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Test J: Brake Warning Indicator Is Never On

  1. Turn ignition switch to LOCK position. If brake warning indicator illuminates, go to step  5 . If brake warning indicator does not illuminate, go to next step.
  2. Ensure parking brake is completely released. Ensure brake fluid reservoir is full. If brake warning indicator illuminates, go to next step. If brake warning indicator does not illuminate, go to step  4 .
  3. Turn ignition switch to RUN position. If brake warning light remains illuminated, go to step  9 . If brake warning light does not stay illuminated, system is working properly at this time.
  4. Connect New Generation Star (NGS) tester. In active command mode, request BRK LMP ON. If brake warning light illuminates, go to step  17 . If brake warning light does not illuminate, go to step  7 .
  5. Turn ignition switch to LOCK position. Disconnect Generic Electronic Module (GEM) harness connector C201b. See Figure . Turn ignition switch to RUN position. If brake warning light stays illuminated, go to next step. If brake warning light does not stay illuminated, go to step  17 .
  6. Turn ignition switch to LOCK position. Disconnect instrument cluster connector C220b and disconnect GEM module harness connector C201b. Turn ignition switch to RUN position. Measure voltage between ground and terminal No. 4 (Light Green/Yellow wire) at instrument cluster harness connector C220b. See Figure . If battery voltage exists, repair short to power in Light Green/Yellow wire. If battery voltage does not exist, replace instrument cluster printed circuit. See PRINTED CIRCUIT  under REMOVAL & INSTALLATION.
  7. Turn ignition switch to LOCK position. Measure voltage between ground and terminal No. 20 (Light Green/Yellow wire) at GEM module harness connector C201b. If battery voltage exists, go to step  17 . If battery voltage does not exist, go to next step.
  8. Disconnect instrument cluster harness connector C220b. Measure resistance between terminal No. 4 (Light Green/Yellow wire) at instrument cluster harness connector C220b and terminal No. 20 (Light Green/Yellow wire) at GEM module harness connector C201b. If resistance is less than 5 ohms, replace instrument cluster printed circuit. See PRINTED CIRCUIT  under REMOVAL & INSTALLATION. If resistance is more than 5 ohms, repair open in Light Green/Yellow wire and retest.
  9. Ensure parking brake is completely released. Ensure brake fluid reservoir is full. If brake warning indicator illuminates, go to next step. If brake warning indicator does not illuminate, go to step  11 .
  10. Disconnect instrument cluster harness connector C220b. Measure resistance between ground and terminal No. 4 (Light Green/Yellow wire) at instrument cluster harness connector C220b. If resistance is more than 10 k/ohms, replace instrument cluster printed circuit. See PRINTED CIRCUIT  under REMOVAL & INSTALLATION. If resistance is less than 10 k/ohms, repair short to ground in Light Green/Yellow wire and retest.
  11. Turn ignition switch to LOCK position. Disconnect Generic Electronic Module (GEM) harness connector C201c. See Figure . If brake indicator light stays on after initial test illumination (prove out), go to step  13 . If brake indicator light does not stay on after initial test illumination, go to next step.
  12. Turn ignition switch to LOCK position. Disconnect parking brake position switch connector C306. Measure resistance between ground and terminal No. 1 (Light Green wire) at parking brake position switch harness connector. If resistance is more than 10 k/ohms, replace parking brake position switch. If resistance is less than 10 k/ohms, repair short to ground in Light Green wire.
  13. Turn ignition switch to LOCK position. Disconnect brake fluid level switch connector C124. Turn ignition switch to RUN position. If brake indicator light stays on after initial test illumination (prove out), go to next step. If brake indicator light does not stay on after initial test illumination, go to step  15 .
  14. Turn ignition switch to LOCK position. Disconnect GEM module connector C201c. See Figure . Measure resistance between ground and terminal No. 3 (Light Green/Yellow wire) brake fluid level switch harness connector C124. If resistance is more than 10 k/ohms, go to step  17 . If resistance is less than 10 k/ohms, repair short to ground in Light Green/Yellow wire and retest.
  15. Turn ignition switch to LOCK position. Ensure that brake fluid reservoir is full. Measure resistance between terminal No. 1 (Black wire) and terminal No. 3 (Light Green/Yellow wire) at brake fluid level switch. If resistance is less than 5 ohms, replace brake fluid level switch. If resistance is more than 5 ohms, go to next step.
  16. Disconnect Anti-Lock Brake System (ABS) module connector C135. See Fig 1 . Measure resistance between ground and terminal No. 2 (Light Blue/Black wire) at brake fluid level switch harness connector C124. If resistance is more than 10 k/ohms, check brake system. See appropriate DISC & DRUM article in BRAKES. . If resistance is less than 10 k/ohms, repair open in Light Blue/Black wire and retest.
  17. Visually inspect GEM module connectors for loose connections, pushed out pins or corrosion. Repair any problems found. Operate system to verify problem is still present. If problem still exists, replace GEM module. See appropriate MODULE COMMUNICATIONS NETWORK article. Repeat GEM self-test. If no problems are found at this point, system is operating correctly at this time.
    Fig 1: Identifying ABS Control Module Connector C135
    G00013161Courtesy of FORD MOTOR CO.
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