I have read practically every ABS thread on this Site (and other Sites as well). Many of the threads on this Site never come to a resolution and the OP never comes back to give the final result. Some that start with discussion on front ABS get hijacked and end up talking about the rear sensor in the pumpkin. This is of course easily determined because it also runs the speedo (below 2001 - thanks fddriver02).
I have just replaced the front Rotors/Pads/Bearings/Seals in my 2004 Ranger 2WD. I replaced the stock rotors with Powerslot Slotted Rotors (8551PSR/8551PSL) and Hawk HPS Pads (HB472F650).
For those that do not know, the front rotors for a 2WD are "full" rotors that slide onto the spindle and not slip on a hub over the wheel studs. They are held in place by the inner and outer wheel bearings with a seal for the inner. They contain the ABS Tone Ring on the inside (back side of the rotor assy).
After installing all of this, I now have the dreaded Ranger ABS kick in at speeds under 40mph. When it kicks in, the front shudders and you can hear the ABS pump working. The truck pulls to the Left (Driver's side). Sometimes it lights the ABS light right away and sometimes it takes awhile for the light to come on. When it does come on, the Red Brake light also comes on. No codes are set in OBC II. Of course when the truck is shut off and restarted, the lights are not there until I brake normally again under 40mph.
When it does light the ABS/Brake lights, the braking system works fine (no more ABS). So, I doubt that there is any air in the system. The fluid in the Master Cylinder is at the proper level. There is quite a bit in the engine compartment where the "mechanic" compressed the calipers, but I have wiped that up as much as I could.
I pulled both front wheel sensors (from the backside of the wheel assembly without taking the wheel off) and found them to be a bit dirty with a "bar" of collected brake dust across the front face of both of them. I cleaned them real good with brake cleaner and wiped them down and they are now nice and shiny. But I still have the problem.
I did not do the replacement of all these parts myself, but had it done at a local shop. I did not get to look at the sensors from inside the wheel housing. I did not get to see if there is a second part of the wheel sensor that slips OVER the tone ring or if the sensor is just the one I know of only on the back (inside) of the tone ring. I am assuming that it is only the one I have described and nothing else is needed (or broken off/mis-adjusted by mistake).
I know the workaround about pulling fuses but on a 2004 the fuse is #20 and it handles backup lights and a few other things as well. I did pull the harness connection from the ABS Pump and that works fine (immediately illuminates ABS/Brake lights on dash when started) by disabling the ABS system and of course the truck brakes fine at all speeds. This is only a work around and I would prefer to fix the problem correctly.
I did have a look at the rotors before they were installed. I did notice something strange that both of the rotors did not look and were not stamped the same. The Passenger side (Right) had lots of numbers and made in Canada. Showed min as 2.45" (as I recall). It was also nice and bright shiny. The Driver's side (Left) had only the stamp of "F78" or something like that and 2.47". It was dull coated (not shiny like the other). Is it possible I got a wrong rotor for the driver's side? I checked the part numbers on both boxes and they were the same. I have sent an email to Powerslot about this and awaiting an answer.
So, other than taking this to FORD and getting totally RIPPED, does anyone have any suggestions? I would like to fix this myself if possible and then post the fix here for the next person that has the same problem (which shouldn't be too long now..........