FordEtis - TECHNICAL SERVICE BULLETIN 18/2008 http://127.0.0.1:8888/tsb/tsbView.do?regionalNumberYear=2008&print...

No.18/2008
TECHNICAL SERVICE BULLETIN 02 April 2008

© Ford Motor Company

All rights reserved.

This bulletin represents technical service information only. Without exception all gratis repairs and
replacements are subject to the individual warranty and policy procedures of the supervisory Ford
Company. The illustrations, technical information, data and descriptive text in this issue, to the
best of our knowledge, were correct at the time of publication.

Subject/Concern: Brake system warning lamp illuminated on the instrument cluster in conjunction
with ABS related Diagnostic Trouble Codes; Water ingress into the rear left ABS
wiring harness connector (C44)
Model:
S-MAX/Galaxy 2006.5 (03/2006–12/2014) Build Date: 26.08.2007-16.01.2008
Build Code: 7T-8B
Assembly Plant: Genk
Mondeo 2007.5 (02/2007–09/2014) Build Date: 26.08.2007-16.01.2008
Build Code: 7T-8B
Assembly Plant: Genk
Markets: All
Section: 206-00
Summary

Should a customer express concern that the brake system warning lamp is illuminated on the
instrument cluster, the probable cause is water ingress into the ABS wiring harness connector
(C44) (left rear brake) causing a high increase of resistance due to contaminated terminals.

In conjunction one or more of the following ABS related DTCs are stored into the brake control
module (BCM):

• C1A92:11 - Rear Left Wheel Speed Sensor Circuit circuit short to ground

• C1A92:14 - Rear Left Wheel Speed Sensor Circuit circuit short to ground or open

• C1A92:1D - Rear Left Wheel Speed Sensor Circuit circuit current out of range

• C0037:29 - Left Rear Wheel Speed Sensor signal signal invalid

• C0037:31 - Left Rear Wheel Speed Sensor no signal

• C0037:2F - Left Rear Wheel Speed Sensor signal erratic

This TSB details the necessary steps to rework the ABS-sensor wiring harness for the left rear
brake.

NOTE: Do not remove any corrosion from the terminals.

NOTE: Depending on the vehicle configuration up to 5 single wires are fitted to the ABS-sensor
wiring harness connector (C44). Remove the insulation from all unused single wires. The open
wire ends then need to be insulated to prevent any short circuits.
Furthermore the fuel wiring harness connector (C33-AB) should be checked and if affected grease
should be applied into the connectors C33-AB (green) and C44-BC (black), to prevent further
water ingress.

Parts Required
Description Finis Code Quantity
Solder/crimp connector Proprietary -
Heat shrink Proprietary -
Insulation tape Proprietary -
Clip (if required) 1 303 474 3
Grease (sufficient for 20 connector repairs) 1 122 540 1
Labor Time
Operation No. /
Operation Description
Time

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ABS-Sensor Wiring Harness For The Left Rear Brake - Rework (Includes: Apply 0.5 hours
Grease To Connector C33-AB And C44-BC)
IDS - Vehicle Connection/Communication 29 099 1
IDS - Read/Delete DTCs 29 099 4
Repair/Claim Coding
Causal Part: 36702
ACES Condition Code: 49
General Equipment
Hot air gun
Production Action
An revised ABS-sensor wiring harness connector has been installed in production since 17.01.2008
(build code 8B).
Service Instruction
See Summary.

1. Raise and support the vehicle. For additional information, refer to Mondeo 2007.5;
S-MAX/Galaxy 2006.5 Workshop Manual Section 100-02.

2. Detach the ABS-sensor wiring harness connector (C44) (left rear brake) from the body.
Detach the retaining clips.
Disconnect the electrical connector.

3. NOTE: Depending on the vehicle configuration up to 5 single wires are fitted to the
ABS-sensor wiring harness connector (C44). Remove the insulation from all unused single
wires. The open wire ends then need to be insulated to prevent any short circuits.
Cut the ABS-sensor wiring harness (left rear brake) approximately 50 mm away from the
connector on both sides (male side shown).
Discard the connector and damaged clip.
Insulate the single cables. For reference, refer to the following table.
Partially peel back the insulation.

Overview of the connector pins:

Connector C44-A (Body side) Connector C44-U (ABS side)

PIN Diameter Wiring Colour Diameter Wiring Colour
1 0.50 VT/WH 0.50 VT/WH
2 0.50 WH/BN 0.50 WH/BN
3 - - - -
4 - - - -
5 0.50 GN/OG 0.50 GN/OG

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Connector C44-A (Body side) Connector C44-U (ABS side)

PIN Diameter Wiring Colour Diameter Wiring Colour
6 0.50 BU/OG 0.50 BU
7 0.50 BN/GN 0.50 BN
8 0.75 YE/BU 0.75 YE/BU
9 - - - -
10 - - - -
11 0.75 GN/BU 0.75 GN/BU
12 - - - -

4. Slide on the solder/shrink connectors (see Parts Required).

5. Crimp the solder/shrink connectors using crimping pliers.

6. WARNING: Use a heat shield to prevent damage to adjacent components.

Join all the solder/shrink connectors using a hot air gun.
Connect the solder/shrink connectors using a hot air gun.
Insulate the repair area (including the unjused single wires) using tape (see Parts
Required).

7. NOTE: Ensure correct cable routing.

Install the reworked ABS-sensor wiring harness to the body using clips (see Parts
Required).

8. Check the fuel wiring harness male side of connector (C33-AB).

If the fuel wiring harness connector (C33-AB) has bond bridges in the housing and has NO
redundant terminal holes plugged, go to next step.
If the fuel wiring harness connector (C33-AB) has NO bond bridges in the housing and blind
plugs fitted, go to step 13.
1. Affected connector with bond bridges in the housing and NO blind plugs fitted.

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9. NOTE: DO NOT cut out the wiring harness connector C33-AB (green) / C44-BC (black).
Disconnect the wiring harness connector C33-AB (green) and C44-BC (black).
1. Connector C33-AB (green)
2. Connector C44-BC (black)

10. To prevent further water ingress on the wiring harness connectors C33-AB (green) and
C44-BC (black), apply grease (see Parts Required) to the male side of the connector.
1. Apply a first layer of grease on the bottom of the male connector.
2. Apply a second layer of grease on the top of the first one to fill the male connector until
5 mm from the top.

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11. Connect the wiring harness connector C33-AB (green) and C44-BC (black).

12. Check the position of the blind plugs and push them back in place if pressed out during the
assembly of the connector.
1. Affected connector with bond bridges in the housing.
2. I.O connector without bond bridges in the housing and correctly installed blind plugs.

13. Lower the vehicle.

14. Connect IDS portable diagnostic unit to the vehicle and establish communication (VID the
vehicle).
Confirm the vehicle details are correct.

15. Check for any stored Diagnostic Trouble Codes (DTCs).

16. Clear any stored DTCs .

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