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Discussion Starter #1
Okay so here is the deal. I finally got around to working on my own cars abs as it has had the abs light on since I bought it. Took it to a local shop and the scanner said that all sensors under voltage, control module under voltage, etc, etc. I went back to my shop and disconnected the control module and metered out all of the circuits. Voltage where it should be and grounds where there should be ground. When I ohm'ed resistance in the sensors I received a reading range of 3.34 on the low to 3.26 on the highest. Not bad I thought. Checked my manual and it stated that they should be in the range of 1100 to 1110 but my book is for a 2000 not a 2004 with the mark 20e so I figured they where good. I did not have voltage at the sensors so I replaced the module with one with traction control option as it is my intention to upgrade. Installed the new module and started the car. Low and behold no abs light. Then the test drive. made it to the end of my long driveway and the light came back on after it self tested over 15 mph. Balls. Now the light is on as soon as I start the vehicle of course until I fix the problem. Did I get a bad module? Is the resistance on the sensors correct? The manual for the 2000 had the specifications in it but the new manuals do not so I "assumed" that since they where all very close that my reading where good. I found the plug for the traction control behind the radio cover do I need the switch for the abs light to go out or the bulb in the dash? I wouldn't think so. So I believe I need another module if any of you folks run across one that can be removed from the power pack in one piece and I also need the traction control switch (new type). Any thoughts would be appreciated!!
 

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I hit **** with sticks!
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Best thing to do, scan the new module, see if you have the same codes;

If you did not install the switch it may be setting a code for the switch.
 

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Discussion Starter #3
same codes with the new controller. If it is because I don't have the button I will have to rethink everything in life.
 

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Discussion Starter #5
Don't have them handy but all where under voltage. wheel sensors, cab etc. I am going to try another abs controller first. If the same issues recur I will find the button and install a bulb in the dash. P.S. looking for abs controller w/traction control and a button! :)
 

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I hit **** with sticks!
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Just the switch missing would set a code for the switch only.

Hard to troubleshoot without the exact code numbers otherwise.

Speculation; well; shorted sensor especially on the common could cause voltage readings to go nuts in the control module.

Really you need to look at all the sensor data on a scanner, see what you have. If you have low or out of range voltage all over the place, first step is to unplug each sensor and see if voltages return to normal on the others. If you unplug one, and other voltages return to normal; you know you have an issue in that sensor; same scenario for the wiring harnesses etc; but its hard to believe there is an issue there without mice, accident damage, corrosion;etc; that is unlikely. More so a sensor. This task is not possible without a scanner. Unless you just want to throw parts at it.

One thing you could do without a scanner, pull the sensors; look for obvious damage on the sensors, and excessive rust or damage on the tone rings. Check the wiring harnesses for damage/corrosion.

It is rare on these cars for there to be any trouble with an ABS module; of course; the newest one is now nearly 15 years old, so that statement could be null now; but I've never seen a bad ABS module on one of these; sensors; yes.
 

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Discussion Starter #7
I checked for shorts to ground on all of the sensors. I still somehow believe it is a short somewhere. It toasted the new controller instantly on test. I am still looking for specs on the resistance for the wheel sensors.
 

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I hit **** with sticks!
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Hard to say without data.

I had a bad sensor on mine a few years ago and it caused 4 different codes.

I forget what codes it had, but in the end was the right rear wheel sensor.

When I pulled the detail on the scan tool voltage was all screwed up on two of the other sensors; and the speed test showed normal on 3 and a zero reading on the right rear.

The voltages returned to normal with that sensor unplugged.

What made things worse is I have a 98 car with 02 wiring LOL; but 98 sensors and 02 abs with traction control; I cant remember all the details because its been so long; but I ordered a sensor off of the 2002 300M that donated all the wiring; thinking it would be no issue; and the system did not care for that. I had different codes after. Had to go back and order a 98 model sensor.

Based off of that and your ohm readings, and from my experience on my car; the sensors must match year wise, controller doesnt care. There are different resistances between years. If one is off, or you mix them up; it will set a code.
 

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Woober Goobers!
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From the 2004 FSM Chassis Supplement:

Symptom:
SYSTEM OVER VOLTAGE

When Monitored and Set Condition:
SYSTEM OVER VOLTAGE

When Monitored: Ignition on. The CAB monitors the Fused B(+) circuit at all times for
proper system voltage.
Set Condition: If the voltage is above 16.5 volts, the Diagnostic Trouble Code (DTC) is set.

POSSIBLE CAUSES
INTERMITTENT DTC
BATTERY CHARGER CONNECTED
FUSED IGNITION SWITCH OUTPUT (RUN) CIRCUIT HIGH
DAMAGED CAB/CAB HARNESS CONNECTOR
CAB - GROUND CIRCUIT OPEN
CAB - INTERNAL FAULT

Symptom:
SYSTEM UNDER VOLTAGE

When Monitored and Set Condition:
SYSTEM UNDER VOLTAGE

When Monitored: Ignition on. The CAB monitors the Fused Ignition Switch Output
circuit voltage above 10 km/h (6 mph) for proper system voltage.
Set Condition: If the voltage is below 9.5 volts, the Diagnostic Trouble Code (DTC) is set.

POSSIBLE CAUSES
INTERMITTENT DTC
DAMAGED CAB/CAB HARNESS CONNECTOR
RUNNING BATTERY VOLTAGE LOW
CAB - GROUND CIRCUIT OPEN
FUSED IGNITION SWITCH OUTPUT (RUN) CIRCUIT OPEN
CAB - INTERNAL FAULT

Like Dan says need to know the exact codes and descriptions. I have the Complete FSM Supplement that I can probably host if you ask nicely.
 
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