Removal of a smallish screw with a rusty head

[Ross365]

Inserting the sensor as far as it will go in to the hub (presumably the point at which the sensor is touching the ring) then there is a gap of ~1.5mm between the underside of the sensor shoulder and the hub. So to give a clearance to the ring of say 0.5mm, the 'shim' would need to be ~2mm thick.

The sensor is all plastic. The video in post 45, and ajlectronics' data clearly show some vehicles have shims. I'm not expressing any sort of opinion on how ABS sensors are/should be used, simply seeking advice on the seemingly odd situation I'm dealing with.

 

[MetalMonkey]

If you need to make it out of something that isn't metal, you could try plastic - I've made various plastic repair bits for cars out of old square downpipe - easy to cut flat strips, UV stable and pretty robust.
Unless you live in the Sahara, I'd give cardboard, greased or otherwise until the first winter puddle... A wheel well is a harsh environment

 

[ajlelectronics]

If you need to make it out of something that isn't metal, you could try plastic - I've made various plastic repair bits for cars out of old square downpipe - easy to cut flat strips, UV stable and pretty robust.
Unless you live in the Sahara, I'd give cardboard, greased or otherwise until the first winter puddle... A wheel well is a harsh environment

Many of us have the facility to print just such a beast, on request.

 

[MetalMonkey]

Many of us have the facility to print just such a beast, on request.

That's a good point, and something I'd like to get into someday - I needed some trim clips the other day which were horrendously expensive from the dealer, but I noticed there was a 3d print file floating about for them.
I have been quite tempted to bite the bullet on a couple of occasions, but I really need to finish some of the other projects before getting distracted and it seems like the technology is getting cheaper and better the longer I wait.

 

[roofman]

Is this shimie shamied yet?? just give it an air gap of 2 to 4mm and all will be shimie shammed just right. Too close and it will pick up corrosion off the tips.

 

[ukracer]

Many of us have the facility to print just such a beast, on request.

But less of us have the ability to produce the file to print it from.

 

[ajlelectronics]

But fewer of us have the ability to produce the file to print it from.

A 2d shim is simple though. It doesn't even need to be the right shape because it can be trimmed down in situ. Besides you only have to shout if you need a design knocking up.

 

[ukracer]

A 2d shim is simple though. It doesn't even need to be the right shape because it can be trimmed down in situ. Besides you only have to shout if you need a design knocking up.

It was a genetic reply . Plus I do regularly.

 

[Ross365]

Firstly, thanks for the offer of help with the shim(s). What I've done is made up an ali shim which (painted) is ~2.1mm which is about what I think it needs to be, but if that is not right, I've armed myself with some cardboard pieces of 1.35 and 0.6mm, so I can mix and match to get it right.

Someone has suggested to me that there are no shims on Celicas and that it's a thick layer of rust that has become detached from the hub. What came off with the sensor was very hard, brittle and slightly magnetic with no silvery metal present and it's hard to believe that Toyota would have used a shim material that would have changed to 100% rust, but it's weird which ever way you look at it.

 

[Ross365]

All problems solved... I think. The outcome is a surprise, but makes everything understandable, which is good.
The issue lies with the precise shape of the sensor; it has a shoulder on the section that goes in to the hub and I had not noticed that the shoulder has a slight taper and so it sits in the hub a bit like a cork in a bottle. The "shim" was 21 years of rust and muck. I've tried to do a reasonable drawing as attached. Put it back with no shim (it's a long story getting to that point) and all is good and the ABS rumbling at low speed appears to be gone. Changed the oil and filter while I had it on stands.

Many thanks for you contributions - always good to be able to bounce ideas off people when you're struggling