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Test J: Brake Warning Light Never/Always On

NOTE: If brake warning light is always on, start test at step 2).
  1. Turn ignition switch off. Remove instrument cluster. See INSTRUMENT CLUSTER  in REMOVAL & INSTALLATION. Remove brake warning light bulb and check continuity of bulb. If bulb is okay, go to next step. If bulb is bad, replace bulb and retest system.
  2. Disconnect all instrument cluster connectors. Connect test light between instrument cluster connector C266 terminal No. 10 (Yellow/Purple wire) and instrument cluster connector C268 terminal No. 2 (Blue wire). See Figure - Figure . Turn ignition on. If test light illuminates, replace printed circuit. See PRINTED CIRCUIT  under REMOVAL & INSTALLATION. If test light does not illuminate, go to next step.
  3. Turn ignition off. Disconnect brake fluid level switch 2-pin connector at brake fluid reservoir. Remove BULB CHECK relay from engine compartment fuse/relay panel. Remove Black diode strip from diode junction box located behind fuse panel. Measure resistance between ground and instrument cluster connector C266 terminal No. 10 (Yellow/Purple wire). If resistance is more than 10 k/ohms, go to next step. If resistance is less than 10 k/ohms, repair short to ground in Yellow/Purple wire. Retest system.
  4. Measure resistance of Yellow/Purple wire between BULB CHECK relay connector and instrument cluster connector C266 terminal No. 10. If resistance is more than 5 ohms, repair open in Yellow/Purple wire. If resistance is less than 5 ohms, go to next step.
  5. Check RELAYS (10-amp) fuse located in interior fuse panel. If fuse is not okay, go to step 8). If fuse is okay, go to next step.
  6. With ignition in OFF position, replace RELAYS (10-amp) fuse. Turn ignition switch to ON position. If fuse fails again, go to next step. If fuse does not fail, go to step 8).
  7. Turn ignition off. Remove RELAYS (10-amp) fuse. Measure resistance between ground and right terminal RELAYS (10-amp) fuse. If resistance is more than 5 ohms, replace RELAYS (10-amp) fuse and go to next step. If resistance is less than 5 ohms, repair short to ground in Blue wire between interior fuse panel and instrument cluster.
  8. Turn ignition on. Measure voltage between ground and BULB CHECK relay connector Blue wire. If voltage is more than 10 volts, go to next step. If voltage is 10 volts or less, repair open in Blue wire between BULB CHECK relay and interior fuse panel.
  9. Turn ignition off. Measure resistance of Black/Yellow wire between BULB CHECK relay connector and diode junction box No. 1 connector C2011 terminal No. 6. See Fig 1 . If resistance is more than 5 ohms, go to next step. If resistance is less than 5 ohms, repair open Black/Yellow wire. Retest system.
  10. Measure resistance between ground and BULB CHECK relay connector Black wire. If resistance is more than 5 ohms, go to next step. If resistance is less than 5 ohms, repair open Black wire. Retest system.
  11. Ensure ignition is off. Connect jumper wire between battery voltage and BULB CHECK relay terminal No. 1. Measure resistances between BULB CHECK relay terminals No. 3 and No. 5. See Fig 2 . Ground BULB CHECK relay terminal No. 2. If resistance between BULB CHECK relay terminals No. 3 and No. 5 is less than 5 ohms with ground connected and more than 10 k/ohms with ground disconnected, go to next step. If resistance between BULB CHECK relay terminals No. 3 and No. 5 is 5 ohms or more with ground connected or 10 k/ohms or less with ground disconnected, replace BULB CHECK relay.
  12. Ensure ignition is off and brake fluid level switch 2-pin connector at brake fluid reservoir is disconnected. Remove screen inside brake fluid reservoir. Depress brake fluid reservoir float with a clean screwdriver. Measure resistance between brake fluid level switch terminals. If resistance is less than 5 ohms with float depressed and more than 10 k/ohms with float released, go to next step. If resistance is 5 ohms or more with float depressed or 10 k/ohms or less with float released, replace brake fluid level switch.
  13. Measure resistance of Yellow/Purple wire between brake fluid level switch and instrument cluster connector C266 terminal No. 10. If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair open in Yellow/Purple wire.
  14. Measure resistance between ground and brake fluid level switch Black wire. If resistance is less than 5 ohms, go to next step. If resistance is more than 5 ohms, repair open in Black wire.
  15. Ensure ignition is off. Disconnect parking brake switch connector. Set parking brake. Measure resistance between ground and parking brake switch connector. If resistance is less than 5 ohms with parking brake depressed and more than 10 k/ohms with parking brake released, go to next step. If resistance is 5 ohms or more with parking brake depressed or 10 k/ohms or less with parking brake released, replace parking brake switch.
  16. Measure resistance of Yellow/Purple wire between instrument cluster connector C266 terminal No. 10. and diode junction box connector C2011 terminal No. 10. See Figure -10. If resistance is more than 5 ohms, repair open Yellow/Purple wire. If resistance is less than 5 ohms, go to next step. Retest system.
  17. Ensure parking brake switch is disconnected. Measure resistance of Green/Black wire between parking brake switch connector and diode junction box connector C2011 terminal No. 9. If resistance is less than 5 ohms, replace Black diode strip on diode junction box No. 1. Retest system. If resistance is more than 5 ohms, repair open Green/Black wire. Retest system.
Fig 1: Diode Junction Box Connector C2010 & C2011 Terminals
G98I01664Courtesy of FORD MOTOR CO.
Fig 2: Testing BULB CHECK Relay
G98B01665Courtesy of FORD MOTOR CO.
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