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Remove broken ABS Pulse Generator

At some point during your MINI adventure, you are going to get the ABS-light trifecta: ABS light; DSC/ASC light; and Tire Pressure light. The most likely culprit: a failed ABS wheel sensor (aka ABS Pulse Generator.) It is most likely to be one of the front sensors rather than one of the rears. If you’re lucky, it’s just the sensor. If the sensor turns out to be OK then it is either the wheel hub or the ABS module. A standard OBD-II scan tool is not going to return any codes from the ABS module. If you don’t want to pay to get your car scanned at the dealer or invest in a Bavarian Technic cable yourself, then here’s the easiest way to troubleshoot:

  1. Check for a blown fuse and replace as necessary. If fuses are good and lights still on, then proceed.
  2. Buy one new front sensor (they’re the same left to right but not front to back).
  3. Replace the front left sensor with the one you just bought. The sensor is on top of the hub carrier. In the photo below the brake rotor has removed to ease access.
  4. Start your car and see if the lights go out. If they do, you just saved yourself a trip to the dealer.
  5. If the lights don’t go out, inspect the cable you just removed. If the wire is not frayed and the sensor still looks good, then clean it up and install on the right side.
  6. Start your car and see if the lights go out. If they do, you just saved yourself a trip to the dealer.
  7. Now you have a choice to make: Go to the dealership or buy a cable.
  8. If you bought the cable, scan the DSC module for fault codes. ABS faults will be reported there.
  9. Note the codes and erase any faults.
  10. Start your car and see if the lights go out. If they do, you just saved yourself a trip to the dealer.
  11. If you can’t get any info from the ABS module, then it’s time to throw in the towel and head to the dealer.

So what else could go wrong? When you try to remove the sensor, it might break.
stuck sensor
Do not despair, it isn’t as hard to remove as it looks.

  1. If you were planning on removing the hub, then proceed with hub removal and just knock it out from the inside.
  2. If you were not planning on removing the hub, hit it with some penetrating oil and wait.
  3. Depending on how stuck it is, you might be able to drive a long screw into it and pull it out with a crowbar. Be sure to mark your drill bit and screw about an inch so you don’t drill too far.
  4. If that doesn’t work, get a drill bit that’s just a bit smaller than the sensor and carefully drill out the old one. Again, mark the bit about an inch and carefully drill. Now get a smaller bit, and drill another 1/4 inch hole into the magnet and pull it out with a screw if it’s still hanging on.

sensor heat shielded
And here’s one final tip: Put some heat shielding around the sensor, especially if you’re removed the stock dust shields to fit your big brake kit. This should help cooking another sensor in the future.