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Test W: Brake Warning Never/Always On

  1. Ensure brake fluid reservoir is full. Turn ignition on. Observe prove-out cycle. If brake warning indicator is always on, go to next step. If brake warning indicator is never on, turn ignition off. Remove instrument cluster. See REMOVAL & INSTALLATION  . Remove indicator bulb. Check for continuity between indicator bulb terminals. If continuity is not present, replace bulb. If continuity is present, go to next step.
  2. Turn ignition off. With instrument cluster removed, disconnect instrument cluster connector C276. See Figure . Turn ignition on. Measure voltage between ground and instrument cluster connector C276, pin No. 20 (Blue wire). If voltage is 10 volts or less, go to next step. If voltage is greater than 10 volts, replace instrument cluster.
  3. Turn ignition off. Disconnect instrument cluster connector C276. Disconnect brake fluid level switch connector, located under brake fluid reservoir. Remove bulb check relay from main fuse panel. See Fig 1 . Disconnect top Black diode strip from junction box No. 1 located behind instrument cluster. See Figure . Measure resistance between ground and instrument cluster connector C276, pin No. 16 (Yellow/Purple wire). If resistance is greater than 10,000 ohms, go to next step. If resistance is 10,000 or less, repair short in Yellow/Purple wire.
    Fig 1: Locating Bulb Check Relay
    G96C01166Courtesy of FORD MOTOR CO.
    Fig 2: Identifying Bulb Check Relay Connector Terminals
    G96E01167Courtesy of FORD MOTOR CO.
  4. Leave ignition off. Measure resistance of Yellow/Purple wire between instrument cluster connector C276, pin No. 16 and bulb check relay connector, pin No. 3. See Fig 2 . If resistance is less than 5 ohms, go to next step. If resistance is 5 or more, repair open in Yellow/Purple wire.
  5. Check RELAYS fuse located in interior fuse panel. If fuse is blown, go to next step. If fuse is okay, go to step 8).
  6. Ensure ignition is off. Replace blown RELAYS fuse. Turn ignition on. If fuse blows again, again, go to next step. If fuse is okay, go to step 8).
  7. Leave ignition off. Remove RELAYS fuse and bulb check relay. Measure resistance of Blue wire between RELAYS fuse (right terminal) and ground. If resistance is 5 ohms or more, replace RELAYS fuse and go to next step. If resistance is less than 5 ohms, repair short in Blue wire.
  8. Turn ignition on. Measure voltage between pin No. 2 (Blue wire) at bulb check relay connector and ground. If voltage is 10 volts or more, go to next step. If voltage is less than 10 volts, repair open in Blue wire.
  9. Turn ignition off. Ensure top Black diode strip of junction box No. 1 is disconnected. Measure resistance of Blue/Yellow wire between instrument cluster connector C276, pin No. 6 and bulb check relay connector pin No. 1. If resistance is less than 5 ohms, go to next step. If resistance is 5 or more, repair open in Blue/Yellow wire.
  10. Leave ignition off. Measure resistance of Black wire between bulb check relay connector and ground. If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, go to step 18).
  11. Leave ignition off and bulb check relay disconnected. Using a jumper wire, connect pin No. 2 of bulb check relay to positive battery terminal. See Fig 2 . Measure resistance between pin No. 3 and No. 5 as follows:
    • With pin No. 2 of bulb check relay connected to positive battery terminal, less than 5 ohms should be present.
    • With pin No. 2 of bulb check relay not connected to positive battery terminal, more than 5 ohms should be present.

    If resistances are as specified, go to next step. If resistances are not as specified, replace bulb check relay.

  12. Leave ignition off and brake fluid level switch disconnected. Remove screen from inside brake master cylinder reservoir. Measure resistance between brake fluid level switch terminals. Using a clean screwdriver, depress brake fluid level switch float. Measure resistance between brake fluid level switch terminals again. If resistance is greater than 10,000 ohms when float is released, and less than 5 ohms when float is depressed, go to next step. If resistances are not as specified, replace brake fluid level switch.
  13. Leave ignition off. Disconnect instrument cluster connector C276. Measure resistance of Yellow/Purple wire between connector C276, pin No. 16 and brake fluid level switch connector. If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, repair open in Yellow/Black wire.
  14. Leave ignition off. Measure resistance of Black wire between brake fluid level switch connector and ground. If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, go to step 18).
  15. Leave ignition off. Disconnect parking brake switch connector (located on parking pedal). With parking brake released, measure resistance between parking brake switch connector and ground. Set parking brake. Measure resistance between parking brake switch connector and ground again. If resistance with parking brake released is greater than 10,000 ohms and less than 5 ohms when parking brake is set, go to next step. If resistances are not as specified, replace parking brake switch.
  16. Turn ignition off. Ensure top Black diode strip of junction box No. 1 is disconnected. Measure resistance of Yellow/Purple wire between instrument cluster connector C276, pin No. 16 and diode junction box No. 1 connector C2011, pin No. 10. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair open in Yellow/Purple wire.
  17. Leave ignition off. Measure resistance of Green/Black wire between diode junction box No. 1 connector C2011, pin No. 9 and parking brake switch connector. If resistance is 5 ohms or less, replace Black diode strip on diode junction box No. 1. If resistance is greater than 5 ohms, repair open in Green/Black wire.
  18. Leave ignition off. Remove joint connector strips from fuse/relay panel junction connector C1001 located in engine compartment fuse/relay panel. See Fig 3 . Measure resistance of Black wire between junction connector C1001, pin No. 1. If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, repair open in Black wire.
  19. Leave ignition off. Measure resistance between junction connector C1001, pins No. 1 and 3 (Both Black wires). Measure resistance between junction connector C1001, pins No. 1 and 2 (Both Black wires). If resistance is 5 ohms or less and sent here from step 10), repair Black wire between bulb check relay and junction connector C1001. If resistance is 5 ohms or less and sent here from step 14), repair Black wire between frake fluid level switch and joint connector C1001. If resistance is greater than 5 ohms, replace joint connector strip.
Fig 3: Identifying Fuse/Relay Panel Junction Connector C1001
G97E28104Courtesy of FORD MOTOR CO.
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