area where the stop is to be performed will aid in the accomplishment of this test.

Drive at approximately 16 km/h (10 mph).

Press on the brake pedal hard enough to lock all four wheels, and observe the rear wheels in mirrors or using an observer.

� Do one or both of the wheels lock up consistently? (Momentary lockup is permissible.)

Yes GO to R3.

No If other symptoms are detected, GO to Symptom Chart. If the yellow ABS warning indicator does not illuminate, GO to R4 . If the yellow ABS warning indicator illuminates and stays illuminated, REPEAT the system pre-check.

R3 CHECK FOR UNWARRANTED ABS ACTIVITY

NOTE: Stopping must be performed on dry pavement.

NOTE: Windshield wipers must be turned off during this test.

Drive at approximately 32 km/h (20 mph).

Perform a normal traffic stop.

Feel for pulsation in the brake pedal during the stop and within 10 seconds after the vehicle has come to a stop.

� Is there any pulsation in the brake pedal at any time during the stop or within 10 seconds after the

vehicle has stopped?

Yes GO to Symptom Chart.

No If the other symptoms are detected, GO to Symptom Chart. If the yellow ABS warning indicator does not illuminate, GO to R4 . If the yellow ABS warning indicator illuminates and stays illuminated, REPEAT the system pre-check.

R4 CHECK THE BRAKE PEDAL POSITION (BPP) SWITCH


� Do the stoplamps function properly?

Yes REPEAT the system pre-check.

No GO to Pinpoint Test P.




S1 CLEAR THE DTCs

Reconnect the system.

Clear all DTCs.

� Does the yellow ABS warning indicator prove out?

Yes GO to S3.

No GO to S2.

S2 WIGGLE TEST

NOTE: Start at one component and wiggle connector by connector until the whole circuit has been tested.

Wiggle an affected circuit in one location only.

Observe the yellow ABS warning indicator.


Yes REPAIR the wire, terminal, or connector in question. GO to S3 .

No GO to S4.

S3 RETRIEVE CODES

Retrieve the DTCs.

� Is a DTC retrieved?

Yes GO to Symptom Chart.

No GO to S4.

S4 VERIFY THE CONDITION IS RESOLVED

Clear all DTCs.

Retrieve the DTCs.

� Is DTC 16 set?

Yes STOP. The repair is complete.

No REFER to Symptom Chart.



~www2.justanswer.com/uploads/fordguy4u/2011-05-23_200733_a1.pdfmay 23, 2011 · dtc 16 — rab...

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