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Thread: D2 DIY front ABS sensor replacement

  1. #1
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    D2 DIY front ABS sensor replacement

    For anybody contemplating a DIY front ABS sensor replacement.

    Firstly, check what the fault is! Dont fix a brake corner that doesnt need fixing. You might look for physical damage (like a broken ABS line), use diagnostics (eg Nanocom which will tell you whats wrong and where) or test the vehicle (eg DSF wheel only locks despite ABS).

    Jack the D2 and use axle stands. Ensure you're in Park and the Handbrake is on.


    My issue specifically was an unclipped ABS line had become chaffed on the tyre or rim. It wore through the wire and the SLABS logged a permanent fault. 3 Amigos.



    Take the caliper off. Undo the two small 10 or 12mm bolts. Hang the caliper on the radius arm so it doesnt pull on the brake hose. Arrange the pads so they go back in the same way they came out. Bolts back into where they came out of (my tip so I dont finish with spare bolts). Check your pads for wear while you're there.



    Next, the caliper mount comes off. Dont be fooled, they're not some fancy back the front torx bolts that hold it on, they're just a 19mm multihex bolts x2 - your ring spanner will fit. These can be tight, so you sometimes need to apply a breaker bar to get these off, or rattle them. I put the bolts into the caliper mount and hung them on the radius arm also.



    Next, the rotor comes off. You can tap and smack these all you like (only with a rubber mallet), but unless that little screw between 2 of the wheel studs is out, the rotors going nowhere! Undo the screw, then pull the rotor off the hub. You may need to tap it around to get it to budge.



    You'll see the ABS sensor at the top of the hub assembly. 5mm Allen key will remove this from the hub assembly. You dont specifically have to remove this right now.



    This is as far as the sensor lead will pull through, thats all of it aside from the plug. I don't think you will pull the plug through.



    On the back of the hub, there are 4 bolts that need to be undone to move the bearing block away to provide clearance to pull the plug through. Undo these by about 5mm. I needed 2ft of breaker bar to undo them, so they're tight. If you can rattle them then it may be easier. Tap the bolt heads lightly to ease the fitted bearing block out. Only tap it out far enough to pass the plug through the gap otherwise you may drop the axle out of the diff.



    Replace the lead once its out. The ABS sensor has a rubber O-ring. To lubricate this while installing the new ABS sensor, just use a very small amount of dishwashing liquid. I prefer not to use oils in case the rubber breaks down. Reassemble and clip the ABS line back in place at the hub so it doesn't rub the CV joint, along the hydraulic brake line, at the mount and at the bodywork. Check nothing pulls at steering lock and hopefully at full suspension travel.



    Put the wheels on and test drive. The 3 Amigos should become the 1 Amigo if all is correctly working. When you reach about 7km/h the SLABS will do a diagnostic and all brake lights on the dash should go out.
    Cheers
    Slunnie


    ~ Discovery II Td5 ~ Discovery 3dr V8 ~ Series IIa 6cyl ute ~ Series II V8 ute ~

  2. #2
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    thanks, seem to remember on mine at the rear the plug came through without undoing the hub.
    are you still using standard length sensor wires and brake lines?.

  3. #3
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    That would have saved a lot of time on the rear if the hub didn't need to be moved! Thats good to know about the rear though, thanks Yorkie!

    I've got extended brake lines on mine. The front ABS lines are standard, but they have been pulled through from up at the plug to give the additional length needed. The rears have got extentions cords on them manufactured by Wabco, but if I did it again then a set of front sensors which have longer leads put onto the rear would probably be a better way to go about doing it.
    Cheers
    Slunnie


    ~ Discovery II Td5 ~ Discovery 3dr V8 ~ Series IIa 6cyl ute ~ Series II V8 ute ~

  4. #4
    Tombie Guest
    Quote Originally Posted by Slunnie View Post

    I see the 'Workshop Manager' is keeping an eye on things

  5. #5
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    Quote Originally Posted by Tombie View Post
    I see the 'Workshop Manager' is keeping an eye on things
    That's why our QA standards are what they are!
    Cheers
    Slunnie


    ~ Discovery II Td5 ~ Discovery 3dr V8 ~ Series IIa 6cyl ute ~ Series II V8 ute ~

  6. #6
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    Quote Originally Posted by Slunnie View Post
    ...........
    My issue specifically was an unclipped ABS line had become chaffed on the tyre or rim. It wore through the wire and the SLABS logged a permanent fault. 3 Amigos.


    .................
    In this situation, it maybe worth trying to re-join the broken cores taking care to re-instate the screen and seal it all up.
    I did this two years ago with no further problems.
    I understand this fix wouldn't be to everyones liking, but it worked for me, is relatively quick, and is worth a try for those trying save the cost of a new sensor.

    Thanks Slunnie for a great tutorial for those wishing to do the job correctly though.
    2002 D2 4.6L V8 Auto SLS+2" ACE CDL Truetrac(F) Nanocom(V8 only)

  7. #7
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    Quote Originally Posted by biggin View Post
    In this situation, it maybe worth trying to re-join the broken cores taking care to re-instate the screen and seal it all up.
    I did this two years ago with no further problems.
    I understand this fix wouldn't be to everyones liking, but it worked for me, is relatively quick, and is worth a try for those trying save the cost of a new sensor.

    Thanks Slunnie for a great tutorial for those wishing to do the job correctly though.
    Absolutely. I read years ago that the wires here were aluminium or something and couldn't be soldered, that was in the early days of people looking for ABS extension ideas. These wires just looked like pretty standard multistrand to me which solders easily. Thanks for the tip.
    Cheers
    Slunnie


    ~ Discovery II Td5 ~ Discovery 3dr V8 ~ Series IIa 6cyl ute ~ Series II V8 ute ~

  8. #8
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    Quote Originally Posted by Slunnie View Post
    For anybody contemplating a DIY front ABS sensor replacement.

    Firstly, check what the fault is! Dont fix a brake corner that doesnt need fixing. You might look for physical damage (like a broken ABS line), use diagnostics (eg Nanocom which will tell you whats wrong and where) or test the vehicle (eg DSF wheel only locks despite ABS).
    Woo Hoo, now I know what to do. Nanocom and multi meter tells me my sensor is shot.
    D2a Td5 Manual, Chawton White. aka "Daisy"
    Build date 11th Oct 2003
    Freelander 2 2011, manual, the daughter calls it Perri
    Before I had a Land Rover I did not have any torque wrenches. Now I have three.
    LROCV #1410

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