No ABS light. Front left brake drags and heats up the brake. Van pulls to the left under power and to the right when braking. I pulled the ABS fuse and the problem went away. Sent off the ABS module for rebuild and things were fine when I reinstalled it.

Now the problem is back. The module has a lifetime warranty, but I'm wondering if something else needs attention?

More here:
One More Time Around: Big Duck Ventures to Lake Strom Thurmond

 

How many miles since the ABS module rebuild and this same problem re-emerge?

To me this doesn't sound like an ABS problem at all, more like a seized caliper or a restriction from the master cylinder not allowing fluid pressure to release.

Its possible when the ABS module was removed for repair residual pressure was relieved. The fact it's back strongly suggests you have other brake system issues.

 

It was about a year after the repair that the problem started again. The first time it happened, I jacked up that corner and tried to spin the wheel thinking it was a brake problem. There was a slight drag, only on that wheel when the motor was running. I pulled the wheel and hub to have a look at things - everything looked OK.

I disabled the ABS by pulling the fuse. Now I had an ABS light on the dash and the problem went away. I sent the module off and when it came back I installed it. Things were fine for about a year.

I've now been running for over 5 months with the ABS disabled and there's no sign of the problem.

I do have the brake pressure cut out on the master cyl for the cruise control bypassed. The cruise kept dropping out. This was done 4 years ago - I haven't gotten around to replacing that pressure switch yet.

I still have the original brakes on the van after 120,000 miles. I don't use them much as I am a very defensive driver and never drive over 55.

 

You seem to have isolated the problem which then suggests the module has one again failed---that sucks! Pulling the fuse strongly suggests the control module is at fault but could the modulator valve be playing a role in this?

Would a brand new OEM module or modulator valve be a better choice at this point? The lifetime guarantee is great but not if it needs returned once a year.

Also try posting this in the Brakes forum: https://www.ford-trucks.com/forums/forum64/

 

Thanks for the comeback.
I'll just run without ABS until I get inspired to tackle both the module and the cruise pressure switch.