How to Replace ABS Sensor 02-05 Mercury Mountaineer
Difficulty: Intermediate · About 70 min · Mercury Mountaineer
Replace the front ABS sensor wiring harness on a 2002–2005 Mercury Mountaineer, routing it through the original frame clips while removing and reinstalling the front brake rotor.
Tools you will need
- A Piece of Pipe (for leverage)
- Torque Wrench
- 14mm Socket
- Hammer
- Jack Stands
- 18mm Socket
- 19mm Socket
- 5mm Hex Wrench
- Flat Blade Screwdriver
- White Grease
- Wire Ties
- Ratchet
- Floor Jack
- Cloth Rags
Parts and supplies
- Front ABS sensor wiring harness
- Front brake pads
- Wheel lug nuts
Steps
Remove the wheel and brake pads
Loosen the lug nuts while the vehicle is on the ground, then raise and support it securely. Unclip the ABS wiring, remove the caliper bolts, support the caliper with a wire tie, and remove the brake pads.
Remove the rotor and old harness
Remove the caliper bracket fasteners and take off the rotor. Unplug the ABS harness near the reservoir and at the hub, release its frame clips, and remove the harness from the vehicle.
Install and route the replacement harness
Connect the new harness at the hub and secure its retaining bolt. Route the wiring along the original path, engaging every frame clip and keeping it clear of the axle, steering, and brake components.
Reassemble the brakes
Reinstall the rotor and caliper bracket, tightening the bracket fasteners to specification. Fit the brake pads, reinstall the caliper, and secure the ABS harness to the knuckle clips.
Reinstall the wheel and test
Refit the wheel and torque the lug nuts to the vehicle's specification. Reconnect the ABS harness, pump the brake pedal until firm, and verify the warning light clears after a cautious low-speed check.
Check your vehicle’s repair manual for exact specifications and fit.