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Old 06-13-2017, 08:59 PM   #26
Khrrck
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I think "playing with the airgap" is your best bet. I didn't read that linked thread too much so I didn't see if anyone specified how much gap they added.

I only have a Bentley manual for 240. It says:

Sensor with 12 tooth wheel (12-window): 0.85mm +/- 0.35mm
Sensor with 48 tooth wheel (1992 and later): 0.6mm +0.2mm -0.3mm
Sensor with 96 tooth wheel (1992 and later): 0.6mm +0.13mm -0.25mm

More appropriate might be the specs from a 740 manual. I suspect they are similar.
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Old 06-13-2017, 10:24 PM   #27
dl242gt
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You could leave the 48 tooth ring alone and use the sensor/cover matched for it. Then install a 91-93 speedo in your cluster which is matched to a 48 tooth trigger wheel. I think that should work.
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Old 06-13-2017, 11:04 PM   #28
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I'm almost at that point. ^^^^.
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Old 06-13-2017, 11:15 PM   #29
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Originally Posted by ZVOLV View Post
I'm almost at that point. ^^^^ I am kicking myself for listening to turbobrickers and trying to cut windows, add shims, etc. I try to do things cleanly and keep the hack work that wastes my time and $ to a minimum.
And yet you claim to be the pro when it comes to diagnosing elementary electrical issues.
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Old 06-14-2017, 02:29 AM   #30
Kjets On a Plane
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I / we cut 3 of 4 windows (12 remaining if you will) and just used the single bolt/blade sensor meant for the alum cover.

It read 2?x too fast with the 2 blade sensor and 12 remaining teeth/windows on the tone ring. 2-blade late sensor is this one:
https://www.fcpeuro.com/products/vol...40-960-s90-v90

Installed this one which has the single blade at the exact same depth as the 2 blades if you will (same distance from the (originally) 48 tooth tone wheel (same diameter wheel between 96T and 48T IIRC):
https://www.fcpeuro.com/products/vol...sor-0265001187

More/maybe most? elegant to use the 1991 240 ABS signal converter relay box or similar and do nothing whatever to the sensor/tone ring/cluster, but neatly trimming 3 of 4 teeth/windows and the single blade sensor worked no fuss whatever in the non-abs 240, but required recombining the parts bin a little and is definitely a long way around the block "hack" if you will, but effective depending what tools/junkpile you have on hand.

Haven't messed with washers or the earlier sensor or any of that...

I neatly filed the tone ring so you couldn't really tell it ever had 48 teeth and had no other scratches or whatever. MUCH easier to R&R those if the diff carrier goes in the freezer for a while and tone ring is warmed. Makes reinstall especially nice if the tone ring sits on the wood stove or is heated and carrier is cold. Reduced the chance of possibly damaging it greatly, especially missing 3 of the 4 teeth!


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Old 06-14-2017, 12:12 PM   #31
Khrrck
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Thanks for the part numbers Kjet. Looks like that second sensor is available on ebay for $80-90. May be NLA elsewhere. Sounds like it's boiling down to ZVOLV having the wrong sensor.
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Old 06-14-2017, 12:25 PM   #32
ZVOLV
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Thanks for the links. I really hope the single blade sensor will be my final solution!

Looks like it's also used as a wheel speed sensor. I should be able to score that sensor somewhere in the yard.

I concur that the tone ring gets fragile once it's been cut up. Mine distorted on me when I tried to get it back on, but I saved it without issue.

Over a year now on the G80 I installed myself without any drama. Just some fun in the rain dumping the clutch going into second gear and breaking the back end free on my stock 240.

Last edited by ZVOLV; 06-14-2017 at 12:55 PM..
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