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The ABS sensors are on all 4 Wheels. They are located Behind the Disks (or in a few models behind the drums). They are most notably visible as a Cog type ring attached to the axle, and a sensor module attached to it with a wire pigtail coming off of it.
The 'cog' noted above is known as the 'exciter ring', and is actually part of the 1/2 axle.
The front ABS wheel sensors are mounted into the steering knuckle - the heavy cast piece that ties the front suspension / steering / drive train systems together:
* Top mount goes into the McPherson strut * Bottom mount sits on the ball joint at the end of the lower control arm * The disc brake caliper mounts to the knuckle * The tie rod end attaches to the rearward side (final connecting to the steering) * The wheel bearing / hub assembly mounts to it (giving the rotor and wheel somewhere to attach to)
* The drive-shaft - 1/2 axle attaches through the bearing/hub for final connection of the drive train
The sensor mounts into the rearward side of the knuckle, facing the exciter ring and is only about ¼ inch away from it.
The sensor is a highly sensitive 'magnet' device - a small electrical pulse is triggered as each one of the individual teeth of of cog/exciter ring passes in front of it.
The ABS control module, and Traction Control if so equipped, then takes that information for processing * sequential "releases" of the individual wheel brake during a skid,
* rapidly applies & releases the brakes during a wheel spin (on ice/snow/rain).
This setup is also able to provide the information necessary to determine if one wheel is traveling at a different speed from all the others - which is exactly what would happen if one tire had a lower tire pressure than the others. This then drives the 'low tire pressure' warning light. ABS trouble codes are stored in the vehicle memory, and can be read by a well equipped tire shop, dealer, etc. (Autozone can't read them!).
Due to the close mounting to the 'exciter ring', road debris, mud, snow and such can block the sensor from generating its signal - thus triggering the ABS warning light / traction control being shut off / ABS system being shut off.
Of course, a failed sensor, broken wires, or a corroded electrical connection will do the same.
ABS sensors are an easy do it yourself project - once you know which one is suspect. A single small size torx bolt, or 8mm bolt holds it to the knuckle.
Early sensors were made of metal casings, and at least from 2001, the sensor was cased in a plastic type material. The metal ones will corrode themselves into the tight fitting opening and will only come out in pieces. The plastic ones have a better chance of being removed intact - but if you're replacing one because of a failure - who cares. Pricing - a local Ford dealer was about the same price as Autozone - and did not require a special order. For example, the left front sensor was $45 (each sensor seemed to have its own price)
NOTES:
* Not all Ford dealers use the same parts price list - check around! * Windstar owners be sure to read about leaks from the master cylinder being a source of ABS control module failure, and even fires - see "Related Link" below.
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