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Old 07-19-2021, 09:21 PM
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Join Date: May 2021
Location: DFW Texas
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rust-jacking keeps wheel sensors from ideal distance from the tone ring

Originally Posted by andrewwynn View Post
Some theories just involve the possibility of rust getting into the sensor hole and messing with the signal. Just removing and cleaning has gotten a flakey wheel sensor going. They are sensitive like cam sensors and can stop working 100% with just one crumb of rust.
Though we don't see it much here in Texas, mechanics in rust-belt states have problems with sensors held back from the proper depth/closeness to the tone ring, and will give faulty, inconsistent readings. The mounting surface needs to be clean and rust-free to achieve the right depth. I presume the BMW sensors can't twist sideways in the holes, like generic Hall sensors often do.

In another industrial application I've had a lot of experience with, we used Hall effect sensors and toothed wheels to control shaft speeds (where exact timing was involved). The factory design was poor, and used sensors that had no"perfect alignment" boss on them, nor did the mounting bracket. It seemed that if the sensor wasn't exactly right depth & right vertical orientation, the speed wasn't accurately measured, causing bad batch sizing and/or machine shutdown. The sensors would vibrate loose at times, making this a recurring problem.

I made a jig that I carried in my pocket, that would instantly align the sensor at the correct depth and verticality, while I tightened the bejeezus out of the locking nut. A quick ten-second fix that worked everytime, for me. I never shared it with the idiots working with/against me (for 40+ years). hahaha
2001 BMW X5 - E53 w/3.0i M54,
topas-blau, Leder-Montana grau
(Born on 2001-07-13, Friday the 13th)
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