Fun with ABS warning and finding parts...

We're just in the process of moving house, to leafy Haslemere. Last weekend I was at our old flat, had seen the removals people off with our stuff and was getting ready to jumping Diane follow them down. About 100 metres into my journey I got three loud beeps, a warning symbol of the DIS and the ABS and Traction Control amber warning lights lit up. Damn.

So I read up a bit on here and it seemed like the issue was probably something in the connection, cable or sensor. I didn't have my old laptop that I setup for VCDS with me so couldn't tell for sure. Brakes seemed to be working OK and nothing else was an issue. I tried turning it all off and on again but the warning reoccured.
So I decided to bite the bullet and drive her down to the house. Everything seemed fine the whole journey (except the flashing red warning) and I tried to drive and control speed with gears and leave the brakes unless I needed them.

Once I got down here and the rain stopped, I hooked up VCDS and got the following...

Address 03: ABS Brakes Labels: None
Controller: 8Z0 907 379 D
Component: ESP FRONT MK60 0101
Coding: 0007175
Shop #: WSC 00000
VCID: 49E5B47460A1
1 Fault Found:
00283 - ABS Wheel Speed Sensor; Front Left (G47)
003 - Mechanical Failure - Intermittent


Sounds like the culprit, a faulty sensor. So I jacked her and took of the wheel to see if the issue was actually the sensor or maybe a worn cable (I had the suspension down recently and am running wider wheels/tyres so it felt like a possibility). To my annoyance what I found was this...
IMG_C5F1B387109E-1.jpeg


Cracked connector housing that likely let in water and ruined the sensor too. I tried dispersing water in sensor and connector and driving up and down the road but the warning persisted even after clearing. After battling the parts manual pages I found the number for the sensor (6Q0927803B), which I ordered on eBay and should be here Monday.

But the cable! Firstly determining which part number I needed was not obvious; between searches on the forums here and checking the manual I determined it to be 8Z0927904 but finding one I can actually buy is another thing entirely. :mad:
I think it might even be easier to replace the connector on the end of the cable rather than hunt for the cable part. If anyone knows the part number for the connector I'd be very grateful to know!
 
Does this help you? Always use these people when I want connectors....


Nothing to do with me , I am only a happy repeat customer of them.
 
A terminal removal tool that will release each pin from the housing without damaging the fixing tabs, these are a handy toolbox items.
 
Last edited by a moderator:
@Mightyleader

The part number for the ABS+Pad Wear loom you found eventually is indeed correct. The loom it is a bit too specialised for the main parts retailes to stock, but out of interest the easiest way to buy it is from Crewe Audi on here, it costs about £60. It will be far far easier and cheaper to renew the ABS connector as you suggest, just buy a decent pin extractor tool.

Andy
 
My thanks to @Andrew @beady73 and @audifan for the tips, they were all gold.
I thought I'd update on the fun I have had with this repair.

  • Connector replacement - this was the easiest part, the rubber protector popped off and slipped back easily. I used the pin extractor tool to remove the pins, labelling them for the way back in. Removing the old one and fitting the new one with rubber seal and lock pin was fine. Great!

  • The bolt holding the sensor in was a nightmare. It was corroded and pretty comprehensively rounded out by some previous person. Sigh... I used everything I could think of up to and including hammering in an oversize torx bit and finally got it out. New bolt required.

  • The real problem was the sensor itself. This did not want to budge. At all. I really did try *everything* I could. Eventually it started to budge, just a little at first then more and more until... pop! It came free! With the sensor head snapped off and stuck in the hole. 15 years of being stuck in there won. It took a while before I was calm again.
I've admitted defeat and taken it in to a local independent who specialise in German cars (http://www.rtmechanics.co.uk, opinions welcome if anyone has experience of them). Spoke to a very nice man who nodded when I explained the problem, had seen similar before and said they could extract the stuck piece and fit my replacement by the end of the week. Fingers crossed!

I felt it was important to post this experience as none of the guides or information I found prepared me for how stuck that sensor was.

IMG_6EB1DB6117B3-1.jpeg

After a bit of cleanup, the rounded out bolt.

IMG_9C6D8560884E-1.jpeg

Bolt removed!
IMG_4B94D3604DEE-1.jpeg

Damn it. Damn damn damn!
 
My thanks to @Andrew @beady73 and @audifan for the tips, they were all gold.
I thought I'd update on the fun I have had with this repair.

  • Connector replacement - this was the easiest part, the rubber protector popped off and slipped back easily. I used the pin extractor tool to remove the pins, labelling them for the way back in. Removing the old one and fitting the new one with rubber seal and lock pin was fine. Great!

  • The bolt holding the sensor in was a nightmare. It was corroded and pretty comprehensively rounded out by some previous person. Sigh... I used everything I could think of up to and including hammering in an oversize torx bit and finally got it out. New bolt required.

  • The real problem was the sensor itself. This did not want to budge. At all. I really did try *everything* I could. Eventually it started to budge, just a little at first then more and more until... pop! It came free! With the sensor head snapped off and stuck in the hole. 15 years of being stuck in there won. It took a while before I was calm again.
I've admitted defeat and taken it in to a local independent who specialise in German cars (http://www.rtmechanics.co.uk, opinions welcome if anyone has experience of them). Spoke to a very nice man who nodded when I explained the problem, had seen similar before and said they could extract the stuck piece and fit my replacement by the end of the week. Fingers crossed!

I felt it was important to post this experience as none of the guides or information I found prepared me for how stuck that sensor was.

View attachment 82916
After a bit of cleanup, the rounded out bolt.

View attachment 82917
Bolt removed!
View attachment 82918
Damn it. Damn damn damn!
Hi I would drill this out it is only
plastic /resin if you carefully drill the centre of the sensor with a drill no bigger than the dimension across the flat section the rest will collapse in on its self with a small screwdriver etc then clean bore with Emery cloth etc.
Hope that helps
Keith.
 
I did consider drilling it out myself, ironically I can’t find my drill kit anywhere, it’s lost somewhere in the sea of boxes from the move that are waiting to be unpacked
 
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