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ABS Problem

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16K views 21 replies 10 participants last post by  richramon  
#1 ·
I'm new to the forum so I apologize if this request for help is a little long:

I need help regarding the ABS on my Tacoma. It is a 2000 4X4 5 speed V6 TRD. Now for the problem. Initially, on about every third start-up, my ABS light would come on and remain on for the entire trip. Other times, the light would extinguish upon start-up and remain off during most of my trip (some of 5 miles, some of 100 miles). There was no identifiable pattern regarding when the light would come on during that trip or what, specifically, I was doing when the light chose to reveal itself. Many times, I was on the freeway at speed, not touching the brakes when the light would appear.

Recently, the ABS light starting coming on (and remaining on) after every start. I queried the ABS computer and discovered I had faults 32 (L/F sensor), 44 (decel sensor), and 49 (brake light switch). I pulled all four wheel sensors, cleaned them up, and correctly re-installed them. No difference. I decided against replacing the L/F sensor at this point in time because almost everyone else with the exact same codes did so to no avail. I next pulled the wire plug that plugs into the ABS computer, cleaned up the male pins (including a slight tweak), applied a small amount of dielectric grease, and reinstalled the plug. The ABS light on the dash now went out after its initial 3 second “test on.”

I thought I had solved the problem. NOT. I went for a ride. As I was coming to a stop, the ABS function (vibration in the brake pedal and a ratcheting sound) occurred at about 5 MPH to stop. The first time, the ABS light stayed off, however after the second stop with the same symptoms, the light came back on (and of course, now the 5 MPH vibration was gone – ABS obviously again disabled). I went under the hood and “re-positioned” the ABS plug wires (coming out of the 90 degree ABS wire plug). The light now went off. Again I thought I had identified the problem (wiring at the plug) and had solved it with the re-positioning using a tyrap to hold the wiring in a slightly different orientation.

Now, the light will consistently go off upon start-up (after its 3 second “light-on” test) giving the mistaken impression all is OK. The ABS will activate from 5 MPH to stop about 60% of the time (approximately every other stop). That activation is not predictable. Sometimes, I will have 4 stops in a row that are normal, then have two or three with the vibration. The light is still off (after its 3 second “test on”) on every start-up. With the light off one would assume no faults in the system or the light would remain on), I again queried the ABS computer. I still had the three codes (32,44,49). I decided to clear the ABS computer and see if the fault codes would reappear. Once erased, no faults re-established themselves in the computer's memory. The ABS activation however continues as previously described with no change.

Now for the questions. With the light off and now no faults stored in the memory, one would think the computer believes all is well. Why is the ABS function consistently activating at under 5 MPH on dry pavement with no wheel slippage? Why not activate at 30 MPH? What is the computer seeing at 5 MPH that is causing it to activate? Could one of the wheel sensors be dropping out at that low speed, confusing the computer? Is this symptom someone recognizes that they have solved? If so, what was the solution?

Is is possible I have one sensor with a weak magnet? The sine wave is easily generated at higher rotational speeds with a weak magnet, but at lower rotational speeds, the disruption speed of the tone wheel teeth in the magnetic field is not enough to generate the sine wave needed by the computer due to that weak magnetic field. Could that lack of a sine wave (assuming that is what is actually happening) at lower speeds cause the computer to believe that wheel has stopped, thus it initiates the anti-lock function?

I was told by one tech that these wheel sensors don't work at under 5 MPH by design. If that is true, what is the computer receiving that is causing it to activate? If the above is true, it stands to reason a correctly working system would stop pulsating the brakes at under 5 MPH on ice. Is that what happens? I live in Northern California so we don't have snow or ice.

I cannot help but believe I have a wiring problem at the plug. The movement of the wires apparently does have an effect on the computer function. I need help from someone who has solved this problem. Once erased, the codes (32, 44, 49) have not reappeared. The ABS computer believes all is well.

My only other thought regarding this issue is with the wheel sensors themselves. If one of the sensor magnets is weak (but operational), the tone wheel teeth would still easily generate the sine wave the computer is looking for during its pass through its magnetic field at higher revolutions. I know the AC voltage generated is directly proportional to the magnetic flux density of the magnetic field and the rotational speed of the tone wheel. When the rotational speed of that tone wheel slows, the above factors could result in a lower than expected induced voltage sent to the ABS computer. Depending on the programming of that computer, it might ignore that “reduced voltage.” If it were to read that reduced voltage as “no voltage” at one wheel, that signal would be translated into “no rotational activity.” The computer would assume that one wheel has locked up (no rotational signal) and trigger the anti-lock function.

It's possible the weak sensor would ohm-out within specs yet not have a strong enough magnetic field to satisfy the induced voltage needed by the ABS computer at low rotational speeds. Has anyone solved this problem with the above symptoms? If so, what is the solution short of mindlessly throwing parts at this problem or disconnecting the ABS function altogether?
 
#2 ·
Welcome to the forums! :)

Looks like you've collected a lot of data to help diagnose yer issue. I'd love to help but luckily I don't have ABS in my T-100. ;)

I guess you could build a test rig with an ABS ring and a place to mount the sensor in question to test yer theory of a weak sensor. Maybe an old hub set up? ;)

Are the wires in the harness a twisted pair setup? Is there shielding around that part of the harness? Is there any aftermarket items that could influence the signal? Are there any common OEM options fer Tacoma trucks with the same issue? ;)

By any chance, do you have a trailer light adapter hooked up? Those have been known to cause electrical gremlins when they fail. ;)
 
#3 ·
The sensors do not appear very sophisticated, thus I believe those sensors just deliver a sine wave to the ABS computer in the form of an AC current. I do have a "third brake light" insert in my 2" receiver, however I have the problem with the light plugged in and with the light disconnected, thus that is not the issue. The twisted pair suggestion was interesting however, as stated above, the sensors are not wired like that and have no shielding.

I have no after-market equipment (except 5100 shocks) that would interfere with the braking system. I did install new slotted rotors and Brakestop pads a while back however the issues as described in my initial post stayed the same before and after. I did not damage the sensors or the tone wheels during installation.
 
#5 ·
You've done your homework extremely well.
If you have access to an oscilloscope you could check the signal from each sensor.
It's strange that the ABS ECM hasn't set any codes again.
You could check it by forcing it to. Disconnect one of the wheel sensors for example and make sure it sets the code for that one.
The deceleration sensor is another possibility .
 
#6 ·
The mileage on my truck was something I did consider. I have 295,000 miles on the truck (owned since new). I have "checked" the wheel bearings using the 6 and 12 o'clock (as well as the 3 and 9 o'clock positions - jacked up of course) and have felt no play at all in the bearings or tie-rods. I have been leaning that direction however everything I have read relates to the bad wheel bearings causing damage to the sensors that create an ABS failure. I have read the sloppy bearings will cause the tone wheel teeth to physically strike (or scrape) the wheel sensors. My sensors are pristine with no physical damage. I know that distance between the tone wheel teeth and the sensor face is important however I believe you'd be able to feel wheel bearing play if the bearings were damaged to such a degree that the sensor gap was compromised. Is that correct? Is it possible to not feel any play in my wheel bearings, yet the bearings have just enough play to narrow or widen the tone wheel teeth to sensor gap, causing my anti-lock function to activate at under 5 MPH?

I'm certainly not a Toyota mechanic however I was under the impression that if bad wheel bearings are the root of my problem, I'd certainly be able to feel (or even hear) a sloppy bearing by physically checking the bearings for play.
 
#7 ·
When you use the 9/3 and 6/12 o'clock method to check bearings, you have to make the movements very subtle.
 
#8 ·
One final question. Does anyone know how the decel sensor plays in the activation of the ABS function? I can understand a speed sensor and how that might interact however I have no idea what specific function the decel sensor plays in the overall scheme. Does it somehow sense "hard" braking and activate at some predetermined threshold? Could that decel sensor trigger the ABS function at under 5 MPH due to a faulty unit (also does it really cost $950+)? What specifically comes into play with the ABS in the 5 MPH to zero MPH range? I do not have any unnecessary ABS activation until 5 MPH to zero. I'm hoping that is a big clue to someone who has solved this frustrating problem.
 
#9 ·
One more "issue" I forgot to mention regarding my ABS problem. The "short pin" is missing from my diagnostic port (the one under the hood next to the intake on the driver's side). What does that "short pin" do? I have no idea what happened to it. To my knowledge, it was never there. Don't tell me that is the solution to this problem!!
 
#10 ·
Most Toyota computers have what's called a check mode, where you can set it via software or jumper wire to throw codes on a one trip fault instead of the usual 2 or sometimes 3 trip fault. This can be very useful for finding intermittent codes.

It sounds to me like you have a failing wheel speed sensor or damaged tone ring or a sensor spacing issue. Being that the sensor generates an AC wave from the teeth going past, the signal is weakest at low speeds and any damage to the teeth, sensor, or change in spacing can cause a low speed signal loss or signal below threshold. Use a DMM on AC millivolts to compare the wheel speed signal voltage at each wheel when they're all turning at lower than the 5mph speed you have the problem with. With any luck you'll find one with lower voltage than the others, then you can try to figure out why. On many makes I've seen rust build up push the sensor up and away from the tone ring causing false low speed ABS activation. On a couple Toyota and Lexus models I've seen stainless steel rings which are part of the hub get pushed into the tone ring and grind the teeth off, rust swells behind and then friction takes its course, the iron ring being softer than the stainless steel.
 
#11 · (Edited)
Sent you a PM. ;)

Looking over my Electrical Wiring Diagram (EWD) fer my 1998 T-100, it does indicate that the ABS wiring fer the wheel sensors are supposed to be shielded before and after the interconnections. It looks like the shielding is returned back to the ABS ECU. ;)

Has this vehicle been in an accident before? Perhaps the wiring has been damaged and repaired incorrectly? Have you owned this vehicle since new or are you a new owner?

Do you have access to the Service Manuals and EWD fer yer vehicle? If not, give Techinfo a visit. You can subscribe fer a 2 day account fer $15 or a monthly account fer $75 and download to yer heart's content. ;)
https://techinfo.toyota.com
 
#13 ·
Doing some research, there seems to be various wire mods that can be done to the Tacoma harness like the "gray wire mod" fer the e-locker and the "blue plug mod" fer 2-low option. Do you know if yer harness has been modified in any way? Maybe the mod(s) has an effect on the ABS? ;)
 
#14 ·
I've owned the truck since new. It has never been in an accident and has lived its entire life in Northern California, thus no rust anywhere. I did clean up the sensor mounting (with sandpaper) to ensure a clean surface when I installed my speed sensors after I cleaned them up. Upon closer inspection, I believe the sensor wires might be shielded. In any case, they are in place and undamaged.

I did install 5100's a year back but was very careful regarding the sensors and their wiring. I also did the "gray wire modification" a long time ago without any anti-lock issues at the time of the modification. My tone wheels appear pristine with no damage however measuring the output voltage at each wheel at low speeds is a good idea. I think I could jack up each wheel and hand-spin the tire while reading the voltage. My problem occurs at such a low speed that I should be able to simulate that speed with a hand spin of each tire.

There still is no identifiable pattern regarding that anti-lock activation other than consistently under 5 MPH. It'll sometimes go 10 stops in a row with no activation (and of course no ABS light on the dash), then I'll have 3 activations in a row. It doesn't matter if the engine is cold or warm, if the outside temperature is hot or cold (of course not much of a temperature range here in the west), if I'm going up hill, down hill, or level ground, etc.

I will measure the AC output for each wheel at "low speeds" (hand-spinning each wheel) and see if I get a "drop-out" at one wheel. Due to my high mileage (295,000 miles), my wheel bearings could be causing a clearance issue between the tone wheel and the sensor even though those bearings have absolutely no play that I can feel.
 
#16 ·
Heck, it could even be a bad solder joint on the circuit board somewhere, not outside the realm of reality, could have a cracked solder joint where the pin meets the board since there's a higher amount of vibration and stress there. 2000 would probably be a good lead solder, not the later ROHS stuff that's prone to cracking before they got it figured out right, but I've seen old stuff break joints too. It shouldn't be too hard to get inside the ABS ECU to check it out, you may need a jewelers loupe or similar to get a good close look with a bright light. Naked eye might not cut it, but I think there are ways to stain cracks to make them more readily visible. If it is a cracked solder a simple reflow with an iron (without adding any solder) should do the trick! A bad joint would explain the randomness somewhat or that flexing or moving wires at the module seemed to cure it for a moments time.

Then there's also something called fretting corrosion, google that one for a fun read about tin plate, terminal tension, and oxidation.
 
#18 ·
Did you ever figure out what the issue with your Tacoma was? I have just encountered the same problem with my 2000 Tacoma 4x4 SR5 and it is EXACTLY what you have described. It is throwing the same 3 codes (32, 44, 49) and all of my wheel bearings, tone wheels, ABS sensors, and decel sensors seem to be in good working order (according to a local Toyota dealership).
 
#20 ·
Hi Forum! First time here. If any body can help, thanks in advance.
I'm having the same problem on my 2002 Tacoma, 3.4L truck. The ABS light comes on when stopping. I connected an Autel Model MS908P Scan tool and it shows NO code, however the ABS system is disactivated at a stop light. I have done a manual reading through the OBD2 port under the dash with the paper clip connecting the pins that Toyota mentions in their service manual and the code that comes up is 44 that means deceleration sensor. That sensor has a list price of $ 1,500.00. Could in fact the deceleration sensor needs to be replaced? Thank you.
 
#22 ·
Hi, I am new to this forum. I have a 2003 Taco 3.4L extended cab prerunner with the same issue as jjohnson48. I plan on removing the front sensors and re-cleaning them and ESPECIALLY clean the tone ring. If that does not help, I will be forced to pay big $$$ to have the brake specialists perform their testing. I do not own the device (costs about $100) to tell which sensor is bad.