ABS light on - Ford Explorer

When you pulled the rear end sensor, did it have metal filings on it? Most of those sensors are magnetic, and the metal worn from the gears ends up on the end of the sensor, thus blocking it from reading the abs wheel. I'd just about bet even though you replaced it, that the new one is covered now. If you take it out and clean it off, it will work again until it covers back over again. I had a crankshaft speed sensor on a Peterbilt which is bascialy the same thing, that would do that every so often. It was located in the bell housing and read the flywheel. The metallic particles worn off of the clutch and flywheel would cover it and the tach would stop working, and the engine would have trouble cranking, but once running, ran fine off of the cam sensor.
On another note, if it turns out that that fixes it, you might want to flush the rear end and refill it with fresh oil to keep it from happening again....

 

Now that you mention it, I have done this. I did it so long ago I don't remember if this vehicle required the reset procedure for removing set codes. Some do require that you hook up to reset, not just disconnect the battery and wait for a period of time.
You said you replaced the sensor so maybe it needs the procedure...?

 

If you have an old computer hard drive rip it apart and take one of the magnets and attach it to the housing to collect the metal particles. They are very strong magnets.

 

I noticed you said the sensor is built into the hub assembly, I have never saw the sensor built into the hub only the " TONE RING" is on the hubs I've seen. Most of the sensors are bolted Thur the steering knuckle, And like the rear sensor they attract a lot of the metal that comes from the rotor, I have in the past blew these off with air and all was fine. Also since you have OBDII you can buy a 35 dollar scanner and get the codes yourself. Also we have a fleet of Fords from 1985 to 2008 and have very few brake related problems. All of our fleet has had the " CRUISE CONTROL" update but have had no other recalls or tech bullitans.

 

I kinda thought about that the same and I took a quick look...
http://cgi.ebay.com/ebaymotors/95-9...ryZ33728QQssPageNameZWDVWQQrdZ1QQcmdZViewItem

 

Wow, that's totally different than what my 93 Explorer had. It had auto locking hubs with replaceable bearings. I'd like to have 4 like those to put on my trailer. If I had a flat, I could just pull a tire off of the Maverick!