Ford Ranger EV (2001 year). Manual - part 96

413-01-28

413-01-28

Instrument Cluster

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST S: RED BRAKE WARNING INDICATOR DOES NOT OPERATE OR STAYS ON
CONTINUOUSLY

TEST STEP

ACTION TO TAKE

S1 IDENTIFY SYMPTOM

NOTE: Verify no diagnostic trouble codes (DTCs) exist and there are no

Yes =

GO to S13.

hydraulic leaks in the brake system before carrying out the following test

steps.

•

With key ON, identify the symptom. 

•

Does the red brake warning indicator stay on continuously?

No =

GO to S2.

S2 CHECK OPERATION OF RED BRAKE WARNING INDICATOR

•

Enter the interface adapter assembly (IAA) module active command

Yes =

GO to S10.

mode INDICATOR LAMP CONTROL and set the active command BRK

LMP to ON. 

•

Does the red brake warning indicator illuminate?

No =

GO to S3.

S3 CHECK RED BRAKE WARNING INDICATOR CONTROL

CIRCUIT

•

Connect 104-Pin Breakout Box (BOB) to IAA module C1945; leave IAA Yes =

REPLACE the IAA module.

module disconnected. REFER to 

Section 412-04.

•

With key OFF, connect a jumper wire between BOB pin 39 and ground

No =

GO to S4.

(BOB pin 80). 

•

Does the red brake warning indicator illuminate?

S4 CHECK RED BRAKE WARNING INDICATOR BULB

•

With key OFF, remove and check the red brake warning indicator bulb. 

Yes =

GO to S5.

•

Is the bulb OK?

No =

REPLACE the bulb.

S5 CHECK RED BRAKE WARNING INDICATOR CONTROL

CIRCUIT FOR OPEN

•

With key OFF, disconnect instrument cluster C216 and measure the

Yes =

GO to S8.

resistance between pin 7 (P/W wire) on instrument cluster C216 and

BOB pin 39. 

•

Is the resistance less than 5 ohms?

No =

GO to S6.

S6 CHECK CIRCUIT 512 (T/LG) FOR OPEN

•

With key OFF, disconnect brake fluid level switch C137 and measure the Yes =

GO to S7.

resistance of the T/LG wire between brake fluid level switch C137 and

BOB pin 39. 

•

Is the resistance less than 5 ohms?

No =

REPAIR the T/LG wire.

S7 CHECK CONTINUITY OF BRAKE FLUID LEVEL SWITCH

•

With key OFF, measure the resistance between the T/LG wire terminal

Yes =

REPAIR the P/W wire

and P/W wire terminal on the brake fluid level switch. 

between instrument cluster

C216 and brake fluid level

switch C137.

•

Is the resistance less than 5 ohms?

No =

REPLACE the brake fluid

level switch.

S8 CHECK CONTROL CIRCUIT FOR SHORT TO POWER

•

With key ON, measure the voltage between BOB pin 39 and ground

Yes =

REPAIR the T/LG, P/W, or

(BOB pin 80). 

LG/R wire.

•

Is the voltage greater than 0 volts?

No =

GO to S9.

S9 CHECK POWER TO INSTRUMENT CLUSTER

•

With key ON, measure the voltage between pin 4 (Y wire) on instrument Yes =

REPLACE the instrument

cluster C216 and ground. 

cluster.

•

Is the voltage greater than 10 volts?

No =

REPAIR the Y wire.

S10 CHECK OPERATION OF BRAKE WARNING INDICATOR

WITH PARK BRAKE DEPRESSED

(Continued)

413-01-29

413-01-29

Instrument Cluster

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST S: RED BRAKE WARNING INDICATOR DOES NOT OPERATE OR STAYS ON
CONTINUOUSLY

TEST STEP

ACTION TO TAKE

•

With key ON, depress the park brake pedal. 

Yes =

GO to S12.

•

Does the red brake warning indicator illuminate?

No =

GO to S11.

S11 CHECK PARK BRAKE SWITCH

•

With key OFF, disconnect park brake switch C202. 

Yes =

REPLACE the park brake

switch.

•

With key ON, connect a jumper wire between the LG/R wire on park

No =

REPAIR the LG/R wire.

brake switch C202 and ground. 

•

Does the red brake warning indicator illuminate?

S12 CHECK GROUND TO BRAKE FLUID LEVEL SWITCH

•

With key OFF, measure the resistance between the BK wire on brake

Yes =

System OK. CHECK wiring

fluid level switch C202 and ground. 

for intermittent connections.

•

Is the resistance less than 5 ohms?

No =

REPAIR the BK wire.

S13 CHECK INSTRUMENT CLUSTER

•

Connect 104-Pin Breakout Box (BOB) to the IAA module and IAA

Yes =

REPLACE the instrument

module C1945. 

cluster.

•

With key OFF, disconnect instrument cluster C216 and measure the

No =

GO to S14.

resistance between BOB pin 39 and ground (BOB pin 80). 

•

Is the resistance greater than 10,000 ohms?

S14 CHECK CIRCUIT 512 (T/LG) FOR SHORT TO GROUND

•

With key OFF, disconnect the IAA module from the BOB; leave BOB

Yes =

GO to S15.

connected to IAA module C1945. 

•

With key OFF, disconnect brake fluid level switch C137 and measure the No =

REPAIR the T/LG wire.

resistance between BOB pin 39 and ground (BOB pin 80). 

•

Is the resistance greater than 10,000 ohms?

S15 CHECK BRAKE FLUID LEVEL SWITCH

•

With key OFF, measure the resistance between the P/W wire terminal

Yes =

GO to S16.

and BK wire terminal on the brake fluid level switch C137. 

•

Is the resistance greater than 10,000 ohms?

No =

REPLACE the brake fluid

level switch.

S16 CHECK PARK BRAKE SWITCH

NOTE: Verify the park brake pedal is not depressed before carrying out

Yes =

GO to S17.

this test step.

•

With key OFF, disconnect park brake switch C202 and measure the

resistance between the LG/R wire terminal on park brake switch C202

and ground. 

•

Is the resistance greater than 10,000 ohms?

No =

REPLACE the park brake

switch.

S17 CHECK CIRCUIT 162 (LG/R) FOR SHORT TO GROUND

•

With key OFF, disconnect park brake switch C202 and daytime running

Yes =

REPLACE the IAA module.

lamps (DRL) module C150 (if equipped), and measure the resistance REFER to 

Section 412-04.

between the LG/R wire on brake fluid level switch C137 and ground. 

•

Is the resistance greater than 10,000 ohms?

No =

REPAIR the LG/R wire.

PINPOINT TEST T: HI BEAM INDICATOR DOES NOT OPERATE

TEST STEP

ACTION TO TAKE

T1 CHECK POWER TO INSTRUMENT CLUSTER

•

With key OFF, disconnect instrument cluster C216. 

Yes =

GO to T2.

(Continued)

413-01-30

413-01-30

Instrument Cluster

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST T: HI BEAM INDICATOR DOES NOT OPERATE

TEST STEP

ACTION TO TAKE

•

Turn the headlamp switch to the ON position, set the multi-function

No =

REPAIR the LG/BK wire.

switch to the high beam position and measure the voltage between pin 1

(LG/BK wire) on instrument cluster C216 and ground. 

•

Is the voltage greater than 10 volts?

T2 CHECK GROUND TO INSTRUMENT CLUSTER

•

With key OFF, measure the resistance between pin 2 (BK wire) on

Yes =

GO to T3.

instrument cluster C216 and ground. 

•

Is the resistance less than 5 ohms?

No =

REPAIR the BK wire.

T3 CHECK HI BEAM INDICATOR BULB

•

With key OFF, remove and check the hi beam indicator bulb. 

Yes =

REPLACE the instrument

cluster.

•

Is the bulb OK?

No =

REPLACE the bulb.

PINPOINT TEST U: LEFT TURN INDICATOR DOES NOT OPERATE

TEST STEP

ACTION TO TAKE

U1 CHECK POWER TO INSTRUMENT CLUSTER

•

With key OFF, disconnect instrument cluster C216. 

Yes =

GO to U2.

•

With key ON, set the multi-function switch to the left turn position and

No =

REPAIR the LG/W wire.

measure the voltage between pin 5 (LG/W wire) on instrument cluster

C216 and ground. 

•

Does the voltage vary from 0 to greater than 10 volts?

U2 CHECK GROUND TO INSTRUMENT CLUSTER

•

With key OFF, measure the resistance between pin 2 (BK wire) on

Yes =

GO to U3.

instrument cluster C216 and ground. 

•

Is the resistance less than 5 ohms?

No =

REPAIR the BK wire.

U3 CHECK LEFT TURN INDICATOR BULB

•

With key OFF, remove and check the left turn indicator bulb. 

Yes =

REPLACE the instrument

cluster.

•

Is the bulb OK?

No =

REPLACE the bulb.

PINPOINT TEST V: RIGHT TURN INDICATOR DOES NOT OPERATE

TEST STEP

ACTION TO TAKE

V1 CHECK POWER TO INSTRUMENT CLUSTER

•

With key OFF, disconnect instrument cluster C214. 

Yes =

GO to V2.

•

With key ON, set the multi-function switch to the right turn position and

No =

REPAIR the W/LB wire.

measure the voltage between pin 8 (W/LB wire) on instrument cluster

C214 and ground. 

•

Does the voltage vary from 0 to greater than 10 volts?

V2 CHECK GROUND TO INSTRUMENT CLUSTER

•

With key OFF, disconnect instrument cluster C216 and measure the

Yes =

GO to V3.

resistance between pin 2 (BK wire) on instrument cluster C216 and

ground. 

•

Is the resistance less than 5 ohms?

No =

REPAIR the BK wire.

V3 CHECK RIGHT TURN INDICATOR BULB

•

With key OFF, remove and check the right turn indicator bulb. 

Yes =

REPLACE the instrument

cluster.

•

Is the bulb OK?

No =

REPLACE the bulb.

413-01-31

413-01-31

Instrument Cluster

DIAGNOSIS AND TESTING (Continued)

PINPOINT TEST W: INSTRUMENT CLUSTER ILLUMINATION LAMPS DO NOT OPERATE

TEST STEP

ACTION TO TAKE

W1 CHECK CIRCUIT 19 (LB/R) FOR OPEN(S)

•

With key OFF, disconnect instrument illumination dimming module

Yes =

GO to W2.

C204 and instrument cluster C214 and C215. 

•

With key OFF, measure the resistance of the LB/R wire between pin 4

No =

REPAIR the LB/R wire(s)

on instrument illumination dimming module C204 and pin 6 on

in question.

instrument cluster C214. 

•

With key OFF, measure the resistance of the LB/R wire between pin 4

on instrument illumination dimming module C204 and pin 3 on

instrument cluster C215. 

•

Are the resistances less than 5 ohms?

W2 CHECK GROUND TO INSTRUMENT CLUSTER

•

With key OFF, measure the resistance between pin 16 (BK wire) on

Yes =

GO to W3.

instrument cluster C214 and ground. 

•

Is the resistance less than 5 ohms?

No =

REPAIR the BK wire.

W3 CHECK INSTRUMENT CLUSTER ILLUMINATION BULB(S)

•

With key OFF, remove and check the instrument cluster illumination

Yes =

REPLACE the instrument

bulb(s) in question. 

cluster.

•

Are the bulbs OK?

No =

REPLACE the bulb(s) in

question.

PINPOINT TEST X: ANTI-LOCK BRAKE SYSTEM (ABS) WARNING INDICATOR DOES NOT OPERATE

TEST STEP

ACTION TO TAKE

X1 VERIFY ANTI-LOCK BRAKE SYSTEM (ABS) WARNING

INDICATOR OPERATION

•

With key ON, check the anti-lock brake system (ABS) warning indicator. Yes =

System OK. CHECK wiring

for intermittent connections.

•

Does the ABS warning indicator prove out?

No =

GO to X2.

X2 CHECK ABS WARNING INDICATOR CONTROL CIRCUIT

•

With key OFF, disconnect anti-lock brake control module C154. 

Yes =

REPLACE the anti-lock

brake control module.

REFER to

 Section 206-09.

•

With key ON, connect a jumper wire between pin 16 (DG wire) on

No =

GO to X3.

anti-lock brake control module C154 and ground. 

•

Does the ABS warning indicator illuminate?

X3 CHECK ABS WARNING INDICATOR BULB

•

With key OFF, remove and check the ABS warning indicator bulb. 

Yes =

GO to X4.

•

Is the bulb OK?

No =

REPLACE the bulb.

X4 CHECK CIRCUIT 603 (DG) FOR OPEN

•

With key OFF, disconnect instrument cluster C216 and measure the

Yes =

GO to X5.

resistance of the DG wire between pin 6 on instrument cluster C216 and

pin 16 on anti-lock brake control module C154. 

•

Is the resistance less than 5 ohms?

No =

REPAIR the DG wire.

X5 CHECK CIRCUIT 603 (DG) FOR SHORT TO POWER

•

With key ON, measure the voltage between pin 16 (DG wire) and

Yes =

REPAIR the DG wire.

ground. 

•

Is the voltage greater than 0 volts?

No =

GO to X6.

X6 CHECK POWER TO INSTRUMENT CLUSTER

•

With key ON, measure the voltage between pin 4 (Y wire) on instrument Yes =

REPLACE the instrument

cluster C216 and ground. 

cluster.

•

Is the voltage greater than 10 volts?

No =

REPAIR the Y wire.