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Help please with Fiesta semi auto odd ABS issue?

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Hi everyone.

Got a weird issue with the ABS on a 2003 Fiesta 1.4 semi auto. In recent months I replaced both the clutch and gearbox actuators with the normal issues. Thinking that all would now be well, and using Ford IDS to carry out clutch learning etc, the car ran without issues for 3-4 months. Got to the car one morning, usual blank display! Hooked it up to the IDS and got several fault codes relating to gearbox. Thinking that either the gearbox or clutch actuator may have thrown a wobbly I removed them and sent them back for testing (ATP electronic in Cannock), who incidentally are first rate. They tested and found no fault, but because I purchased from them in the first place, sent me new replacements. So I can rule them out.

The weird issue is as follows: IDS sends fault code of U0415 which relates to a communication fault between the ABS and transmission control module. At this point my attention went to the wiring. Checked it and found no fault but changed the whole engine loom anyway! So I can rule out wiring. 

Now went to the ABS module. Replaced it with a known good used module, bled the brakes. Still the identical issue and fault code. 

The fault code produces possible causes: faulty wheel speed sensor - changed all 4 and checked pulses at the module. Okay. ABS Active. ABS/EBD module configuration failure - Programmed option content inconsistent. Incorrect Tyre/wheel type: Checked this and all is well.

So.... Has anyone out there had this issue? And if so, how the hell did you sort it out? IDS communicates with the ABS, and doesn't actually show fault when diagnosing it. The problem is when I attempt the gearbox learning mode with IDS. It fails the learning process and then throws out the U0415 fault (Which was cleared prior to attempting the learning process)

Here's the other weird thing though. I decided to have the ABS module refurbished. But nobody can refurbish this particular ABS module (2S61-2M110-CE/10.0206-0093.4)

Any help or advice out there?? I would really like to get this sorted. The car has been off the road for more than a month. Any pointers would be appreciated greatly!! :sad:

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Long shot, but I've had bad wheel bearings throwing up weird ABS codes, but looks like you've probably checked this.

Common faults with that code indicates a wiring issue.

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If you'd said you were using Forscan with a cheap OBD reader I'd be inclined to suspect that it is the reader causing issues on canbus and preventing modules talking to each other. Ordinarily these are benign issues given their momentary nature (the Forscan authors acknowledge this) but if it is preventing some form of learning/initialising from occurring then that's obviously a problem. BUT... you said you were using Ford IDS and so surely it wouldn't not be causing such issues.

I am not familiar with what the gearbox learning mode is but can it be done with the ABS module disconnected?

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Thanks for the input guys! I will certainly attempt the gearbox learning procedure with the ABS disconnected. Must admit I didn't think of that. Fairly sure though that all the ECU's need to communicate with each other, but it's certainly worth a try. I have used 2 versions of IDS... V101 and now have the latest V106 which is very reliable. Forscan does give the same fault codes but I mainly use IDS for its reliability. 

I'll certainly report back when I've tried the gearbox learning.

Thank you for your help.

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Don't get your hopes up though - thinking about it if there's one sure way of triggering a module communication error it's removing said module! Worth a try though. 

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