No Surprise - MOT Fail

PHaTGRoB · January 7, 2011

So, my Ex failed it's MOT today. No surprises though, since the ABS light has never come on, which previous postings have highlighted as a forgone fail, and the wipers / washers totally stopped working just as I arrived at the garage - another couple of hours and I'd have been fine.
ABS - The garage I bought the car off a year ago promised it would sort the ABS system since the light was on all the time. They did. It was too late by the time I realised that they had fiddled it. Looking at it now, the ABS diode is missing from the Power Distribution Box and the wiring diagrams show this linked to the light. No diode, no light. Where can I source a new diode? Do I have to go to Ford? Also, assuming it is a wheel sensor issue that caused the light to be on before I bought it, which is the best way to go...just fit new sensors or take the hit and fit new front hub assys inc ABS bits?
Wipers - following on from my other thread about this issue (and no windows, dome lights etc.), it was happening more often and for longer. I am now convinced that it is a poor connection and it seems to be in the GEM. Tapping it once too often seems to have finally pushed it over the edge....just at the wrong time!...so the systems now blip on once every now and again before blipping straight off again.

A couple of advisables were also raised such as degraded rear anti-roll bar bushes and exhaust hangers but otherwise, the handbrake, emissions, wheel bearings, brakes, etc. all pronounced good and healthy, so it's worth putting the time, effort and money into sorting the failures.

I have no proper garage and work most of the week at the moment so, based on your own experiences of the above issues, your advice on the best way forward would be much appreciated. GRoB.

janolsson · January 7, 2011

Sorry to hear that grob
Used GEM and diode from chris or justin or you could try opening it up (watch out for static) and scrubbing with contact cleaner then go over with a magnifying glass and resolder any dodgy looking joints paying particular attention to the connector conections with the pcb.
Then replace one of the abs sensors (guess passenger front first) if you have one. If this works great if not take the one you just took off and try it on the other side. This is assuming you don't break it pulling it out!! Otherwise you could just replace the whole hub on both sides but if your bearings are good this seems a bit of overkill to me.
If your rear roll bar bushes aren't too bad you could use rubber conditioner on them to prlong their life.
You'll get there eventually, keep up the good work

PHaTGRoB · January 8, 2011

Thanks Jan. I was expecting a fail and was actually pleased with the result, in that it was only bcause of the things I knew about. Does the passenger side sensor tend to be more of a problem that the driver's side? Where is the best place for sensors? Ford are quoting me over a hundred quid but there are various on ebay. Is USAuto OK?

PHaTGRoB · January 8, 2011

I have just looked at transferring the PCM diode to the supposed ABS diode location within the Power Dist Box (Main Relay Box under Bonnet) and there are no contacts to plug it into where it is supposed to be! The diode is also shown on the wiring diagrams Jim supplied me. Does anyone else have this diode on a '99 model? Photo of PDB below. I'm now ripping out the intrument panel to see if the garage have just removed the ABS bulb. If not, I'm going to be spending a lot of time sorting this problem!!

PHaTGRoB · January 8, 2011

Bulb missing! Quality garage I bought this off. Quality MOT station that MOT'd it for them too!

jcasey007 · January 8, 2011

Just checked my 1997 and the ABS diode is in power dist board as you indicated in you picture.

BWT, re your PM, I posted the GEM before xmas

janolsson · January 8, 2011

Just checked my s reg 98 and i do NOT have the diode.

PHaTGRoB · January 8, 2011

Thanks Jim. Although our post is normally very good, since the start of December we've had quite a few items of post not turn up. I checked at the Ruthin sorting office this morning and they have nothing for us that hasn't been delivered. I'll have another root around the outbuildings in the light tomorrow and see if it's been put somewhere silly by a locum postman. Shame since you went to all the trouble of sending it. Cheers. GRoB.

PHaTGRoB · January 8, 2011

Thanks Jan. Switching one of the other warning light bulbs over has the ABS light operating. The light is permanently on, so it's now down to checking the sensors.

mike213735 · January 8, 2011

PHaTGRoB said:
Thanks Jan. I was expecting a fail and was actually pleased with the result, in that it was only bcause of the things I knew about. Does the passenger side sensor tend to be more of a problem that the driver's side? Where is the best place for sensors? Ford are quoting me over a hundred quid but there are various on ebay. Is USAuto OK?

Grob,

You can get the hub and the sensor on "the Bay" for £89.95. I think I may have to do one of mine soon.
Also, A1Auto have a good tutorial video on "the Tube" on how to fit it

Thanks
Mike

blueka · January 8, 2011

I unplugged my ABS system at the plug behind the battery....

Si

PHaTGRoB · January 8, 2011

I'll be honest. I have a (slightly!) geeky problem (not just one, to be honest)...I always want my cars to work as per the original design intent. This means that the ABS not working has bugged me since I bought the Ex but I had hoped to sort it in my own good time but it looks like I'll be sorting it sooner rather than later. It would have been nice to resolve it in the sunny summer but so be it. I'm considering doing what Mike suggested but are these aftermarket ebay hubs made to the same standard as the originals? Reading another discussion talking about cleaning the build up of rubbish from the rotor teeth (all 270 of them?) has had an impact on my decision along with the cost of new sensors. Or I could take Si's advice and fight my originality obsessions!

jcasey007 · January 8, 2011

when I had an ABS sensor problem, the ABS light did not come on to show a fault, it would be a pitty to spend a couple of hundred quid for nothing when the problem is else where.

I assume you have done some basic electrical testing of the sensors. and whilst they are hall effect sensors the coil resistance should be about 400 ohms.

Anybody else get a warning light for a sensor problem?

blueka · January 8, 2011

The fact that the ABS is unplugged drives me nuts, but I didn't have the money to fix it at the time... and with everything else... it got put to the back burner, then forgotten about.. before it comes over here, I'll send over 2 new hubs and a rear ABS sensor just to make sure it works ok...

Si

PHaTGRoB · January 8, 2011

I've had to spend most of the day on other stuff so have not had a proper look at it yet. However, tomorrow, The wheels are coming off and I'll be looking at the sensors, cables, connections, etc. to see what I can find. I'll check the resistance on the two front sensors as suggested. Thanks. GRoB.

PHaTGRoB · January 9, 2011

This forum has been inaccessible for most of today and I've felt like someone chopped off my arms, I have missed it that much.

Right chaps, here's the result of today's ABS testing by a damp and cold engineer!

- Front offside sensor - ~388 Ohms, ~0.08 V AC max. when wheel is turned slowly by hand.
- Front nearside sensor - ~383 Ohms, ~0.085 V AC max. when wheel is turned slowly by hand.
- Rear sensor in diff housing - ~1200-1400 Ohms, ~0.07 V AC max when n/s/r wheel is turned slowly by hand.

Since this forum was unavailable, I looked at other sources of info and these results seem to show that the sensors are all OK. I also can't find an issue with wiring or connectors. Does that mean what I think it does....the ABS controller is a fault? Is this an easy change if I can get a replacment? It looks like on the year of Ex, the controller and valve unit are one. Is that correct?

P.S. Jim, still no sign of your GEM by the way. I have searched in all possible locations and nothing is there. I'll let you know if and when it arrives. GRoB.

PHaTGRoB · January 12, 2011

Following my testing at the weekend, I've got no further in working out the problem with the ABS. I spoke to the local tame Ford dealer today and they do not have diagnostic capability for the ABS on this thing. However, he gave me a local travelling diagnostic man. I've spoken to him and he's confident he can interrogate the system sufficiently. Once I know the fault, I can then set to trying to resolve the issue. GRoB.

BIGHVM · January 14, 2011

Hmmm, hard one, I also have my ans light on- but I swear also that I saw it go off and come on on a corner a few times? I have a few months till next mot and am waiting for warmer days and also my poxy finger to heal up proper like. Hoping the sensors needs cleaning, degraded wiring or another simples problem.....really hoe its not hub, as I will change both fronts as it wont be long before the other side goes south assuming they are as old as each other!

Ilikemice · January 14, 2011

I think I have a spare sensor or two if they're any use to you. The problem I have is the hub itself since three different sensors didn't help my problem.

PHaTGRoB · January 14, 2011

Hopefully the diagnostics feller will be able to talk to the system and will point his finger at a particular part...hopefully a sensor. He's here tomorrow morning and, if this is the case, Ilikemice, I'll gladly do a deal on a sensor. As with H, I hope I don't need to change the hubs, since there's no play or other problems wih them. Here's to the right diagnosis tomorrow.

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