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Yet another ABS light problem!

  • gordonm
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25 Apr 2016 10:46 #165779 by gordonm
Yet another ABS light problem! was created by gordonm
Hi there - The ABS light on my 2004 O2 Jimny has been staying on intermittently for a while, but is now on permanently.

At first I blamed my clumsy handling of the hub with the annual king pin bearing change, but a check of the sensors seems to show that everything there is OK.

It took a while to find the connector and diode hiding in plain sight in the driver's footwell, but I managed to get the fault code 61 - 'ABS Pump Motor and/or relay circuit' according to the book. I tried unsuccessfully to clear the code, it just keeps repeating the 61 sequence.

How likely is it to be the main ABS motor assembly at fault - I see that a replacement unit is somewhat hard to find, so I assume that they don't fail often, in which case could it be the relay unit and where is it located?

Is there an easy way to test and /or fixing the motor? (i've tried the Jeremy Clarkson hammer method already!), alternatively where is the best place to source a replacement Denso 81A1 or equivalent unit or a recommended refurbisher?

thanks

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27 Apr 2016 20:09 #165904 by skywalker65
I've come across a similar issue with some of our bike abs systems that work along a similar system. We get the motor fault issue and it's usually down to the motor brushes making a poor contact with the commutator. I'd get the brushes out and clean them up as well as the commutator

If in doubt ...... Flat out ??

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  • gordonm
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28 Apr 2016 20:24 #165946 by gordonm
Replied by gordonm on topic Yet another ABS light problem!
I took the motor off of the ABS pump today, just a couple of screws - stuck 12v across it, and it works a treat, so sadly it's probably not that. However, as I removed the motor, the two pins that the offset shaft bearing pushes to make the pump work extended and I can't refit the motor - I even ruined a set of feeler gauges in the hope that they would help to guide the pins back as I inserted the motor. In my case not too much of a problem as I'd pretty much decided to send the pump away to be rebuilt anyway, but it'd have been nice if was something simple . . .
So, fr anyone out there curious as to how their ABS pump works, I wouldn't recommend removing the motor as you'll never get it back on again!!
So, having resigned myself to giving the braking system a long overdue overhaul, having refitted the ABS pump is it just a normal calliper/cylinder brake bleed or is there something else that I should be aware of? (I'm not used to ABS systems - more of a drum brake kinda guy)

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