I have managed to remove my dead driver's side abs sensor over the weekend but it has prooved a real challenge. here goes:
Firstly, I bought a abs sensor off ebay (which is actually for a ford escort mk5,6 rs2000) as the looked the same. And guessing from an electronical point of view, it should work if it has the same connectors and it has the same impedance as the standard puma's ABS sensors. The reason why I used the escort's one is because it has the magnet is encased behind an aluminum cover, which would, from my point of view, protect the magnet circuit and prevent corrosion
as you can see from the picture, it isnt very different, only the magnet enclosure is different.
So I proceeded to remove the old abs. After unscrewing the nut (size 8mm socket) I discovered that the abs sensor cannot be removed. Thinking it has seized, I deployed the WD40 and a screw driver to try and wedge it out. This method has cost me a flat head screw driver as the screw driver broke in the end.
I then decided to purchase myself a chisel and attack it with it.
chiselling it seems to work but I was left with the head still stuck in the mounting hole. After thinking through I came to the conclusion that the only way to get it out is to knock the abs from the front.
So, I had to remove the brake disc which means removing the calipers. so 2 other specialized sockets needed, one 13mm socket to remove the retaining bolts to the hub, and one inverted allen key type of socket for removing the retaining slider bolts.
After removing the calipers and the discs, I got a nail to knock the abs sensor through from the front (used a nail as it fits through the tone ring's holes) Hurray, the abs came out.... but no not yet, the plastic case is still in there... only the internal bits came out <_<.
Next I improvised and as I do not have a blow torch to burn the plastic off, I used a dremel, loads or matches and some kerosene and managed to get the bugger out.
finally, filed the mounting bracket down and put tons of copper grease on everything that requires screwing and bolting and fixed everything back.
Feeling confident, I then ignited the engine, drove to 12-15mph, the crunch came and hey presto
no more sickening TC and ABS lights.
Just for info, i measured the impedance of the abs sensor and it is 0.001 different from the std puma abs sensor. another thing i found out is that the original abs sensor for the puma, the one with the black plastic casing, is slightly bigger than the mounting hole and is designed to be squeezed into the mounting hole. This imo has caused the so call "seizure" and made the removal very difficult. should you endeavor to use the std abs sensor, I would suggest that you sand down the casing a little make sure it will still be removable. The abs sensor has a nut holding it in place so i do not see why the abs sensor has to fit soooo tightly into the mounting hole.
hope this thread has help would be abs sensor replacing DIY mechanics
