TD5 Intermittent ABS pump issue

[Layno]

Gday,

I’ve been having an intermittent ABS issue with my 2005 TD5 110.
It’s driven daily. On average the issue was only occurring about once every 1-2 weeks.

The Issue:
- Start the car
- Abs pump kicks in making a loud noise
- Abs and traction control light up on dash
- Brake locks up and kicks back when depressing pedal

Previously it would stop if I restarted the car or just waited a couple minutes but it’s now gotten worse.
I went to start it the other day and the pump would not turn off even when I turned the car off. To stop the pump I tried disconnecting the battery (which worked) but it would just start straight back up as soon as the battery was reconnected. To stop the pump and get the brakes working again i had to tap the abs pump with a wrench.
I managed to get the car home and have kicked it over a few times since with no issue.

Ive had the relay tested showing no faults, I might replace it anyway to be sure.
Also going to give the sensors a good clean.
I assume my abs pump is on the way out and will need replacing. I wanted to rule out any smaller issues first as pumps are hard to find and pretty expensive.

Has anyone had a similar issue?

Thanks in advance!
Layne

[V8Ian]

Can the pump be rebuilt?

[Layno]

Can the pump be rebuilt?

I’m hoping it can if the problem is the pump

[DazzaTD5]

As an alternative to i'm guessing a very expensive rebuild or replacement...

A Discovery 2 abs assembly works fine. although the letters designating which line is which is wrong, if you connect it the same way as your old one it will work.

Justin Cooper (indy repairer in tassy) mentioned it many years ago, i've done two, all good.

its also easier to remove the guard.

[Tins]

That's interesting. I guess a D2 one is more common than a Deefer. I have a spare off a wreck, and I imagine I'm not alone in this.

Question: Is a D2a one different?

[Layno]

As an alternative to i'm guessing a very expensive rebuild or replacement...

A Discovery 2 abs assembly works fine. although the letters designating which line is which is wrong, if you connect it the same way as your old one it will work.

Justin Cooper (indy repairer in tassy) mentioned it many years ago, i've done two, all good.

its also easier to remove the guard.

I wondered if a discovery one would work as they’re a bit easier to come by. I checked most of the electrical components today and cant see any faults so must be the pump, definitely worth a try.
Thanks for the tip!

[gavinwibrow]

Can the pump be rebuilt?

On the assumption that the RRC Wabco ABS pump is the same/similar in principle (it may not be, I can't remember), I bit the bullet and sent mine to the gurus - Falconworks in USA for a full rebuild.
Ended up costing about $1,700 all up for rebuild, 2 way transport etc - anyone want to buy one still in its transport box? I also have some Falconworks documentation about the RRC pumps if anyone is interested - PM me if so.

For the record their details are as follows
5603 S Palo Verde Rd
Tucson AZ 85706-7810 USA
Phone 520 294 3572

[Layno]

Turns out the ABS relay was sticking and causing the problem.
Gave it a squeeze and everything started working as normal. Have since replaced it with a new one.