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 Posted: Sat Oct 20, 2012 11:35 am |
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Joined: May 19, 2012
Posts: 75
Trade Rating: +2
Location: UK
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Hi everybody,
I went ahead with my Drum to Disc conversion all seemed great until the ABS light wouldn’t go out...probably not surprising!
I did a lot of research and asking around and it seems like it was gonna be a straight swap for a 98-01 pre-plexed GTi rear disc axle with the handbrake cable change to the GTi one and really that should have been it.
But even after having picked up all the parts ready for the conversion the ABS issue has come into play at the last second.
So I really need some help with this, at least to diagnose the issue and see if this can be fixed.
What I’ll do is describe both axles in detail and tell you what I had done.
My car is a 2001 2.0 HDi just missed out the ‘multi-plexed’ phase. I know this by the key and dash so 100% sure it is a 98-01 ’pre-plexed’.
The GTi rear Axle, the seller said was off a V reg so 1999 most likely...buy I fear it may not be but I’ll give a description and we’ll see.
MY HDi DRUM REAR AXLE:
Basically a fully working rear drum axle with ABS.
It was very rusty when it came off and a lot of bolts were ‘baked on’ but not snapped off, it is 11 years old.
Brake pipes are copper and come in on the passenger side.
Haynes says: non-ABS axles come with a Load Sensitive Pressure Regulating Valve my one didn’t. It also says some models have the valve incorporated into the rear wheel cylinder (Section 9.14 in the 2002-2006). I have no idea what that means btw. All I can tell is if it has Load Sensitive Pressure Regulating Valve or not.
ABS sensors were very hard to take out, so one was pulled out. It is black and has magnetic strips on it. HERE IS THE BIT THAT WORRIES ME: the outer cable was a lot thicker than the GTi. The plug is a square blue type with a metal clip, like on indicators or side lights. Numbers I found: 9635280980 / 100741 – 11163 / >PA66 GF25< / 2261 & ‘HU’.
GTi 138 REAR AXLE:
Rear Disc axle w/ABS in extremely good condition for 12-13 years?? (no rust on the beam or torsion bars but some where the 4 bolts join) my one looks like it was under the sea for the past 10 years!...just strange how it has no rust on the beam...
Now this one HAD a Load Sensitive Pressure Regulating Valve on the driver’s side?? Again very confusing but could just be me...
Also the brake pipes look to be coming from the driver’s side where the Load Sensitive Pressure Regulating Valve is located. Brake pipes are black probably not copper...
ABS sensors...they looked totally different to my HDi ones...I was told if it’s a 98-01 GTi axle they should fit my HDi...
As you can see I am using a lot of long pauses as I am puzzled!
Numbers found: 9640921980 / PA66 – GF21 / 100711 - 5133.3.
The wire was thinner than HDi’s too.
Plug was cut off so hard to say if it was the square or the newer blue like on front headlights?
INSTALLMENT:
Some mods had to be made.
Exhaust came off, everything unplugged, HDi Drum axles came off.
Basically the GTi axle went in the same place no problem.
The Load Sensitive Pressure Regulating Valve and all the GTi pipes came off as the pipes on the HDi went straight into the drum hub.
New GTi handbrake cables were fitted and adjusted, all working fine.
Bake pipes were put back with some tweaks but shouldn’t cause a problem as the brakes work and the car breaks in a straight line and all and it’s been filled and bled.
System was filled up and bead until the brakes went back to normal, same as mentioned above.
Now ABS Sensors...As the GTi sensors were different it was decided to cut the plugs off the HDi axle and re-soldered them back on the GTi sensors...don’t know if it was the best decision but it’s just a connection like to your lights...
All was connected back up and car dropped down...not literally of course!
Well that’s about it for details.
Now, I wonder IF the axle is in fact 01-onwards multiplexed so that would explain the sensor issue...so can the sensor be changed to a stock 98-01 preplexed GTi and make the ABS active with these 98-onwards hubs?
If that fails can the hubs be changed back to actual 98-01 and use the perplexed sensor as I know my HDi is 98-01?
If you know...DO, the 98-01 Drum and Disc use the EXCACT same ABS sensor or are they in fact different.
Also could the absence of the Load Sensitive Pressure Regulating Valve be causing this???...
Well you’ve heard my story, now can anybody think what may cause this ABS issue and if the points I have mentioned could be a solution?
And the most important, does it sound like a 98-01 axle?
Thanks for reading, hope to hear some responds and solutions.
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| 2001 Peugeot 206 2.0 HDi 90 D TURBO in China Blue (98-01) [57 MPG] | |
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Posted: Sat Oct 20, 2012 11:49 am |
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Joined: May 19, 2012
Posts: 75
Trade Rating: +2
Location: UK
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Hi everybody,
I went ahead with my Drum to Disc conversion all seemed great until the ABS light wouldn’t go out...probably not surprising!
I did a lot of research and asking around and it seems like it was gonna be a straight swap for a 98-01 pre-plexed GTi rear disc axle with the handbrake cable change to the GTi one and really that should have been it.
But even after having picked up all the parts ready for the conversion the ABS issue has come into play at the last second.
So I really need some help with this, at least to diagnose the issue and see if this can be fixed.
What I’ll do is describe both axles in detail and tell you what I had done.
My car is a 2001 2.0 HDi just missed out the ‘multi-plexed’ phase. I know this by the key and dash so 100% sure it is a 98-01 ’pre-plexed’.
The GTi rear Axle, the seller said was off a V reg so 1999 most likely...buy I fear it may not be but I’ll give a description and we’ll see.
MY HDi DRUM REAR AXLE:
Basically a fully working rear drum axle with ABS.
It was very rusty when it came off and a lot of bolts were ‘baked on’ but not snapped off, it is 11 years old.
Brake pipes are copper and come in on the passenger side.
Haynes says: non-ABS axles come with a Load Sensitive Pressure Regulating Valve my one didn’t. It also says some models have the valve incorporated into the rear wheel cylinder (Section 9.14 in the 2002-2006). I have no idea what that means btw. All I can tell is if it has Load Sensitive Pressure Regulating Valve or not.
ABS sensors were very hard to take out, so one was pulled out. It is black and has magnetic strips on it. HERE IS THE BIT THAT WORRIES ME: the outer cable was a lot thicker than the GTi. The plug is a square blue type with a metal clip, like on indicators or side lights. Numbers I found: 9635280980 / 100741 – 11163 / >PA66 GF25< / 2261 & ‘HU’.
GTi 138 REAR AXLE:
Rear Disc axle w/ABS in extremely good condition for 12-13 years?? (no rust on the beam or torsion bars but some where the 4 bolts join) my one looks like it was under the sea for the past 10 years!...just strange how it has no rust on the beam...
Now this one HAD a Load Sensitive Pressure Regulating Valve on the driver’s side?? Again very confusing but could just be me...
Also the brake pipes look to be coming from the driver’s side where the Load Sensitive Pressure Regulating Valve is located. Brake pipes are black probably not copper...
ABS sensors...they looked totally different to my HDi ones...I was told if it’s a 98-01 GTi axle they should fit my HDi...
As you can see I am using a lot of long pauses as I am puzzled!
Numbers found: 9640921980 / PA66 – GF21 / 100711 - 5133.3.
The wire was thinner than HDi’s too.
Plug was cut off so hard to say if it was the square or the newer blue like on front headlights?
INSTALLMENT:
Some mods had to be made.
Exhaust came off, everything unplugged, HDi Drum axles came off.
Basically the GTi axle went in the same place no problem.
The Load Sensitive Pressure Regulating Valve and all the GTi pipes came off as the pipes on the HDi went straight into the drum hub.
New GTi handbrake cables were fitted and adjusted, all working fine.
Bake pipes were put back with some tweaks but shouldn’t cause a problem as the brakes work and the car breaks in a straight line and all and it’s been filled and bled.
System was filled up and bead until the brakes went back to normal, same as mentioned above.
Now ABS Sensors...As the GTi sensors were different it was decided to cut the plugs off the HDi axle and re-soldered them back on the GTi sensors...don’t know if it was the best decision but it’s just a connection like to your lights...
All was connected back up and car dropped down...not literally of course!
Well that’s about it for details.
Now, I wonder IF the axle is in fact 01-onwards multiplexed so that would explain the sensor issue...so can the sensor be changed to a stock 98-01 preplexed GTi and make the ABS active with these 98-onwards hubs?
If that fails can the hubs be changed back to actual 98-01 and use the perplexed sensor as I know my HDi is 98-01?
If you know...DO, the 98-01 Drum and Disc use the EXACT same ABS sensor or are they in fact different.
Also could the absence of the Load Sensitive Pressure Regulating Valve be causing this???...
Well you’ve heard my story, now can anybody think what may cause this ABS issue and if the points I have mentioned could be a solution?
And the most important, does it sound like a 98-01 axle?
Thanks for reading, hope to hear some responds and solutions.
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| 2001 Peugeot 206 2.0 HDi 90 D TURBO in China Blue (98-01) [57 MPG] | |
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Posted: Sat Oct 20, 2012 12:20 pm |
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Joined: Feb 08, 2010
Posts: 10151
Trade Rating: +12
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too long, can't be bother to read all of them
but even in preplexed axle, drum and disc use difference rear abs sensor; so essentially there will be 4 different type of rear abs sensors in total
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Posted: Sat Oct 20, 2012 1:41 pm |
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Joined: May 19, 2012
Posts: 75
Trade Rating: +2
Location: UK
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| Seabook wrote: |
too long, can't be bother to read all of them
but even in preplexed axle, drum and disc use difference rear abs sensor; so essentially there will be 4 different type of rear abs sensors in total |
Sorry if it's too long but I wanted to include every bit of info to help diagnose the problem better. I can't condense it more...I just hope someone will read it.
Does anyone have part numbers for the 4 different sensors or which one might be best considering my situation? And if the ABS sensors came from that axle why is it reading a fault?
Also anything about the Load Sensitive Pressure Regulating Valve missing?
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| 2001 Peugeot 206 2.0 HDi 90 D TURBO in China Blue (98-01) [57 MPG] | |
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Posted: Sat Oct 20, 2012 1:44 pm |
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Joined: Nov 27, 2010
Posts: 11519
Trade Rating: +10
Location: What's it to you? ? ?
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| Jaeger wrote: |
Also anything about the Load Sensitive Pressure Regulating Valve missing? |
Later multiplexed 206's fitted with ABS, EBD & EBA dont have a rear brake compensator valve fitted.
As for the ABS sensors, the ones fitted on the rear of the very early 206's are also no longer available from Peugeot.
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| Toyota C-HR GR Sport 2.0 Hybrid with JBL & Alcantara packs. | |
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Posted: Sat Oct 20, 2012 1:48 pm |
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Joined: Feb 08, 2010
Posts: 10151
Trade Rating: +12
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if you got ABS you shouldn't have brake compensator valve....
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Posted: Sat Oct 20, 2012 1:51 pm |
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Joined: Nov 27, 2010
Posts: 11519
Trade Rating: +10
Location: What's it to you? ? ?
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| Seabook wrote: |
| if you got ABS you shouldn't have brake compensator valve.... |
Not true, some earlier 206's still have the rear brake compensator valve even with ABS fitted 
Depends on the ABS system installed on the car.
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| Toyota C-HR GR Sport 2.0 Hybrid with JBL & Alcantara packs. | |
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Posted: Sat Oct 20, 2012 2:00 pm |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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My GTi is a December 2000 build and doesn't have the load valve...seems odd that they'd cut the plugs off the ABS sensor wires...certainly sounds like an early axle though.
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Sat Oct 20, 2012 2:09 pm |
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Joined: Nov 27, 2010
Posts: 11519
Trade Rating: +10
Location: What's it to you? ? ?
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Service Box lists 206 GTI up to RPO 08420 as having the compensator valve fitted with ABS.
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| Toyota C-HR GR Sport 2.0 Hybrid with JBL & Alcantara packs. | |
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Posted: Sat Oct 20, 2012 5:35 pm |
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Joined: May 19, 2012
Posts: 75
Trade Rating: +2
Location: UK
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Hmm...Very interesting responses guys! 
MrBSI - ''some earlier 206's still have the rear brake compensator valve even with ABS fitted'' well this certainty clears up some things and that thing you mentioned about later multiplexed models not having a PRV at all.
Although I am still confused why I have the error if I am still using the ABS sensors that came with it...did soldering them damage them? Could the sensors be already damaged?? So do I need to get 'new' ABS sensors off a V reg?
Also what did you mean by: ''206 GTI up to RPO 08420''?
So if some early models do have both and my GTi axle is one of them...are the sensors still expecting the PRV to still be there? As I removed it and connected the pipes into the disc hubs...
Edward, I was actually after a 2000 GTi axle. But this 'V reg' came up at an unbelievably good price. It is mid 1999 to 1th month of 2000 if I remember....w/ABS and PRV. Of course I didn't know there was gonna be a sensor and PRV issue...
BTW I didn't mean to double post.
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| 2001 Peugeot 206 2.0 HDi 90 D TURBO in China Blue (98-01) [57 MPG] | |
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Posted: Sat Oct 20, 2012 8:03 pm |
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Joined: Feb 08, 2010
Posts: 10151
Trade Rating: +12
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i am almost 100% certain you miss match the ABS sensor.
BCV shall not cause the ABS problem.
i just have a quick look of those parts number you provide, the abs sensor off your gti axle is not preplexed sensor!
it is 4545A3 sensor, which look like this:
www.ebay.co.uk/itm/AB1...43b2dadf82
your HDi sensor is 454579 or 454577, which look like this:
www.ebay.co.uk/itm/Peu...4cfe79bd0d
now in this case; i am not 100% sure what you can do but i guess you need a new hubs and abs sensor which is for preplexed 206
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Posted: Sun Oct 21, 2012 11:35 am |
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Joined: May 19, 2012
Posts: 75
Trade Rating: +2
Location: UK
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| Seabook wrote: |
i am almost 100% certain you miss match the ABS sensor.
BCV shall not cause the ABS problem.
i just have a quick look of those parts number you provide, the abs sensor off your gti axle is not preplexed sensor!
it is 4545A3 sensor, which look like this:
www.ebay.co.uk/itm/AB1...43b2dadf82
your HDi sensor is 454579 or 454577, which look like this:
www.ebay.co.uk/itm/Peu...4cfe79bd0d
now in this case; i am not 100% sure what you can do but i guess you need a new hubs and abs sensor which is for preplexed 206 |
Thanks for the answer.
I did fear it might not be preplexed...something didn't add up.
So pretty much the axle will not be a V reg 1999 as was stated, cause why would a preplexed axle have multiplexed sensors...
s**t, I just cut my old ones off...hmm I guess it wouldn't hurt to try the old ones back in the disc axle...so do pre and muli axles come with completely different hubs then?
Which brings me to my next question, do preplexed Discs and Drums hubs use magnetic ABS sensors with the teeth like on my drum axle??? The sensors have metal strips on them so I assume it magnetic.
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| 2001 Peugeot 206 2.0 HDi 90 D TURBO in China Blue (98-01) [57 MPG] | |
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Posted: Sun Oct 21, 2012 12:42 pm |
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Joined: Feb 08, 2010
Posts: 7045
Trade Rating: +5
Location: In the garage
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Did it come complete with brake calipers or was it just a bare axle?
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| 2001 GTi 138, Bilstein Sprint dampers, H&R springs, 21mm Peugeot Sport torsion bars, 22mm rear ARB, Peugeot Sport Group A wishbones, 283mm discs, Goodridge stainless hoses, Maniflow 304 grade 4-2-1 2.5" manifold and system, 200 cell cat, Richard Longman head, 45mm Jenvey throttle bodies, 9.5mm TB spacers, 90mm air horns, Jenvey throttle linkage, Jenvey fuel rail, Aeromotive and Goodridge fuel fittings and braided hose, ITG sausage filter, Radtec custom radiator, Piper Ultimate Road cams, Piper vernier pulleys, Omex 600 ECU. Saxo electric PAS pump, Vibra Technics engine mounts. Samco coolant hoses, TTV steel flywheel, 4.76 final drive ratio, 307 CC 180 ratios. 2019 BMW 530i. 2017 Mercedes C300 convertible. | |
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Posted: Sun Oct 21, 2012 1:14 pm |
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Joined: May 19, 2012
Posts: 75
Trade Rating: +2
Location: UK
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| Edward wrote: |
| Did it come complete with brake calipers or was it just a bare axle? |
Came with everything, yeah and not a patch of rust on beam or torsion bars too...
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| 2001 Peugeot 206 2.0 HDi 90 D TURBO in China Blue (98-01) [57 MPG] | |
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Posted: Tue Oct 23, 2012 12:03 pm |
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Joined: Feb 21, 2012
Posts: 2277
Trade Rating: +16
Location: west midlands
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seabook is the second ebay link the sensor for multiplex and would this be the one on a 52 plate?
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