2008 rear abs sensor stuck

[John d]

I can't remove the abs sensor from the sensor housing on the rear wheel - it's stuck or corroded into place. The sensor seems like a delicate part and I don't want to take a hammer to it. I'm thinking of just using penetrating oil, but I'm not sure that is safe either.

Any ideas?

I did manage to remove the sensor and housing as a unit so I can proceed to change the tire, but would prefer to free up the sensor before I put it all back together again.

 

[Chuck35]

Penetrating oil should do it. The rubber o ring is just stuck. On the way back together give the o ring a wipe of your favorite grease.

 

[ABQFJR]

The sensor and its housing are one unit. There is one allen bolt that holds the whole thing on. Once you've removed the little allen bolt holding the silver plate on, the sensor and housing should pull out rather easily. No further disassembly is required, nor, AFAIK, possible.

 

[ABQFJR]

Damn, Chuck beat me to it.

Going off what he said, and off your concern, this thing is designed to stand up to all manner of road grit, grime, moisture, and temperature extremes. Penetrating oil shouldn't be a problem.

 

[Fred W]

This was mentioned elsewhere recently. It does seem that (on second gens) the seal for the ABS sensor into the plate is a hard plastic rather than rubber or neoprene. I had a heck of a time getting a local fellow rider's sensors out while doing tire changes recently and used penetrating oil to do that eventually. There was no corrosion to speak of on his, just the seal was very stiff. We greased it lightly (with silicone grease) when reassembling, so I guess he will see next time if that helped at all.

 

[mcatrophy]

There's no real need to take the sensors out to change either tyre. My '06 went its entire time with me with both seized.

The rear is no problem at all during a change, I found the front needed the wire released higher up to prevent strain, I posted a mini-how-to here.

For my '10 I removed both sensors very soon after I had the bike, then used copper grease on them, which has prevented seizure since, even with what the bike has to put up with during our winters.

I think you would be safe to use a hammer and a screwdriver to gently tap the base-plate (after removing the screw!) to rotate it a little. This on the '08 or later, where the sensor probably doesn't have a magnet in it. '07 and earlier I wouldn't. The difference I described here.

 

[El Toro Joe]

John, I had the same issue on my last tire change. Riding during winter has finally started to cause some corrosion /rust.

 

[John d]

Well I ended up marinating the sensor with penetrating oil for about 2.5 hours, at which point it was still not budging, so I took pliers to the the plastic part of the sensor and wiggled it free from the housing, after which I realized the plastic sleeve had snapped off the sensor and remained imbedded in the metal housing. I wish I would have waited for mcatrophy's post and just left the damn thing alone.

Here is the sensor. You can see small areas where the plastic sleeve used to adhere to the sensor.



Here is the housing with the broken plastic sleeve still firmly stuck in the housing.



Here is the sensor showing plier marks on the plastic outside part of the sensor.



I couldn't just stick the sensor back into the sleeve because it was an interference fit, so I took a 3/8" drill bit and wrapped it with some 320 grit sandpaper and reamed the plastic sleeve just enough to fit the sensor back in. I used some JB weld epoxy to fill in the gaps of the sensor tube to the plastic outside piece, then lubed the sensor tube with some brake grease, and fitted it all back together.

Next I took took out for a test ride to see if the ABS braking still worked. Several panic atops on a gravel road proved everthing is still in order....phew!

Joe. Damned winter, it sucks. I managed to ride every month but February.

 

[mcatrophy]

... Next I took took out for a test ride to see if the ABS braking still worked. Several panic atops on a gravel road proved everthing is still in order....phew!

...

If the speedometer works, the rear sensor works. On Gen IIs the speedo shares the rear ABS sensor. So, no need to test the ABS (though that's something you should do occasionally to exercise the ABS pump, they have been known to seize).

 

[Fred W]

Well I ended up marinating the sensor with penetrating oil for about 2.5 hours, at which point it was still not budging, so I took pliers to the the plastic part of the sensor and wiggled it free from the housing, after which I realized the plastic sleeve had snapped off the sensor and remained imbedded in the metal housing. I wish I would have waited for mcatrophy's post and just left the damn thing alone.

Here is the sensor. You can see small areas where the plastic sleeve used to adhere to the sensor.



Here is the housing with the broken plastic sleeve still firmly stuck in the housing.



Here is the sensor showing plier marks on the plastic outside part of the sensor.



I couldn't just stick the sensor back into the sleeve because it was an interference fit, so I took a 3/8" drill bit and wrapped it with some 320 grit sandpaper and reamed the plastic sleeve just enough to fit the sensor back in. I used some JB weld epoxy to fill in the gaps of the sensor tube to the plastic outside piece, then lubed the sensor tube with some brake grease, and fitted it all back together.

Next I took took out for a test ride to see if the ABS braking still worked. Several panic atops on a gravel road proved everthing is still in order....phew!

Joe. Damned winter, it sucks. I managed to ride every month but February.

That was how it looked when we took it out of the other guy's second gen too. But his went back together fine.

If the outer shell of his sensors were seized and broke away from the inner sensors, that would explain why they were so hard to get out. [foreheadslap]

I had thought that when I'd removed 2nd gen sensors previously (on MEMs bike) they looked more like my 1st gen sensor, but it had been a while since I worked on one (a 2nd gen). I need to find a picture of a good 2nd gen ABS sensor.

 

[08FJR4ME]

I don't remember seeing any black plastic washer on mine! I have had corrosion since I do a lot of winter riding. Never had a problem getting it out as I recall. I did have it fall out once on the way to TN because I hand tightened it and forgot to go back with a wrench later. As I was going down the Merrit parkway I got all kinds of lights going off on the dash. Bike ran o.k. so I was somewhat miffed. Soon I pulled over at the last gas station and found my Goooofaaaaa. Quite embarrissed to say the lease. Well I found I highly price roll of ducktape at the quick mart inside. After performing surgery we got off the next exit and found a hardware store witch actually had a metric screw to fit. Won't make that mistake again.

Dave

 

[LAF]

I have used lithium soap grease on it since new. When I remove it I put a little on and reinstall it. Mine always come out by hand with no fighting. I did have to look in the shop manual when I took them off the first time and it does say to lightly grease them.

I guess we just have to pay attention to these a little better. Sorta like brake pedals and shifting linkage.

 

[John d]

I have used lithium soap grease on it since new. When I remove it I put a little on and reinstall it. Mine always come out by hand with no fighting. I did have to look in the shop manual when I took them off the first time and it does say to lightly grease them.
I guess we just have to pay attention to these a little better. Sorta like brake pedals and shifting linkage.

Unfortunately, my 2008 factory service manual does not mention using any lubricant on the sensor (I just checked). It always used to slide out easily with no resistance.

 

[LAF]

I have used lithium soap grease on it since new. When I remove it I put a little on and reinstall it. Mine always come out by hand with no fighting. I did have to look in the shop manual when I took them off the first time and it does say to lightly grease them.
I guess we just have to pay attention to these a little better. Sorta like brake pedals and shifting linkage.

Unfortunately, my 2008 factory service manual does not mention using any lubricant on the sensor (I just checked). It always used to slide out easily with no resistance.

You are correct. That tidbit was from here:https://www.fjrtech.net/getdbitem.cfm?item=31

I also used 400 grit paper on the mating surfaces to help rid it of any oxidation. I use just a very small amount on the mating surfaces and less on the sensor proper. It does not take much. I am not sure if I interpreted the article but three tire changes later they do come out like butter and I have never thrown a ABS light.

 

[Donal]

I had thought that when I'd removed 2nd gen sensors previously (on MEMs bike) they looked more like my 1st gen sensor, but it had been a while since I worked on one (a 2nd gen). I need to find a picture of a good 2nd gen ABS sensor.

How about this?

 

[Fred W]

Thanks for the pic.

Now I can see it is just that plastic collar that is stuck (sticking) in the ABS plates. No big deal I guess.

And these 2nd gen sensors do look considerably different than the 1st gen variety.

 

[RossKean]

The pre-2008 sensor is different from the one shown.

 

[roggiedog]

I never thought to take the sensor off the plate that it's mounted onto to change the tire. Why are you guys even removing it?

 

[escapefjrtist]

I remove the sensor with every tire change, never even considered leaving it attached. Thorough cleaning and light lube every time and never had any issues. On friends bikes we have run across a couple that were a ***** to remove...

YMMV

--G