LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2001 >> Windstar Base >> Repair and Diagnosis >> Electrical >> Gauges >> Instrument Panels - Analog >> System Tests >> Test K: Brake Warning Indicator Never/Always On ( DTC B2479 & C1189)

Test K: Brake Warning Indicator Never/Always On ( DTC B2479 & C1189)

NOTE: Before testing, ensure brake fluid level is correct.
  1. Turn ignition switch to RUN position and observe brake warning indicator. Start engine and observe brake warning indicator. Brake warning indicator should illuminate for 3 seconds, then turn off. If brake warning indicator operates as specified, system is operating correctly at this time. If brake warning indicator does not operate as specified, go to next step.
  2. Turn ignition switch to RUN position. Observe Anti-Lock Brake System (ABS) warning indicator. Start engine and observe ABS warning indicator. ABS warning indicator should illuminate for 3 seconds, then turn off. If ABS warning indicator operates as specified, go to next step. If ABS warning indicator does not operate as specified, repair ABS concern. See ANTI-LOCK/TRACTION CONTROL - WINDSTAR article in BRAKES.
  3. Using New Generation Star (NGS) tester, perform Front Electronic Module (FEM) self-test. If FEM DTC C1189 was retrieved, go to step  4 . If FEM DTC B2479 was retrieved, go to step  12 . If no DTCs were retrieved, go to step  6 . If any other DTCs were retrieved, perform appropriate test in accordance with DTC retrieved. See FRONT ELECTRONIC MODULE DIAGNOSTIC TROUBLE CODE INDEX  table under SELF-DIAGNOSTIC SYSTEM.
  4. Using NGS tester, select and monitor FEM PID BRK_LVL. If PID reads notOK, go to next step. If PID does not read notOK, go to step  19 .
  5. Turn ignition switch to LOCK position. Disconnect brake fluid warning switch 3-pin harness connector. Using NGS tester, monitor FEM PID BRK_LVL. If PID reads NO, replace brake fluid warning switch. If PID does not read NO, repair short to ground in Dark Blue wire between brake fluid warning switch and FEM.
  6. Turn ignition switch to LOCK position. Disconnect brake fluid warning switch 3-pin harness connector. Using NGS tester, monitor FED PID BRK_LVL. Connect a 10-amp fused jumper wire between ground and brake fluid warning switch harness connector terminal No. 1 (Dark Blue wire). Monitor FEM PID BRK_LVL. If PID changes from OK to notOK, go to step  9 . If PID does not change from OK to not OK, remove jumper and go to next step. If fused jumper wire blows, remove jumper wire and go to step  8 .
  7. Turn ignition switch to LOCK position. Disconnect FEM 12-pin harness connector C190. Measure resistance of Dark Blue wire between brake fluid warning switch harness connector terminal and FEM harness connector C190 terminal No. 11. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Dark Blue wire.
  8. Measure voltage between ground and FEM harness connector C190 terminal No. 11 (Dark Blue wire). See Figure . If voltage exists, repair short to voltage in Dark Blue wire. If voltage does not exist, go to step  19 .
  9. Measure resistance between ground and brake fluid warning switch harness connector terminal Black wire. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Black wire between brake fluid warning switch and ground point. Ground point is located on lower left front of engine compartment.
  10. Measure resistance between brake fluid warning switch terminals (component side) with fluid level empty then full. Resistance should be less than 5 ohms when empty and 10 k/ohms or more when full. If resistance is as specified, go to next step. If resistance is not as specified, replace brake fluid warning switch.
    11. NOTE: Verify parking brake is fully released during this FEM self-test.
  11. Using NGS tester, clear DTCs and repeat FEM self-test. If DTC B2479 is retrieved, go to next step. If DTC B2479 is not retrieved, go to step  14 .
  12. Select and monitor FEM PID PRK_BRK. If PID reads ON, go to next step. If PID does not read ON, go to step  18 .
  13. Disconnect parking brake warning switch single-pin harness connector. Monitor FEM PID PRK_BRK. If PID reads ON, repair short to ground in Red/Yellow wire. If PID does not read ON, replace parking brake warning switch.
  14. Select and monitor FEM PID PRK_BRK with parking brake released and applied. If PID reading does not agree with parking brake switch position, go to next step. If PID reading agrees with parking brake switch position, go to step  19 .
  15. Turn ignition switch to LOCK position. Disconnect parking brake switch single-pin harness connector. Connect 10-amp fused jumper between ground and parking brake switch harness connector Red/Yellow wire terminal. Monitor FEM PID PRK_BRK. If PID does not read ON, go to next step. If PID reads ON, replace park brake switch. If fused jumper wire blows, remove jumper wire and go to step  17 .
  16. Turn ignition switch to LOCK position. Disconnect FEM 20-pin harness connector C346. Measure resistance of Red/Yellow wire between FEM harness connector C346 and parking brake switch harness connector. If resistance is less than 5 ohms, go to step  18 . If resistance is 5 ohms or more, repair open in Red/Yellow wire.
  17. Measure voltage between ground and FEM harness connector C346 terminal No. 19 (Red/Yellow wire). See Figure . If voltage exists, repair short to voltage in Red/Yellow wire. If voltage does not exist, next step.
  18. Disconnect all FEM harness connectors. Inspect for corrosion and pushed out pins. Connect all FEM harness connectors, ensuring they seat correctly. Operate system and verify if concern is still present. If concern is still present, replace FEM. Clear DTCs and perform FEM self-test. If concern is not present, system is operating correctly at this time. Concern may have been caused by a loose or corroded connector.
  19. Disconnect all instrument cluster harness connectors. Inspect for corrosion and pushed out pins. Connect all instrument cluster harness connectors, ensuring they seat correctly. Operate system and verify if concern is still present. If concern is still present, replace instrument cluster. Clear DTCs and perform instrument cluster self-test. If concern is not present, system is operating correctly at this time. Concern may have been caused by a loose or corroded connector.
scientia non olet · About LEMON Manuals