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AdamFeneley

Member Since: 27 Dec 2023
Location: Bedfordshire
Posts: 2

Axle Rebuild Help (ABS & Shock Mounts)

Hi All,

So I have had my 05 110 TD5 XS for nearly a year now. I have done a few bits, but now built up the courage to start some of the bigger jobs! I have removed the rear axle with the intention of a full refurb (only started with the job of replacing the a-frame ball joint!)

I have watched as many youtube videos as i can, but there are a couple of areas that i was hoping to get some help. Current issues:

1 - ABS Sensor removal. My sensors seem to be really seized in, does anyone have any tips for removing these:

Click image to enlarge

Click image to enlarge

2 - The seats/cups (terminology!?) where the socks attach seem to be fixed to the axles. The are knackered, but i was expecting this to be just a hole in the pressed steel rather than for these to remain attached to the axle. Are they just rusted on and I should cut them off or should they remain attached and can you replace them? Sorry if this is a stupid noob question!!

Click image to enlarge

Click image to enlarge

3 - I am going to get the axles shot blasted and will paint them before rebuilding. What are the best primers/paints to use? Am I best to just calling Buzzweld and asking them or is there an accepted best product/(s) to use? For info, I intend to hand paint with a brush as I don't have the gear to spray.

Thanks for any help that you can give me before I start breaking sensors and cutting bits off that I shouldn't be!

7th Dec 2024 1:14pm

custom90

Member Since: 21 Jan 2010
Location: South West, England.
Posts: 20447

Those are the rear damper lower bush cups, they are needed if you have pin to eye rear dampers.

You can take them off and use pin to pin dampers with a different top mount fitted, I would take the cups off leaking just the axle hole in the bracket.
So remove just the remains of the cups flush to the bracket.
The hole in the bracket remains, and that’s where you’d install the pin to pin damper, and appropriate pin to pin bushes.

There are different lower bushes for the eye to pin dampers with the cups, to pin to pin with it the cups.

If you look up pin to pin rear damper conversion, on YouTube there is videos on techniques to take those cups off, a cold chisel is one ideal tool.

Just avoid damaging the brackets or hole in it.

This sounds more complex than it is, if you want to keep the cups, you’ll need to get new ones and they are spot welded, I wouldn’t bother. That’s just me. No Guts, No Glory.
🇬🇧🏴󠁧󠁢󠁥󠁮󠁧󠁿🏴󠁧󠁢󠁷󠁬󠁳󠁿🏴󠁧󠁢󠁳󠁣󠁴󠁿🇮🇪🇺🇸⛽️🛢️⚙️🧰💪

7th Dec 2024 1:33pm

DSC-off

Member Since: 16 Oct 2014
Location: North East
Posts: 1428

2015 Defender 110 Puma 2.2 XS CSW Aintree Green

Hi, Regarding the bush cups.
The old ones can be chiselled or ground off and the area cleaned up with a grinder or file.
When refitting the shocks, use lipped washers or bushes to prevent rubbing on the eye of the bracket.
Explained here,

Part number for lipped washer, RYF500200 or NRC4365

If you've got conical bushes at the lower shock mount the cone and the dish of the washer should face away from the mount, for articulation. Bottom of this pic,

Click image to enlarge

8th Dec 2024 12:57pm

landy andy

Member Since: 15 Feb 2009
Location: Ware, Herts
Posts: 5729

2006 Defender 110 Td5 USW Zermatt Silver

As said. The bush caps serve no real purpose as most aftermarket dampers come with lipped washer. So no loss there.

The ABS sensors just need a gentle bit of love to get them moving and the they will just pop out

8th Dec 2024 3:10pm

bankz5152

Member Since: 02 Feb 2017
Location: South London/North Kent
Posts: 2178

Remove the axle cups. They serve no purpose if the correct washers are used. If anything they are detrimental and cause shocks to snap.

Sensors gently tap them out with rubber mallet. Try and clear as much debris as you can. Very gentle taps. Instagram @defender_ventures
Empire Tuning - Agent

8th Dec 2024 4:50pm

AdamFeneley

Member Since: 27 Dec 2023
Location: Bedfordshire
Posts: 2

Thank you all for the feedback, I will remove the cups!

I have removed the ABS sensors, but i will need to replace. They really were stock in there. The housing on the hub they fit into is corroded on this inside of the hub, is this possible to replace (not the brass cage that fits inside the housing)?

9th Dec 2024 8:43am

bankz5152

Member Since: 02 Feb 2017
Location: South London/North Kent
Posts: 2178

Yes, must replace the brass cage. They are available.

If you get new sensors use G rated ones only, cost around £180. I wouldn't replace them unless yours are faulty or damaged. Instagram @defender_ventures
Empire Tuning - Agent

9th Dec 2024 8:45am

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