Brakes - ABS Sensor Availibility/Replacement
No: 70/02/04/NASRef: TA04 7001
Issue: 1
Date: June 04, 2004
ABS Sensor Replacement
AFFECTED VEHICLE RANGE:
Discovery Series II (LT) All
SITUATION:
ABS SENSOR AVAILABLE AS PART FOR REPLACEMENT
Investigating the root cause of ABS sensor faults indicates that the ABS sensor can now be reintroduced as a service part.
RESOLUTION:
REPLACE ABS SENSOR WHEN INDICATED
NOTE:
This bulletin supersedes and replaces Technical Alert TA04 7001
The ABS sensor can be used instead of replacing the complete hub assembly when a fault with the sensor has been confirmed. If an ABS sensor is to be replaced, follow the procedures detailed in this bulletin.
The Workshop Manual will be updated to include these procedures at the earliest available opportunity.
NOTE:
Overlay harnesses have been released for any concerns with the connectors to the ABS sensor, or for any issues with the harness between the ABS sensor and connector C0505 (front) and C0392 (rear). Refer to Technical bulletins 86/04/04/NAS for further information.
PARTS INFORMATION
DDW WARRANTY CLAIMS:
DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.
REPAIR PROCEDURE
ABS SENSOR REPLACEMENT PROCEDURE - FRONT
1. Release the ABS sensor harness grommet from the inner fender valance and disconnect the multi-plug. (Figure 1)
WARNING:
Always support the vehicle on safety stands.
2. Raise front of vehicle and support with stands.
3. Remove the wheel and tire assembly.
4. Pull the ABS sensor harness through the aperture into the wheel arch. (2 in Figure 2)
5. Release the ABS sensor harness from the brackets on the inner wing valance, suspension turret and the front hub. (3 in Figure 2)
6. Refer to RAVE/GTR section 70.12.10 and remove the front brake disc.
CAUTION:
The ABS sensor and the surrounding area must be clean to prevent contamination from entering the hub assembly.
7. Perform the following: (5 in Figure 3)
^ Remove the Allen screw from the sensor
^ Release the ABS sensor from the front hub.
^ If the original 0-ring remains in the sensor bore, remove it and discard.
8. Loosen four bolts securing the front hub to the swivel hub. (6 in Figure 4)
9. Release the front hub from the swivel hub sufficiently to allow the ABS sensor harness to be removed. (7 in Figure 4)
10. Clean the ABS sensor and mating surface, ensure any metallic particles are removed.
11. Apply grease supplied in the kit to the ABS sensor.
12. Lubricate new '0' ring on the new ABS sensor.
13. Position the ABS sensor between the hub and the swivel hub.
14. Tighten Allen screw to 18 Nm (13 lbf.ft).
15. Position the hub and the tighten bolts to 100 Nm (74 lbf.ft).
16. Secure the ABS sensor harness to the brackets and secure the grommet to the inner fender valance.
17. Connect the multi-plug to ABS sensor harness.
18. Install the front brake disc.
19. Lower the front of vehicle.
ABS SENSOR REPLACEMENT PROCEDURE - REAR
1. Raise rear of vehicle and support with stands.
2. Refer to RAVE/GTR section 70.12.33 and remove the rear brake disc.
3. Disconnect the ABS sensor multi-plug. (2 in Figure 5)
4. Release the ABS sensor harness from the brake hose and the hose bracket. (3 in Figure 5)
CAUTION:
ABS sensor and the surrounding area must be clean to prevent contamination entering the hub assembly.
5. Remove the Allen screw, release the ABS sensor from the hub and discard the '0' ring. (4 in Figure 6)
6. Remove the ABS sensor from the hub. (5 in Figure 6)
7. If the original 0-ring remains in the sensor bore, remove it and discard.
8. Clean the ABS sensor and mating surface to ensure any metallic particles are removed.
9. Apply grease supplied in the kit to the new ABS sensor.
10. Lubricate new '0' ring on the new ABS sensor.
11. Position the ABS sensor to the hub and tighten the Allen screw to 18 Nm (13 lbf.ft).
12. Connect the ABS sensor multi-plug.
13. Secure the ABS sensor harness to the brake hose and the ABS sensor harness bracket.
14. Install the rear brake disc.
15. Lower the vehicle.