S5 leaky ABS unit fix! - RX7Club.com - Mazda RX7 Forum

2nd Generation Specific (1986-1992) 1986-1992 Discussion including performance modifications and technical support sections.
Sponsored by: Banzai Racing

S5 leaky ABS unit fix!

Reply

 
 
Old 05-21-16, 09:24 PM
  #1
the machinest
15 Year Member
Thread Starter
iTrader: (9)
 
need-a-t2's Avatar
 
Join Date: Mar 2002
Location: binghamton, ny
Posts: 1,050
Thanks: 0
Thanked 3 Times in 3 Posts
S5 leaky ABS unit fix!

Ever since I bought my S5 turbo the ABS unit has leaked. So after failing my yearly state inspection for it, I figured it was finally time to tackle this project. Mazda specifically states in the FSM that the ABS unit is not serviceable and no one sells rebuild kits for them, so I decided to try and cobble my own together. So this thread will document my adventure and hopefully help out others with leaky ABS units. So first things first removal. There are 5 barke lines, 2 connectors, 1 ground wire and 3 bolts that secure the ABS unit to the car. So here she is removed from the car
Name:  20160511_171333_zps3tqqlg7w.jpg
Views: 134
Size:  288.8 KB
Name:  20160511_171338_zpsasbvelmh.jpg
Views: 131
Size:  346.6 KB

My unit was leaking from the bottom of the 3 solenoids. Disassembly is fairly straight forward. The relays pull right out and the electronics tray is secured to the motor with 4 phillips head screws.
Name:  20160511_173605_zpsuel1aphf.jpg
Views: 131
Size:  277.6 KB

The motor is removed by removing the 4 bolts holding it on. After removing this, I realized i didn't really need to remove it, and putting it back in was a PITA.
Name:  20160511_174449_zpsp9r8sajs.jpg
Views: 130
Size:  774.8 KB

Onto the good stuff. The main body is held together with one giant M12 bolt. once the bolt is removed, you can use a rubber mallet and tap the two halves apart. I highly suggest labeling the solenoids and the location they came from. Once apart they all look the same.
Name:  20160514_104536_zpsmdtkvztt.jpg
Views: 128
Size:  254.3 KB
Name:  20160514_112829_zpss5fkhfnu.jpg
Views: 129
Size:  800.2 KB
need-a-t2 is offline  
Reply With Quote
The Following User Says Thank You to need-a-t2 For This Useful Post:
Gen2n3 (11-16-17)
Old 05-21-16, 09:41 PM
  #2
the machinest
15 Year Member
Thread Starter
iTrader: (9)
 
need-a-t2's Avatar
 
Join Date: Mar 2002
Location: binghamton, ny
Posts: 1,050
Thanks: 0
Thanked 3 Times in 3 Posts
Ok, so onto the repair. These are the orings I bought. I got most of them right from mcmastercarr, but had to source the 22mmx1.5mm elsewhere. You can order them lots of places but be sure to get EPDM rubber.
Name:  20160518_184427_zpszd5gx6rw.jpg
Views: 74
Size:  256.8 KB

Please note the 17x2.5mm orings are x rings and are not round. This is the location of the 17x2.5 orings. In the center hole where the bolt threads into, there is an internal oring. that's where the 17x2mm oring is installed.
Name:  20160518_191025_zps2bltkvww.jpg
Views: 76
Size:  263.4 KB

On the top side of the casting the 4x2mm orings are installed.
Name:  20160518_191246_zpsecqfo3tw.jpg
Views: 74
Size:  583.2 KB

The dowels have orings on both sides that take a 5x1.5mm orings.
Name:  20160518_191255_zpsmzq6epdl.jpg
Views: 73
Size:  633.2 KB
need-a-t2 is offline  
Reply With Quote
The Following User Says Thank You to need-a-t2 For This Useful Post:
Gen2n3 (11-16-17)
Old 05-21-16, 09:55 PM
  #3
the machinest
15 Year Member
Thread Starter
iTrader: (9)
 
need-a-t2's Avatar
 
Join Date: Mar 2002
Location: binghamton, ny
Posts: 1,050
Thanks: 0
Thanked 3 Times in 3 Posts
last but noy least I put the 22x1.5mm orings on the top of the solenoids. These orings are viton, and i'm guessing i'll have to replace them eventually. If you do this buy EPDM! Also note there is a small rubber washer on top of the solenoids. I reused these as they are specially washers and not easily sourced. Good news is that i'm 99% sure they do not actually seal anything and are just a bumper of sorts.
Name:  20160518_191346_zpsbo4ftud1.jpg
Views: 73
Size:  641.4 KB

So that's it! Reinstall, bleed your system, and enjoy not having to carry brake fluid in the bin behind you.

If by chance your's is leaking from between the casting and the big motor on the back, there are 2 xrings that seal the shafts inside the casting. I didn't measure them so I'm not sure what size they are. To remove them, there are 2 set screws on the sides of the lower casting. Remove them and you can then push the shafts out from where the motor shaft goes. They are pretty tight, but keep pushing and they pop right out. You'll have to remove these shafts to get the motor back in if you opt to remove it.
need-a-t2 is offline  
Reply With Quote
The Following User Says Thank You to need-a-t2 For This Useful Post:
Gen2n3 (11-16-17)
Old 05-23-16, 08:05 AM
  #4
Eats, Sleeps, Dreams Rotary
iTrader: (1)
 
Turbonut's Avatar
 
Join Date: Feb 2002
Location: NJ
Posts: 3,657
Thanks: 0
Thanked 2 Times in 2 Posts
Nice write up.
Always wondered the size/quantity of the seals that were needed. Last year found that my original
pump was leaking and wanting to do a delete, was going to rebuild one of the other three I have,
but the leak was noting more than a brake line fitting that needed to be tightened.
Still might just bite the bullet and rebuild one of the others.
Turbonut is offline  
Reply With Quote
Old 11-11-17, 09:31 PM
  #5
Junior Member
 
Join Date: Jul 2005
Location: VA
Posts: 12
Thanks: 0
Thanked 0 Times in 0 Posts
Awesome right up, needed to bump this for props.
DaKeL is offline  
Reply With Quote
Old 11-14-17, 01:56 PM
  #6
(blank)
iTrader: (1)
 
pfsantos's Avatar
 
Join Date: Nov 2005
Location: YYZ
Posts: 2,231
Thanked 0 Times in 0 Posts
Nice.
pfsantos is offline  
Reply With Quote
Old 11-16-17, 03:36 PM
  #7
Senior Member
iTrader: (1)
 
Gen2n3's Avatar
 
Join Date: Jun 2004
Location: Virginia Beach, VA
Posts: 743
Thanked 20 Times in 20 Posts
Great write-up! Sadly, the Part Numbers stamped on the packages do not cross to anything.

To the OP:
Is this the correct list of o-rings needed for this repair?
1. 22x1.5mm
2. 5x1.5mm
3. 4x2mm
4. 17x2.5mm (X-ring)
5. 17x2mm

What quantities are required?
Are all o-rings made of Viton or EPDM?
How has the ABS unit held up after the repair, 1.5+yrs later?

Has anyone else approached this repair with success?

Cheers,
George
Gen2n3 is offline  
Reply With Quote
Old 11-17-17, 04:52 PM
  #8
Full Member
 
Join Date: Apr 2013
Location: Suffolk, Va
Posts: 169
Thanked 1 Time in 1 Post
I am curious on this as well. My abs been leaking for some time now.
smikels is offline  
Reply With Quote
Old 11-17-17, 08:47 PM
  #9
I don't know man...
iTrader: (10)
 
Join Date: Aug 2005
Location: O Fallon MO
Posts: 2,093
Thanked 17 Times in 17 Posts
I think he spells out pretty good, buy extras if you're not sure, they're just freaking o-rings for Christ's sake! I'll add to make sure you use EPDM rubber for anything that could touch brake fluid. He said he used Viton on the outside of the solenoids. I wouldn't if I could avoid it. Don't forget there are some of the X-type o-rings in specific places. Re-reading does wonders on the understanding of what's going on.
TonyD89 is offline  
Reply With Quote
 
 
 

Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
gabescanlon
Suspension/Wheels/Tires/Brakes
1
05-08-16 11:23 AM
Namxi
3rd Generation Specific (1993-2002)
19
04-23-16 01:34 AM
Nomega
3rd Generation RX-7 (1993-2002) Parts
2
03-28-16 07:18 PM
silverflash2
3rd Generation RX-7 (1993-2002) Parts
3
03-28-16 01:59 AM
Vartok
Interior / Exterior / Audio
0
03-26-16 04:22 PM

Thread Tools
Search this Thread
Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are Off
Pingbacks are Off
Refbacks are Off



All times are GMT -5. The time now is 07:12 AM.


All content Copyright 2007 by Internet Brands, Inc. We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.
 
  • Ask a Question
    Get answers from community experts
Question Title:
Description:
Your question will be posted in: