Replaced wheel bearings and now I have a christmas tree! Please Help the new gal!!

[mojoracing]

I have a 2012 Audi A6 quatro premium with a supercharged v6. Installed new wheel bearings on both front wheels. MAJOR PITA! Anyhow, got everything put back together and I have an abs, stability control, parking brake and tpms malfunction dash lights. While doing bearings, I disconnected the brake wear sensor on left side along with unplugging the abs sensor. I did not however remove the abs sensors on either side. I thought it went back together without damage but the left side did look kind of funky inside the hub. I tried clearing the codes with a carista obd device but they will not clear. Is it possible I damaged the sensor(s) and do they also control stability control due to (i believe) them sensing wheel speed? Please tell me I don't have to remove the hubs again to repair this issue. Id rather clamp certain body parts in a vice. Not sure why the parking brake error light would flash. I did have the parking brakes on while the front wheels were in the air. Also had to push brake pistons in a hair to get calipers back on but they would hardly move at all. Any help would be appreciated. I tried to search but there is nothing specific.

[ajconrad10]

I had the same issue. ABS sensors are easily damaged during wheel bearing replacement, particularly if you need to use heat and/or mechanical “persuasion”. You do not need to remove the hub but be prepared to drill them out as they tend to seize in place. Once I replaced mine, a short drive and the warning lights disappeared. Note that right & left are different shapes and thus different part numbers. Use the Bosch brand.



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[mojoracing]

Thanks I will try and keep you updated.

[mojoracing]

How do you drill out without knowing if you are drilling into the bearing? I know that may sound stupid but after replacing those bearings, I NEVER want to tackle that job again. It was a pain!

[wwhan]

How do you drill out without knowing if you are drilling into the bearing? I know that may sound stupid but after replacing those bearings, I NEVER want to tackle that job again. It was a pain!

The instructions look easy;

"Removing _ front wheel speed sensor
– Release and unplug electrical connector at speed sensor -1-.
– Remove bolt -2-.
– Pull speed sensor out of wheel bearing housing.

Installing
Installation is performed in reverse sequence; note the following:
– Before inserting speed sensor, clean inner surface of fitting hole and coat speed sensor thoroughly with lubricating paste - G 000 650- .
– Fit and secure speed sensor.
– After installation, turn steering to full left and right lock and
check clearance of speed sensor wire.


Tightening torques
Exploded view - front wheel speed sensor Wheel bearing housing
Bolt - 9 Nm
Speed sensor Front right speed sensor - G45- / front left speed sensor - G47-

Wheel bearing unit - ABS sensor ring is incorporated in wheel bearing unit"

http://www.audizine.com/gallery/data/504/ABS.JPG

[mojoracing]

Yes instructions look easy but ajconrad10 said they might be seized and to drill them out if needed.

[mojoracing]

You do not need to remove the hub but be prepared to drill them out as they tend to seize in place.


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Curious on how to drill them out without damaging wheel bearing housing

[wwhan]

Curious on how to drill them out without damaging wheel bearing housing

If they are seized, use a drill bit smaller than the sensor and drill stop collar on the bit, to limit the depth. Then work up to a larger bit & collapse the housing.

Drill Stop Set: https://www.harborfreight.com/7-piece-drill-stop-set-38336.html

https://shop.harborfreight.com/media/catalog/product/cache/1/image/9df78eab33525d08d6e5fb8d27136e95/i/m/image_17257.jpg

[ajconrad10]

I would try to remove the sensors with pliers first. There are various methods floating around the interwebs that involve heat and/or penetrating fluid, but most of the time these methods fail and the exposed head of the sensor (connector housing) snaps off leaving the tubular plastic body of the sensor embedded in the upright knuckle housing.

Try wiggling out the sensor head with pliers first, but if this fails, you can fairly easily drill it out. Start with a 1/8 bit or even slightly smaller. Make sure that you are drilling in the center of the tubular housing. I think I heated the knuckle and or drill bit slightly to soften the plastic and help get it started. Drill slowly and work your way up to larger diameter bits as needed. I don't think I needed to go above 1/4 inch, and eventually got to the point where the plastic remnants of the sensor could be picked out with small tools. Just be patient and watch your drilling depth, stopping if you hit any real resistance. I did not need to use a drill bit stop set.

[mojoracing]

Thanks. So I took it for a drive today, all the dash warning lights were on. I played with the ABS connector, cleaned it real well and took it for another drive. All of the lights went out. IF they go back on again, at least I know what the issue is and I will replace sensor. Thank you for all the help.

[mojoracing]

Now I have a bigger problem. Got under it to change abs sensor and there is what looks like heavy differential fluid coming from around the area I replaced the wheel bearing!! How could this be leaking? What did I do or fail to do while replacing the wheel bearing? Should there have been a gasket or o ring replaced somewhere?? Im sick.......

[mojoracing]

Looks like the boot slipped out of the clamp when I reassembled everything. What is best way to get it back in? Do I have to take hub apart again or can I cut off factory clamp and put a different one on? Im not familiar with cv joints is there an aftermarket worm clamp and is that the way to go or can I do it differently? I hope I dont have to take the hub all apart again. Does entire driveshaft and joint have to come out? Sorry just not sure what easiest route is.

- - - Updated - - -

here is a pic of the boot sticking out.
http://imgdump4.novarata.net/image.uploads/29-04-2019/original-dba79debaa49d039b35f5af0b91c16fe.jpg

[15 Phantom S6]

ughh, what a mess! I feel your pain but shouldn't be too bad in the end..

Usually those boots are crimped on but I guess a stainless gear clamp might hold it tight enough if that's all you have access to.. You might be able to put one on with the axle still installed on the car but it would be much easier to take the axle out completely, repack it with grease properly, and then clamp it tight.. also, check there is no damage to the boot from it slipping off.. Last thing you want is to discover a tear or rip on the boot after you've put it all back together... The spindle/hub doesn't have to come out to fix the boot..