The wear sensors just have the wire looped inside a molded tab of plastic, so their resistance should be near zero ohms. I have repaired sensors in the past by simply soldering the broken wire back together and gluing the loop into the new brake pad with JB Weld 2-part epoxy.

 

OK, thanks!!! I was kind of hoping that this could explain, why the brake warning light has a life of its own...

Coming close to the point of just giving up...

 

Update...

The brake warning light still has a life of its own... Sometimes the light goes out after a short while and sometimes the light flickers and seems to be indecisive...

What else could be done? The brakes seem to work fine though... Bordering annoying is what it slowly is becoming...

 

Update...

Yesterday it was time for MOT.. I told them of the problem I had and after having tested the brakes with a perfect score, the brakes passed...

Now I'm thinking if the warning light problem could be attributed to a design/construction problem, rather than a actual problem!?

 

Hi Roland,

I suspect you still have either an electrical problem or a misbehaving component.

First of all, at one point you had both the ANTI-LOCK and BRAKE warning lamps illuminated. Do I understand correctly that it is only the BRAKE lamp that is coming on now?

You might study Figures 12 (page 33 of the pdf) and 23 (page 55) in the 1991 Electrical Guide. If you don't have the manual, send me your email address via private message and I'll email it to you.

Figure 12 shows the Instrument Cluster hazard warning schematic and the sources of the various signals that trigger warning lamps.

Figure 23 shows the schematic for the Anti-Lock Braking System, and by following wire colors between the two pages, you can see which components tell the Instrument Cluster to trigger the various warning lamps. Some of the possible sources are the ABS ECU (Anti-Lock Failure), ABS Pump Relay (Circuit 6 (ABS Fuse) Failure warning), the Combined Pressure Switch (Brake Pressure Warning), the Fluid Reservoir (Brake Fluid Low Warning), and the ABS Relay & Brake Switch (Circuit 5 (ABS Fuse) Failure).

I'm not positive as to which problems trigger the BRAKE lamp as opposed to the ANTI-LOCK lamp, but that information may be given in the Workshop Manual or even the Owner's Manual.

When you get the lamp illumination, you may be able to measure the voltage or ground state of the relevant circuits and eventually trace the source of the problem.

Please keep us informed. I think you'll eventually solve this one!

Cheers,

Don

 

Sometimes the ABS takes a few seconds longer than the other warning lights to go out, but most of the time it goes out with the other lights.

Yes, the brake warning light is still having a will of its own, but usually goes out after a while, usually after some minutes and only sporadically comes on for a few seconds after that... and not necessarily when braking.

While still on after starting, the VDM indicates FAIL, but after having gone out, there are no codes...

Please do mail me the 1991 electrical guide... Much apreciated!!!

It would be sooooo great, solving this annoying problem...

 

Hi Roland,

Manual emailed to you. Let me know if it comes through successfully - it's a 10MB pdf so it's too large to post directly to the forum.

That's fairly normal behavior on our '93 also. It takes awhile for the ABS pump to pressurize the system and satisfy all the conditions that extinguish the warning lamps. I think the more often you drive the car, the less pressure that is lost in the system and the less time it takes to recharge at startup.


I'm hopeful that you may find some clues in the Electrical Guide from studying the various components that send hazard signals to the Instrument Cluster.

Please keep us informed!

Cheers,

Don

 

Time to update...

I've been occupied with lots of other stuff...

I still haven't found the problem, although it seems as if the warning light isn't as active as before.

I must confess, I haven't had the time to dig in to the schematics and and possibly not having the skills to analyze it and kind of hoping the problem will miraculously go away somehow...