Part identification
We have all new brakes on this van, does have the two solenoids located under the master cylinder for the ABS, we can not figure out why the brakes will not work properly
Thanks for any help with this
Anti-Lock Control
Refer to Wiring Diagrams Cell «42», Anti-Lock Brake System for schematic and connector information.
Special Service Tool(s)
ABS Adapter Cable or equivalent
418-F038 (007-00108)
New Generation STAR (NGS) Tester or equivalent
418-F048 (007-00500)
EEC-IV 60-Pin Breakout Box or equivalent
418-005 (014-00322)
73 Digital Multimeter or equivalent
105-R0051
88 Digital Multimeter or equivalent
105-R0053
Principles of Operation
The anti-lock brake control module receives wheel speed readings from both front wheel speed sensors and the rear differential speed sensor, and processes this information, along with other sensor inputs, to determine if an ABS event is necessary. The wheel speed sensor electrically senses each tooth on the ABS sensor indicators as it passes through the wheel speed sensor's magnetic field.
The anti-lock brake control module continuously monitors and compares the rotational speed of each wheel speed sensor indicator and, when it detects an impending wheel lock, modulates brake pressure to the appropriate brake caliper(s). This is accomplished by triggering the hydraulic control unit (HCU) to open and close the appropriate solenoid valves. Once the affected wheel returns to normal speed, the ABS control module returns the solenoid valves to their normal position, and normal (base) braking resumes.
The ABS control module is self-monitoring. When the ignition switch is turned to the RUN position, the ABS control module will do a preliminary electrical check, and at approximately 20 km/h (12 mph), the pump motor is turned on for approximately one-half second. Any malfunction of the ABS system will cause the ABS to shut off; however, normal power assisted braking remains.
Dynamic Rear Proportioning (DRP)
Vehicles with four wheel disc brakes are equipped with dynamic rear proportioning (DRP). The DRP system is integral to the anti-lock brake control module. The DRP maintains brake balance and maximizes brake efficiency for all loading configurations. DRP detects the onset of front versus rear slip imbalance and limits the rear pressure. If the rear slip significantly exceeds the front slip, the DRP system will reduce the rear pressure. If this condition occurs, the driver will feel a slight pulsation in the brake pedal. The DRP system will be disabled if one diagnostic trouble code (DTC) is set from condition 1 and condition 2 or condition 3, or if one DTC from condition 2 and condition 3, or if two or more DTCs are set from condition 1.
Condition one:
l C1095
l C1196
l C1200
l C1212
l C1216
Condition two:
l C1155
l C1158
l C1233
Condition three:
l C1145
l C1148
l C1234
If any DTCs are retrieved, GO to Inspection and Verification — NGS.
Inspection and Verification — NGS
Communication Check
1. Verify the customer concern by applying the brakes under different conditions.
2. Visually inspect for obvious signs of mechanical and electrical damage.
Visual Inspection Chart
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³ Mechanical ³ Electrical ³
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³ ù Parking brake ³ ù Central junction ³
³ cable ³ box (CJB) Fuse: ³
³ ù Tire pressure ³ - 1 (20A) ³
³ ù Tire size or ³ - 2 (15A) ³
³ mismatched tires ³ - 11 (15A) ³
³ ³ ù Battery junction ³
³ ³ box (BJB) Fuse 19 ³
³ ³ (60A) ³
³ ³ ù Ground integrity ³
³ ³ ù Connectors or ³
³ ³ connections ³
³ ³ ù Harness routing ³
³ ³ ù Wire chafing ³
³ ³ ù Circuitry open ³
³ ³ /shorted ³
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3. If the fault is not visually evident, connect New Generation STAR (NGS) Tester to the data link connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle:
l check that the program card is correctly installed.
l check the connections to the vehicle.
l check the ignition switch position.
4. If the NGS still does not communicate with the vehicle, refer to the New Generation STAR Tester manual.
5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with:
l CKT914, CKT915, or CKT70 = ALL ECUS NO RESP/NOT EQUIP, refer to «Section 418-00».
l NO RESP/NOT EQUIP for anti-lock brake control module, go to Pinpoint Test A.
l SYSTEM PASSED, retrieve and record the continuous diagnostic trouble codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the anti-lock brake control module.
6. If the DTCs retrieved are related to the concern, go to Anti-Lock Brake Control Module Diagnostic Trouble Code (DTC) Index to continue diagnostics.
7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart.
Inspection and Verification — Drive Cycle Test
The drive cycle test can be used as a system evaluation test or repair verification test, or during diagnosis (for intermittent concerns).
For system evaluation, the customer may only have a general concern about the way the vehicle is braking. There may not be a clear system concern to troubleshoot. This test is designed to produce common system concern symptoms. Once a symptom is found, a symptom diagnostic procedure can be followed to repair the vehicle.
Always use this test after vehicle repairs because the anti-lock brake control module is unable to detect some system concerns unless the vehicle is driven under specific conditions. After completing the drive cycle test, carry out the self-test using New Generation STAR (NGS) Tester.
Note:
Wetting down the area where the stops are to be performed will aid in this test.
Note:
An assistant should be used to monitor the wheels during the ABS stop. Momentary lockup is permissible.
1. While driving the vehicle approximately 16 km/h (10 mph), depress the brake pedal hard enough to lock all four wheels.
2. Does one wheel lock consistently?
l If yes and the yellow ABS warning indicator is not illuminated, proceed to the Symptom Chart.
l If yes and the yellow ABS warning indicator is illuminated, retrieve and document DTCs. Proceed to Anti-Lock Brake Control Module Diagnostic Trouble Code (DTC) Index.
3. Note:
If the pump motor turns on and the vehicle pulls immediately, the front anti-lock brake sensor opposite the pull should be checked using the ABS Misfire, ABS Too Sensitive, ABS Fires On Normal Stop procedure from the Symptom Chart. If the pump motor turns on and the vehicle does not pull, the rear anti-lock brake sensors should be checked using the ABS Misfire, ABS Too Sensitive, ABS Fires On Normal Stop procedure from the Symptom Chart. If the pump motor does not turn on and the vehicle pulls immediately, the system should be checked using the Vehicle Pulls During Braking procedure from the Symptom Chart.
Note:
Turn off the windshield wipers.
While driving the vehicle approximately 32 km/h (20 mph), perform a light-to-medium (normal traffic) stop.
4. Does the pump motor turn on and are brake pedal pulsations felt at any time during the stop?
l If yes and the yellow ABS warning indicator is not illuminated, proceed to the Symptom Chart.
l If yes and the yellow ABS indicator does illuminate, retrieve and document DTCs. Proceed to Anti-Lock Brake Control Module Diagnostic Trouble Code (DTC) Index.
5. Clear continuous DTCs.
6. Start the vehicle and shift the transmission into low gear.
7. Allow the vehicle to creep forward at idle for at least 45 seconds.
8. Does the yellow ABS indicator illuminate?
l If yes, retrieve and document DTCs. Proceed to Anti-Lock Brake Control Module Diagnostic Trouble Code (DTC) Index.
9. Slowly accelerate to 40 km/h (25 mph). Let at least 45 seconds elapse before reaching 40 km/h (25 mph).
10. Does the yellow ABS warning indicator illuminate?
l If yes, retrieve and document DTCs. Proceed to Anti-Lock Brake Control Module Diagnostic Trouble Code (DTC) Index.
11. Has the customer concern been addressed and corrected by the previous actions?
l If yes, the system is OK.
l If no, proceed to the Symptom Chart.
Anti-Lock Brake Control Module Diagnostic Trouble Code (DTC) Index
Symptom Chart
Condition(s):
Note:
Refer to the Wiring Diagrams for connector numbers stated in the Pinpoint Tests.
o No communications with the anti-lock brake control module
o Unable to enter self-test
o ABS misfire, ABS too sensitive, ABS fires on normal stop
o Wheels lock up
o Soft/excessive pedal travel
o Lack of deceleration during medium/hard brake application
o Vehicle pulls during braking
o ABS warning indicator illuminated with system pass
o The red BRAKE warning indicator does not self-check
o The red BRAKE warning indicator stays on with the ignition switch in RUN
o The yellow ABS warning indicator does not self-check
o The red BRAKE warning indicator and yellow ABS warning indicator are illuminated
Module — Anti-Lock Brake Control
Removal
1. Remove the hydraulic control unit (HCU); refer to «Hydraulic Control Unit—(HCU)».
µ 2. Detach the bracket from the HCU.
1 Remove the bolts.
2 Detach the bracket from the HCU.
µ 3. Remove the anti-lock brake control module.
1 Remove the screws.
2 Remove the anti-lock brake control module.
Installation
µ 1. To install, reverse the removal procedure.
Hydraulic Control Unit — (HCU)
Removal
WARNING:
Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately.
CAUTION:
Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.
1. Disconnect the battery ground cable; refer to «Section 414-01».
µ 2. Position the radiator coolant recovery reservoir (8A080) aside.
1 Remove the bolts.
2 Position the radiator coolant recovery reservoir aside.
µ 3. Note:
Do not disconnect the hose from the power steering pump reservoir.
Remove the bolts and position the power steering pump reservoir aside.
µ 4. Disconnect the brake lines from the brake master cylinder.
µ 5. Note:
Plug each port of the hydraulic control unit (HCU) to prevent brake fluid from spilling.
Disconnect the brake lines.
1 Remove the 7/16-24 brake lines.
2 Disconnect the 1/2-20 brake lines.
µ 6. Disconnect the anti-lock brake control module electrical connector.
1 Lift the lock tab upward.
2 Disconnect the anti-lock brake control module electrical connector.
µ 7. Remove the HCU bracket to inner fender well nuts.
µ 8. Remove the HCU.
1 Disconnect the anti-lock brake control module electrical connectors.
2 Remove the HCU.
Installation
µ 1. Note:
When the battery (10655) is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
Note:
Bleed the HCU after installation; refer to «Section 206-00».
To install, reverse the removal procedure.
I was told that these vans have a device in them that will adjust the brake pressure according to the load in the back, it supposedly lessons the amount of brake pressure to the rears when it is loaded to keep the rear in place when in a panic/slippery stop.
I don't know if this is true or not
That cd says in 99 they had two abs systems. A rear only system, and a 4 wheel system. All that info in the other posts is for a 4 wheel system.











