ABS Sensor Questions

[BaseCamp]

So I did an advanced search and was unable to find my answer. So here is my question:
I have a 96 E350 7.3 with front ABS, the axles that I am swapping in are 06 f250's with ABS. I would like to make a pig tail connector between the old sensor connectors and the new sensors connectors. I had read on another thread that I would need to replace the 06 sensors with an 99-04 sensors, is this accurate or can I just plug and play with a homemade pigtail/splice job? My new bearings came with new sensors. I have pretty much everything else figured out and the axles rebuilt completely otherwise, with all the parts needed for the conversion in my garage, gonna get this finished up right after my elk season ends. Had to take a recharge day today to catch up on work, maybe I should have harvested one of those cows or the 5x5 that I called in this past weekend. Thanks!

 

[mgmetalworks]

A recent customer of mine sent me this email describing what he had to do. Thankfully, he had some time to sort this out and write it down. Credit to Trevor K.

"My van is a 2002, and my front axle is a 2014....

I tried a 2006 F-series sensor ( same for 2005 to 2010 according to Rock Auto, Motorcraft PN BRAB-323) and after testing it, it also appeared to be an active-type sensor like the 2014 piece instead of a passive sensor as I required. It actually behaved a little differently than the 2014 sensors; It seemed to only momentarily show any conductance and only after swapping polarity on my ohmmeter back and forth where the 2014 sensor would show a mega-ohm magnitude resistance in one direction and an open circuit in the other.

I went to a local parts store and got my hands on a 2004 F-Series sensor (BWD PN ABS3080). This was what ended up working. Resistance measurements were in the kilo-ohm range and I could generate a small AC voltage by moving my keys back and forth past the end of the sensor. At home and installed, I get the same sinusoidal waveform on the scope as I get with the E-series hubs when the wheel is rotated.

The sensor body and cable diameter are physically larger but they work. The probe end and the mounting hole appear to be the same dimensions (within injection-molding tolerances) as that of my 2014 sensors (which looked almost exactly the same as the 2005-2010 sensors). I had to bend the rotor dust shield a little to run the wire and then bend it back, but other than that it fit right in. I also have no issues with clearance to the teeth on the reluctor wheels in the hub, so I did not use any sort of shim. I did notice that the 2004 sensor used a smaller o-ring (cross-section diameter) but a larger ID o-ring groove, so its OD was about the same. Its hard to tell but it may have a lower o-ring contact pressure in its mounting hole.

Another piece of info that may be useful: Both of the sensors I tried use the same type of connector as my 2002 E-series, however the F-series male and female ends are swapped compared to the standard E-series setup. I ended up cutting off the ABS sensor-end connector from my I-beam assemblies and wiring that into the harness-end of the van. Its nice because its free, and this end of the connector has the little christmas-tree clips so the assembled connector can lock into the existing slots in the van's frame. It makes for a really clean looking installation.

So at the end of the day, no more ABS light and the ABS system engages on loose surfaces as expected."

 

[BaseCamp]

Thank you very much MGmetalworks, this is what I had expected, I will order the other sensors and swap them in, hopefully this is the same for the 96 model year. If anyone can confirm that would be helpful. Thanks!

 

[gaetzjm]

It appears the BWD part # is actually ABS308.:ylsmoke: