Brake Fault - Stop - Service Manual ???

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  1. #1
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    Brake Fault - Stop - Service Manual ???

    Learned Passat junkies,

    Recently, my 2001.5 Passat 1.8t has restorted to informing me of what it thinks is a serious issue. 3 minutes or so after starting the car, or as soon as I start moving, this warning comes on the info display in the dials:

    STOP - BRAKE FAULT - STOP - SERVICE MANUAL - STOP
    accompanied by wild beeping and the 'brake' like flashing.

    Now, I can obviously read that, but I drive the car around, the brakes work fine, and there is no clear problem with any component. Is this a sensor problem? Brake fluid (it was flushed about 5 months ago by a dealer)?

    I don't have near access to a dealer, so any help would be appreciated.

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  3. #2
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    ABS module failure. $250 plus s/h at http://www.modulemaster.com/

    I've been driving around for a month with mine like that, brakes will work, just no ABS.

  4. #3
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    It could be something as simple as low brake fluid. That would be the first place I would start. If that is it, it won't cost you more that $5 to fix. Of course, you will need to eventually find out where it is leaking.

    If this is the case, I would not wait to check it. The last thing you want is to run out of brake fluid while driving 65mph on the highway.

  5. #4
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    i have the same problem right now... happens usualy within the first 5 minutes of my drive and sometimes happens once or twice later on. but it happens every time i drive.... i as well have noticed no problems with my brakes, and when i scanned it with vag-com, it found no codes.

    anyways, people have told me it is either brake fluid or abs module failure. bringing it to an indy this week to do the timing belt and such, gonna have him check it out.

  6. #5
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    by the way, mines an 2002 with AWM 1.8T

  7. #6
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    thanks

    Ok, brake fluid fixed it for now. I couldn't find DOT4, so I used DOT3. Seemed to work. we shall see.

  8. #7
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    Quote Originally Posted by HowIroll View Post
    Ok, brake fluid fixed it for now. I couldn't find DOT4, so I used DOT3. Seemed to work. we shall see.
    Sorry for the bad advice above, I jumped to conclusions because of my own experience. You may have had it low since you had the flush done and just needed to be topped off.

    Scanning for codes with vagcom is the sure way to diagnose ABS module failure. It shows as a fault code in the ABS control module when intermittent and a fault code in the engine control module when communication stops altogether.

  9. #8
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    Brake Fault Abs Service Manual Warnings!! 1.8t B5

    Hi All! (im new to this so please be gentle! ;-) )

    Just wanted to let you all know that for a month now I've been having problems with my B5 1999 1.8T. It all started when we had the rear pads changed and the front CV gaitors changed as they had split. After the repairs were done, I kept getting a constant amber ABS light. For days I was trying to figure out what it could be, checking forums etc. Then after a week of driving it like this, all of a sudden the red Brake light lit up and kept flashing as well as 3 beeps and STOP and Brake Fault warnings flashing on the dash! WHEN THIS APPEARS...THE ABS SYSTEM IS SHUTDOWN AND THE BRAKES WORK LIKE A NORMAL SYSTEM

    I was worried it was the ABS sensor module - which i knew would be VERY expensive to fix! I then checked all the connectors in the brake pad sensor/ABS wiring looms on each of the front wheels. I could see nothing. There was no way i was gonna take it to the Stealers. I took it to a local VW specialist and they cleared the ABS code error .... but after 30 seconds of driving , the lights came back!

    He did a scan and found that the driver wheel sensor was at fault. I took it home and had a look and found that that sensor was not fully pushed into the hub. I took the sensor out, gave it (and the area it plugged into) a good clean and connected it all back together again. Turned the ignition and the dash lit up like a christmas tree again! Took it for a drive and the lights disappeared! I was overjoyed.....then after 30 mins of driving the damn lights appeared again!! I thought that the error code must still be in the system and needed to be cleared. Hooked it up but now the front wheel sensor error was gone, a new error appeared saying "Communication failure from Instrument panel to sensor"

    HOW VAGUE COULD THIS BE - which SENSOR??!!!!! :-(

    At this point i was so sick and tired of the car with jacking it up and down, wheels on and off - checking everything! Everyone i spoke to inc VW said it must be the ABS module as it has a tendency to go bad and VW normally charge something stupid like £800 + labour for a replacement!!!! I was prepared to bite the bullet and cough up £300 for a rebuilt ABS module (the electronics part only). A garage would check it to see if its the module and if they found it to be perfectly OK, then they would only charge £25 for the testing - which i felt was reasonable.

    Anyhow....i then read on another forum that a fellow Passat owner had disconnected the Brake fluid resevoir wiring sensor. My brake fluid was near Max...no where near the MIN mark (so nothing out of the ordinary there). I then took it for a drive and for a day now i have not seen those damn ABS warning lights!!!!! HOORAAAH!!

    It seems that so many of us (inc myself) are thinking its the damn ABS system/module at fault, but the way these VWs are designed, any break in the wiring causes the ABS and Brake lights to flash!

    It seems that the ABS was NOT at fault and it was just a wiring fault with the sensor on the resevoir unit. I have since ordered the new loom and once fitted with a full brake fluid flush, will see if this sorts the problem once and for all!!!

    Hope this helps you guys out there as i know this is a common and ongoing issue for years now!!

    Good luck!

    ps For those with loss of acceleration and engine power.... i installed a new battery and found that the power was back! Just a thought.

  10. #9
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    About 1 week ago I had 4 new brake rotors and brake pads installed in my wife's 2000 B5 Variant (108K miles), and twice now this has happened (once while she was driving; once while I was driving). I'm bringing the car into my shop (independent) tomorrow and will print out this thread for my mechanic.
    Last edited by rgoetz; 11-05-2006 at 10:45 AM.

  11. #10
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    Quote Originally Posted by tesh View Post

    Anyhow....i then read on another forum that a fellow Passat owner had disconnected the Brake fluid resevoir wiring sensor. My brake fluid was near Max...no where near the MIN mark (so nothing out of the ordinary there). I then took it for a drive and for a day now i have not seen those damn ABS warning lights!!!!! HOORAAAH!!

    It seems that so many of us (inc myself) are thinking its the damn ABS system/module at fault, but the way these VWs are designed, any break in the wiring causes the ABS and Brake lights to flash!
    .
    So where exactly is the resevoir wiring sensor?

    Thanks

  12. #11
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    yes where is it. In the engine bay or somewhere under the dash? I need to try this.

    I looked at front sensors, they were a little dirty but ok.

    I tried to look at rear sensors----------how do you get them out. I took off the little plastic clip, but the sensor would not budge? Any ideas?


    2000 passat 1.8t wagon

  13. #12
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    ok, so i am answering my own question.

    I dissconnected the wiring to the brake reservoir and it only added a "brake fluid" to the flashing abs brake stop etc. fireworks display.

    so i guess it is working ok, just the abs is still not right with mine. will get a vag reading soon.

  14. #13
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    Hmmm... My problem is that I occasionally get the "brake fault" message and have never gotten the abs light. Anybody have this problem, or is it always in conjunction with the flashing abs brake stop display?

  15. #14
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    abs light on
    brake light on

    4 beeps on startup and then quiet

    flashing stop and brake fault on computer screen that never goes away and wont allow computer to function.

    I have heard of other things, maybe yours is not the abs controler.

  16. #15
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    Same ABS problems after brake pad change?!

    I've been having similar ABS problems for about the past month starting the same day I had my rear pads and rotors changed on my 2000 Passat at one of those muffler/brake places. Now, the "Stop", "Brake Fault" and "See Service Manual" with the ABS light and a flashing brake warning light turn on almost every time I drive the car. Once or twice I've seen the ASR light come on as well (although the users guide indicates that the ASR light will come on when the ABS is failing). The car drives and brakes fine, but I imagine I don't have ABS most of the time.

    I recently purchased a proper VAGCOM and I get the following faults on a full scan:

    ------------------------------------------------------------------------------
    Address 01: Engine
    Component: 2.8L V6/5V G 0003

    3 Faults Found:
    18057 - Powertrain Data Bus: Missing Message from ABS Controller
    P1649 - 35-10 - - - Intermittent
    17521 - Oxygen (Lambda) Sensor; B1 S1: Internal Resistance too High
    P1113 - 35-10 - - - Intermittent
    17539 - Oxygen (Lambda) Sensor; B2 S1: Internal Resistance too High
    P1131 - 35-10 - - - Intermittent
    Readiness: 0000 0000

    -------------------------------------------------------------------------------
    Address 03: ABS Brakes
    Component: ABS/ASR 5.3 FRONT D10

    2 Faults Found:
    18256 - Please check DTC Memory of Engine Controller
    P1848 - 35-10 - - - Intermittent
    01203 - Electrical Connection between ABS and Instrument Cluster
    03-10 - No Signal - Intermittent

    ------------------------------------------------------------------------------

    Most of the threads that I've read indicate that I probably have to have my ABS unit serviced (as does this VAGCOM reading), but I just can't get past the fact that it never happened before this brake service and has always happened since. A couple other people in this thread seem to have had the same problems right after a brake pad change. I have plenty of brake fluid, btw.

    On a final note, the trip right before I saw the first ABS warning lights, I pulled up to a stoplight and a smelly cloud of smoke rolled right past me from the rear of the car. I pulled over and smelled the wheels, and the smell was definitely from the left rear wheel. I asked the knuckleheads at the brake place (no offense to other brake places, but these guys really were knuckleheads) and he said that there was probably just a film on the brake that had burnt off. I could buy that for a dollar, but I thought it was worth mentioning since my problems started shortly afterward. I do get successful VAGCOM readings from wheel sensors if that's useful. Does anyone have any suggestions before I remove the ABS unit this weekend? Any thought would be greatly appreciated!

    Thanks,
    J.W.

  17. #16
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    Anyone?

  18. #17
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    Quote Originally Posted by jweasley View Post
    Anyone?
    You would be better off starting your own thread on this topic.

  19. #18
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    I have those same three codes (not the O2 sensor ones). Any answers yet?

  20. #19
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    I have the same warnings but my brakes do seam to be hard to stop when first started. Should I change brake pads and flush the whole system?

  21. #20
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    ABS Still Lighting up

    Well I replaced the brake pads on the front and bleed the brakes. Made sure to replace them with pads that have sensor wire. The ABS Brake Fault warning still lite up. So I recently brought it ot a VW Expert but not the Stealer, and he checked out the entire system. He found nothing wrong with the brakes and erased the codes. But they still lite up. He recommended I either replace the ABS Module. Although I can not afford to replace the module at this time I am still going to check out the fluid, sensors and clean all in hope that it will stop lighting up. Wish me luck.

  22. #21
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    Don't think hoping is going to do it. BBA Reman rebuilds ABS modules at reasonable rates. Check ebay for their discounted listings.

    http://www.bba-reman.com/us/index.aspx

  23. #22
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    Hello Izzy, I saw that few years ago you had a problem with your Passat,

    I have the same problem. On right hand turns, I get a "STOP" warning and the BRAKE light lights up and I get three beeps followed by a Service Manual. The ABS light never lights except when starting the car, so I know the bulb works The brakes are working fine (did not test ABS feature). This has been going on now for several months.

    I pulled the front drivers side sensor and cleaned it, No change. I will do the passenger side next, followed with pulling the reservoir sensor.

    Did you ever find a fix for your problem?

  24. #23
    PZ
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    Check your brake fluid level, sounds like it is low.

  25. #24
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    STOP Bake light and 3 beeps.

    This only hapens when turning right and with some speed. It does not happen when I take a slow right hand turn

    I checked my brake fluid level, it was topped off already. I think it may be the sensor in the reservoir. Can I replace the sensor or must I replace the whole reservoir assembly. If I can replace just the sensor, where can I find one?

    I seem to remember this starting a while ago after I got a brake job and fluid flush. Maybe they damaged the sensor and it just keeps getting worse>

  26. #25
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    In that case, it would be good to have the car scanned with a vag-com and see what comes up.

  27. #26
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    Quote Originally Posted by Melstien View Post
    STOP Bake light and 3 beeps.

    This only happens when turning right and with some speed. It does not happen when I take a slow right hand turn

    I checked my brake fluid level, it was topped off already. I think it may be the sensor in the reservoir. Can I replace the sensor or must I replace the whole reservoir assembly. If I can replace just the sensor, where can I find one?

    I seem to remember this starting a while ago after I got a brake job and fluid flush. Maybe they damaged the sensor and it just keeps getting worse>
    Today I popped the hood and removed the sensor connection. I then drove about 20 miles and received no alarm at all. Based on this, it appears to be the sensor in the reservoir. I checked and my fluid was topped off.

    Can I just buy the sensor?

  28. #27
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    Question EXACT same problem with my passat!

    Quote Originally Posted by Melstien View Post
    Hello Izzy, I saw that few years ago you had a problem with your Passat,

    I have the same problem. On right hand turns, I get a "STOP" warning and the BRAKE light lights up and I get three beeps followed by a Service Manual. The ABS light never lights except when starting the car, so I know the bulb works The brakes are working fine (did not test ABS feature). This has been going on now for several months.

    I pulled the front drivers side sensor and cleaned it, No change. I will do the passenger side next, followed with pulling the reservoir sensor.

    Did you ever find a fix for your problem?
    I have the EXACT same problem (the BRAKE error on right turns, etc.)... Please let me know how you resolved it. I read you unplugged the sensor? Where is the sensor located? Where did you find a replacement sensor for purchase? I have a 2002 6 cylinder wagon.

  29. #28
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    Hey Chebert, I'm having the same problem, probably now for about a couple of months, I just kind of got used to it.

    I got the BRAKE FAULT, STOP SERVICE MANUAL and the ABS lights, right after changing the back brake pads.. I was told it might be something as simple as air in the lines and I should have it all flushed, as of now I can't find anybody with a vagcom near me.. Could anybody point me to where the sensors for this?

    2001 passat 1.8T B5

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