ABS 4x4 question (bob)
 

ok so as many know i did the inspiring 4x2 to 4x4 swap.
sense then my ABS light has been on steady. i have swaped the 4x2 module/pump to the 4x4 unit, both the front speed sensors are functioning properly.

today i had ford (gasp) re-flash my cluster (gasp, 90 bucks), yes it has its own processor, and re-calibrate the spedo, the trans shifts into overdrive much better now.

the ABS light is still on.

heres the deal, 2004's did not come with manual transfer cases, so i know i need to trick the instrument cluster to think theres a 4x4 module.

Bob?

this i do know, i need to pull the cluster and install both 4x4 and 4 low bulbs in the cluster, i assume there not there seeing as my truck was 4x2 factory. I'll do this tomorrow and post the results.
the instrument cluster only sees two maybe 3 wires from the 4x4 module.
a gray wire, 4WD light and a light blue with black stripe, 4 low. maybe a brake switch wire, not sure.
the 4x4 module needs a brake switch wire for a input? and another to the ABS module. the 4x4 module also looks at the VSS.

some how i wonder if i can trick the cluster to think there is a 4x4 module or a way to get the ABS functioning properly?

sweet, just found out the bulbs are LED's

I truly know nothing about the 2004+ cluster or how it works.

The 4x4 lights may not be a problem because it looks like the cluster supplies voltage to the hot side of the bulbs when the key is on and the ground is supplied to each individual bulb by the 4x4 Module when in that mode. There's also a branch off the low range ground that goes to the PCM, presumably to tell it to correct the speedometer signal because of the 2.48:1 reduction after the OSS in the trans.

Assuming that the bulbs are there or can be added and assuming that the cluster can supply the hot side, the lights should be adaptable to the manual case conversion. It also has two ground wires controlled by a single switch on the transfer case.

So, as far as I can tell, you should be able to wire the two switched grounds from the cluster (GY and LB/BK) directly to the 2 pins at the T-case switch and be good to go. That's how mine is and it worked for the stock 1354 manual case and the 4406 manual case I have now.

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ABS- I don't remember which year the 4x4 front hubs and rotors came from in your swap. Maybe there's a different pulse/revolution than what the 2004 4x4 ABS unit wants to see? Do you have any ABS fault codes?

shoot forgot that. it has a C1414 code, incorrect module or something.

when troubleshooting this code the first thing it tells you to do is make sure the 4x4 is functioning properly.
somehow the 4x4 module is linked to the cluster and the ABS module.
the front hubs are off a 2003, when doing "live data" all 3 front and rear sensors are showing equal MPH.

Sorry, I have nothing on that code.

bob i could email "alldata's" troubleshooting procedure to you?

dont tell me i have stumped the almighty bob.

pulled my cluster today. the bulbs are built into the cluster. the gray wire(4x4 high) is not present at the plug or in the harness at the cluster, the 4low (lb/bk) wire is present at the plug but i have no clue as to where it goes in the harness.

i did manage to pull the cruse control feed wire out of the plug and put it in where the gray wire goes, i cut it back about 8 inches in the harness, i dont have cruse control so yeah. i also cut the lb/bk wire about 8 inches from the plug and extended both wires down towards the kick panel. as soon as i can fab up a plug from the transfer case switch i will have those lights working as they only need ground. so one thing is somewhat covered.

now back to the ABS. there is a light blue wire that comes off the ABS module and goes to the cluster. it is a "4x4 status" wire. i'm gonna go see if this wire is indeed in the harness and hooked up to both the cluster and the ABS module.

bob dont give up on me ok

I know the ABS controller is different on the 4x2 than 4x4 -- probably because of the different ways the wheels can spin up front with the axle engaged.

Other than that, I know less than Bob -- as usual...

already swaped the 4x2 ABS module to the 4x4 unit a long time ago. after doing that then i had a cluster problem.

I see the light blue in the 2004 ABS wiring diagram but it gives no definite info on its function or operation. I suspect that the LB is an output from the cluster to the ABS Module, not the other way around. The cluster microprocessor probably judges whether 4WD is active by the ground level of the 4x4 indicator bulb(s) and passes that info on to the ABS Module through the LB. The problem is that this is all pure guesswork. I don't own any Ranger service manual other than 2002 and that LB wire did not exist then.

In the military they call that a cluster f... oops... nevermind...

funny john.

bob, i dont have any info on that either. maybe later or tomorrow i'm gonna see if that wire is there. i suspect that it is not and may be the cause of the code C1414 and the steady ABS light.

maybe that is the link between the cluster and the ABS module

I think you're right. The manual shows a dotted line box around a section of the LB wire which usually means that it is present only with optional equipment - next to the box it says "with 4x4".

So, it looks like only the 4x4 dash harness has the LB and that it should run from pin 9 of the black cluster connector to pin 57 at the large firewall bulkhead connector.

Unless the book is lying, the LB should already be in the engine bay harness from the firewall to the ABS Module, regardless of whether the truck was built as 4WD or 2WD.

you rule bob!.

ok so i need to either run a new wire from pin 10 at the ABS module to pin 9, black connector on the IC. or do what you say, run a wire from the firewall connector to the IC.

according to my data this wire is pin 10 at the ABS pump and goes to pin 9 at the IC black connector.

Yes, I have the same thing at the ends with the circuit passing through the 57 pins of the firewall bulkhead connector in the factory 4x4 configuration.

i'll pull the cluster (gasp) again tomorrow if i can and check for this circuit.

only had time today to check under the hood. yes the LB wire in pin 10 is there. its not really LB but yeah.
maybe monday i will pull the cluster again.

ITS FIXED!

so the LB wire was not there on the dash side. hooked a new wire to the cluster and ran it to the bulkhead plug and

Attachment 205161 look no more ABS light!


hooked the scanner up to check it and this

Attachment 205162

sometimes i amaze myself!

Good job. Now let's see those 4WD lights working.

sweet, now your annoying abs will work again.

there already wired, just have to pull the switch on the t case and fab up some sort of plug.

theres 3 pins on the switch. i assume one is ground and the other two are 4high and the other 4low from the cluster.

Both of my manual cases had the same plug with 2 pins, not 3. Each of the 2 wires can ground through the switch body to the t-case when the switch is in the correct position.

i'll look at it closer tomorrow. if thats the case then it will be very easy to hook up

so the t case switch had a 2 wire plug. i fabed up a plug to the switch and ran the wires to the cluster.

in 4high i get this
Attachment 205152

so in four low i get the same dash light even though the second wire is hooked to the 4 low light?

maybe the switch is bad or wrong?

Mine lights 4x4 in both low and high range and 4x4 LOW in low range only.