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Test G: Brake Warning Light Never On

  1. Turn ignition switch to LOCK position. Remove instrument cluster. See INSTRUMENT CLUSTER  under REMOVAL & INSTALLATION. Remove and check continuity of brake warning light bulb. If bulb is okay, go to next step. If bulb is not okay, replace bulb and retest system.
  2. Disconnect all instrument cluster harness connectors. Turn ignition switch to RUN position. Using voltmeter, measure voltage between terminal No. 10 (Yellow/Violet wire) at instrument cluster harness connector C266c and terminal No. 2 (Blue wire) at instrument cluster harness connector C266b. See Figure and Figure . If battery voltage exists, replace printed circuit. See PRINTED CIRCUIT  under REMOVAL & INSTALLATION. If battery voltage does not exist, go to next step.
  3. Turn ignition switch to LOCK position. Disconnect brake fluid level switch 2-pin harness connector C122 at brake fluid reservoir. Remove bulb check relay from engine compartment relay box. Remove joint connector located behind top right side of instrument cluster. Remove top shorting strip. Measure resistance of Yellow/Violet wire between terminal No. 10 at instrument cluster harness connector C266b and terminal No. 10 at joint connector C2011. See Fig 1. Measure resistance of Yellow/Violet wire between terminal No. 5 at bulb check relay socket C183 and terminal No. 10 at instrument cluster harness connector C266c. Measure resistance of Yellow/Violet wire between terminal No. 1 at brake fluid level switch harness connector C122 and terminal No. 10 at instrument cluster harness connector C266c. If any resistance measurement is greater than 5 ohms, repair open in Yellow/Violet wire. If all resistance measurements are 5 ohms or less, go to next step.
  4. With ignition switch in LOCK position. Connect jumper wire between battery voltage and terminal No. 1 (Blue wire) at bulb check relay socket C183. Measure resistance between bulb check relay terminals No. 3 (Black wire) and No. 5 (Yellow/Violet wire). See Fig 2. Ground bulb check relay terminal No. 2. If resistance between bulb check relay terminals No. 3 (Black wire) and No. 5 (Yellow/Violet wire) is less than 5 ohms with ground connected and greater than 10 k/ohms with ground disconnected, go to next step. If resistance between bulb check relay terminals No. 3 (Black wire) and No. 5 (Yellow/Violet wire) is greater than 5 ohms with ground connected or 10 k/ohms or less with ground disconnected, replace bulb check relay.
    Fig 1: Identifying Joint Connector C2011 Terminals
    G98I01664Courtesy of FORD MOTOR CO.
    Fig 2: Identifying Bulb Check Relay Socket C183 Terminals
    G99H02229Courtesy of FORD MOTOR CO.
  5. Turn ignition switch to RUN position. Measure voltage between ground and terminal No. 1 (Blue wire) at bulb check relay socket C183. If battery voltage exists, go to next step. If battery voltage does not exist, repair open in Blue wire between bulb check relay and fuse junction panel.
  6. Turn ignition switch to LOCK position. Measure resistance of Blue/Yellow wire between terminal No. 2 at bulb check relay socket C183 and terminal No. 6 at joint connector C2011. See Fig 1 and Fig 2 . If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, repair open in Blue/Yellow wire.
  7. Measure resistance between ground and terminal No. 1 (Black wire) at brake fluid level switch harness connector C122. If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, repair open in Black wire.
  8. With ignition switch in LOCK position and brake fluid level switch 2-pin harness connector C122 disconnected, remove screen inside brake fluid reservoir. Depress brake fluid reservoir float. Measure resistance between brake fluid level switch terminals. If resistance is 5 ohms or less with float depressed and greater than 10 k/ohms with float released, go to next step. If resistance is greater than 5 ohms with float depressed or 10 k/ohms or less with float released, replace brake fluid level switch.
  9. With ignition switch in LOCK position, disconnect parking brake switch harness connector C250. Measure resistance of Green/Black wire between terminal No. 1 at parking brake switch harness connector C250 and terminal No. 9 at joint connector C2011. If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, repair open Green/Black wire.
  10. Ensure parking brake switch is disconnected. Set parking brake. Measure resistance between ground and terminal No. 1 (Green/Black wire) at parking brake switch harness connector C250 (component side). If resistance is 5 ohms or less, go to next step. If resistance is greater than 5 ohms, replace parking brake switch.
  11. Measure resistance between joint connector C2011 (top shorting strip) terminals as follows: Since shorting strip is a diode shorting strip, ensure polarity is correct.
    • Terminal No. 6 (+) and No. 5 (-).
    • Terminal No. 2 (+) and No. 5 (-).
    • Terminal No. 10 (+) and No. 9 (-).
    • Terminal No. 10 (+) and No. 8 (-).
    If resistance in all measurements is 5 ohms or less, perform TEST H: CHARGE INDICATOR NEVER ON . If resistance in any measurement is greater than 5 ohms, replace top diode shorting strip on joint connector C2011.
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