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 Posted: Tue Jul 26, 2022 1:09 am |
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Joined: Jul 05, 2022
Posts: 17
Trade Rating: 0
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Hi guys. I'm breaking down the 206 GTi rear axle for a replacement and everything is going well - believe it or not! I'm taking my time with it and I have one side completed. All the points I thought would be difficult were easy given that it has never been broken down in the lifetime of the car (2002). All bolts were still in place with their original threadlock compound. After slowly releasing them with an extension on the tommy bar that makes removal a little slower but it hasn't caused any real problem. Even the 4 vertical axle mounting bolts which I know are prone to seize came loose easily.
I've ordered new backplates as the old ones were literally rotting out. Does anyone know offhand what the screw size for those is as a couple had to be ground off to remove them after the inner head rounded off. They were T30 Torx cap head with a shoulder which could probably be forgotten about and, I think, were M6. Nothing exotic, they only hold the backplate in place.
So everything is removed except the one issue, the ABS sensor. It is determined it isn't being driven back out of the carrier and without it out the whole job stalls. Is it possible to remove these after they have been in place for so many years? It has sat for hours with regular sprays of penetrating fluid and tapped with a close fitting socket over the active part sitting against the shoulder. So far I'm being very gentle with the hammering of these as they are a magnetic component and magnets don't like rough treatment. Does anyone have a personal trick to releasing them or is destroying and replacing the only practical option?
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Posted: Tue Jul 26, 2022 4:55 pm |
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Joined: Jul 05, 2022
Posts: 17
Trade Rating: 0
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Thought someone else might benefit from knowing how I got round this so here it is.
I solved the issue very simply. I decided to s**t or bust the job and looked for the best impromptu tool to do it with. All of my sockets went over the sensor head but sat unsteadily on the edge of the cylindrical body. I wanted something a bit less likely to damage the thing when it was hit. I came up with an old 12mm tubular spanner which fits beautifully over the sensor head onto the meat of the shoulder, slotted it home, and welted. Two big thumps, (yes - BIG), and the sensor popped out of the back. As an afterthought, a large thick washer of the right diameter seated underneath that or even under a bigger socket would have done the job too. The trick is to get the thrust onto the face of the sensor body and not on the edges.
I don't appear to have damaged anything from the outside but the test will be when it is set up to run again of course. Even so a cheap sensor replacement is about £12 and, once the original has been out and refitted, replacing it should be much easier. I think I'll make sure to gently reduce the diameter of the plastic cylinder body by a tad at the rear where it swells slightly to lock home. With a bolt in the back holding it firmly mounted I don't really understand why it needs to be so tight a fit in the first place. It could have been a "slight pinch screw home" fit which only needed a tap to remove it.
Got to wait for a replacement axle now. IMAxles are out of GTi torsion bars and they don't know when they will be delivered. They promised to knock one up for me as soon as they arrive.
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| They mock and say ask a stupid question?
"A moment of embarrassment is better than a lifetime of ignorance". | |
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Posted: Thu Jul 28, 2022 11:22 am |
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Joined: Jun 30, 2021
Posts: 46
Trade Rating: 0
Location: Eastern Scotland
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Smacking them out does seem to be the only way - I drowned the ones on the CC with release spray, pretty sure I then took a screwdriver to them... They still worked!
Hopefully sooner rather than later with the torsion bars coming in!
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Posted: Fri Jul 29, 2022 9:11 am |
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Joined: Jun 20, 2012
Posts: 1171
Trade Rating: +1
Location: West Country
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Nice writeup!
I placed folded cloth over the sensor and clamped a molegrip on each side, then wiggled the whole contraption ever so carefully.
When I heard the first snappy noise my heart sank, but it actually freed up intact, accepting even more pen. spray thereafter.
| Bordonbert wrote: |
| Got to wait for a replacement axle now. IMAxles are out of GTi torsion bars and they don't know when they will be delivered. They promised to knock one up for me as soon as they arrive. |
Would they take your old axle and re-use its torsions?:)
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Posted: Sat Jul 30, 2022 11:58 am |
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Joined: Jul 05, 2022
Posts: 17
Trade Rating: 0
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I did wonder whether that would be the way to go Sim but I think it interferes with the guarantee they can then give on the axle. This is only a project replacement car for the wife's 1.4i so she is still mobile and I can wait out the time for a completely new stock to come in. In the meantime I'm trying to sort out the A/C on my own GTi. As you can see in the thread list I'm having trouble getting confirmation of the correct condenser type. Got one coming now with fingers crossed. I've also discovered a large patch of sill rust which will have to be fixed before it is on the road. It never seems to end...
Anyway, axles... Incidentally, the guy at IMAxles was very helpful and free with his advice. I asked about the brand new option and he recommended not waiting for brand new axles to come in. He reckoned their own in house refurbished which would be based on the original base parts were more long lived. Searching around before talking to him I know at least some of the new ones are made at Antalex in Poland. My Polish is non-existent but I gather they couldn't supply direct to me in the UK and advised I contact their UK agents - guess who - IMAxles!
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| They mock and say ask a stupid question?
"A moment of embarrassment is better than a lifetime of ignorance". | |
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Posted: Sat Jul 30, 2022 12:06 pm |
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Joined: Jul 05, 2022
Posts: 17
Trade Rating: 0
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I'm with you now on the manhandling Sim. There is no reason why a bit of heavy handling should damage something which is basically nothing more than a magnet with a coil wrapped around it. That said, magnets don't like too much shock treatment though it takes a pretty energetic wallop to upset their magnetism. The coil should be potted into the sensor body so should be immune to that as long as there is no loose wire left to whip around and fracture when thumped. Your way might damage the sensor surface but a bit of gnarliness which can be sanded down won't stop it working nor being refitted. I do worry too much about jobs sometimes. 
How on Earth did you get a screwdriver to take them out 2V50? Were you able to get it under the rear flange and lever them? That was impossible for me, mine were in so tightly.
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| They mock and say ask a stupid question?
"A moment of embarrassment is better than a lifetime of ignorance". | |
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