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ABS, brake warnign light and speedo
#1

I've read all i can find in the 968 forums on the above topic and still have some questions I hope you can help resolve. First, I just got my 1994 Cab back from six months at the body shop after an off road incident. I found that the brake warning light was on (parking brake switch didn't help), ABS warning was on and the speedo didn't work. All were OK before the "incident". After jacking onto jack stands, removing wheels, the pads and wear sensors all look OK. But rear rotors are worn (have ridges), so I'll replace rotors and pads and maybe wear sensors.

 

First question: Is there a trick to removing the wear sensors without destroying them? Pad backing plates have a small tab that appears to require a troublesome lateral movement before pulling out. Also, the plug connectors on the wear sensors are a cylindrical shape, about 1 in diameter, held in place by a black plastic strap, and the plugs on the replacements pictured on Pelican appear much smaller,  with a figure 8 shape, so may not plug into the chassis wiring. I broke the LF wear sensor plug trying to pull what looked like a plug for wear sensor out of the white cylindrical piece. This makes me consider straight wiring the sensors at the plug and doing away with the sensor function. Did that on my '88 911 and it works fine (no ABS on that car though).

 

Second question: In deference to the heightened electrical complexity in the 968, will wiring past the sensors work to eliminate this from the possible causes for brake warning light and/or ABS/speedo issues?

 

In checking prices today, the speed sensor for the left front is about $200, and the ABS relay is about $100. So plan is to buy the cheaper of the two (relay) and hope, then spring for the front speed sensor (more hope), but then there are the other three speed sensors. I have a decent volt meter, so is there a quick check these items to see if the work before replacing them?

 

Third question: I've read on this forum about the ABS pump, and perhaps some associated electrical items near it, but so far have not found details on accessing, removal, checking. Any suggestions on this?

 

Last question: The off road incident involved a 180 degree spin with a short backward run, although clutch and brakes were in at that point. Could this have affected ABS system (pump perhaps)?

 

Many Thanks.

 

 

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#2

After digging further to identify the "white cylindrical' piece i broke, I can't find it in KATALOG. On my car, looks like individual single pin plugs from wear sensor and speed sensor plug into this thing (as I had presumed before pulling too hard on the wears sensor plug). So does anyone have a part number for this plug receptacle? How do you get the plugs out without breaking stuff?

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#3

The white plug is part of the wheel arch loom, and only available as part of that



So quick tests, stick your multi meter on AC 2v connect across each wheel sensor and spin the wheel, you should see about 0.5v generated by each sensor



When you turn the ignition on all the lights should light up inc the abs light, should go off after a few seconds as the electrical test completes



The speedo is driven by the drivers side abs sensor through the frequency multiplier in the fuse box, this sends a signal to the speedo drive motor,



So if the wiring is broken or disconnected between the drivers ABS sensor and the ECU for brakes and the relay in the fuse box nothing is going to work



If you can get as far as the dash lights off, and as you drive off before reaching 5mph you should hear the abs pump activation from the passenger foot well, that primes the system ready to save your ass
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#4

Hey thanks Waylander. After coaxing the wear and speed sensor plugs out of the driver's side front wheel arch connector (a little soapy water and gently rocking the plugs out did the trick) I found that it was not the connector that I broke earlier, but the insulator around the wear sensor plug. So new wear sensor will be ordered (probably times four).

Attached the VOM at 2V setting to the two pins in the speed sensor plug, and spun the wheel. On first movement through slow rotation, the reading went to .001, then .002, then when spinning a bit faster (maybe 30 or so rpm), reading went to 0. Does that indicate a failed sensor? I haven't done other wheels yet, but if voltage is supposed to increase with increasing rpm, looks like it may have failed. Or is the slight voltage reading just an indication that a frequency signal is being sent??
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#5

Yes you are correct its a Hall effect sensor, it outputs a tiny pulse voltage up to 0.5v AC, you can also resistance test it too, not sure what the reading would be possibly about 900ohms



I do know they can be a real pain to get out the hubs, and are shockingly expensive, I have posted on here before a check sheet for ABS



You should not be able to mix the plugs up in the white socket, they are different shapes

I think you need to check some of the others to get a reference for the one you think is suspect
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#6

Waylander, i have checked and cleaned all four speed sensors (AC voltage all about the same, 0.5V as you have indicated) removed and cleaned ground wires from hub connectors and the ground for the ABS pump assembly, and have confirmed continuity on all four pad wear sensors (no pad wear warning in dash).

Still get no speedo movement when spinning the driver's side front wheel by hand (she's up on jack stands) but maybe rpm's too low, and the red brake warning light and amber ABS warning light are still on.

I have found your ABS checklist, but am reluctant to attempt much more on the ABS pump assembly (ECU, relay) as it appears I'll need to remove it (lots of plumbing) to get at the ECU (?).  Aside from that looks like I'm at the point of buying relay C22 ($83) or Frequency converter C16 ($258) and hope. Really hate that.

What's do you recommend?

Thanks for your help!

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#7

Hey, just discovered that the ABS fuse is blown. Replacement blows instantly. Does this perhaps point to the ABS relay??

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#8

Points to a short somewhere, the abs ECU is tucked behind the A pillar kick panel, I would unplug that and replace the fuse, see if it blows again, if it does then I would disconnect the big red lead that is possibly connected to the + on the battery as well as the main battery lead, then try the fuse again



If it does not blow then its your ABS pump and relays on the pump, your best course of action at this point is a Mercedes 190 era abs pump, it wont fit but the motor and relays are exactly the same, cheap source of parts
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#9

Thanks Waylander! I used your logic but removed the ABS relay G22 and replaced the fuse - did not blow. So it looks like that means no wiring short and the G22 relay is bad (maybe the diode in the relay failed leaving an internal path to ground?). Do you agree?

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#10

Yes its possible indeed, shame your not a bit closer, I have a full set of spare abs relays



But saying that I would replace one relay at a time and discover which one causes the blow

Bit more logical progression
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#11

After ordering a relay ($84 + shipping) it occurred to me to check the old one for continuity through the diode (schematic printed on the side of the relay). If it's failed, should show zero ohms across pins 30 and 31 in both directions ... and it does. But I guess that doesn't mean there's not another failed component elsewhere. I also ordered a replacement speed sensor ($164) for the left front since I broke the plastic insulation around the plug getting it out. Old one would probably work, but for how long? Lesson here is to use soapy water and gentle tugging (no pliers allowed) to get these out.

Thanks again for all your advice!

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#12

Finally received the new G22 relay. Before installing, i checked the diode (pins 31 and 30 on the relay) with the VOM (discovered it has a diode check mode). The new one checked out ok, Installed it and all braking symptoms disappeared (except of course the pad wear indicators as I was still progressing with new rotor/pad/sensor job (Zimmerman/Porterfield/Sebro parts). Now all is done and everything works well. Many thanks for all your help! BTW, I'm about to post another problem on another thread ... the more I lay hands on this great car, the more problems I run into!

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