repair your own ABS module

[Tonner Matt]

Deleted

 

[oska]

The second pin from left side of your photo?

just below the 5 cent piece the 2 silver wires

 

[VT&VX]

the 2 aluminium wire break

the board is covered in a gel

1 you need to remove the gel without breaking the even finer gold wires
2 you need to solder the aluminum wire
3 aluminium oxidizes

OK, looking at your photo, those two wires appear to use the same contact. Wondering why they have two thin wires?

If one wire is broken does it still work?

Wondering if the gel could be removed just over the two contact points and then a patch wire used?

 

[oska]

These Bosch abs 5.3 were fitted to lots of different makes BMW AUDI SAAB VW i think it was a production fault

if you get to open the unit you'll see how thin the wires are and they are ultrasonically bonded and not soldered
this is the problem

 

[VT&VX]

Wire glue $10 from Jaycar?

Description
A soldering iron in a jar. Wire Glue is a electrically conductive adhesive that enables you to make solder-free connections when you don't have a soldering iron handy, or aren't able to apply heat for some reason. Hundreds of hobby, trade and electronics uses. Lead-free, cures overnight

 

[VT&VX]

When the small metal components in plumbing, metalwork, or, most often, electronics, need to be repaired, chances are there will be soldering involved to fix them. Essentially, soldering involves melting a metal with a low melting point, then applying the molten material to other metals, and in the process, strongly bonding the broken pieces back together. When soldering things like plumbing or jewelry, the ability of the soldering material to conduct electricity is unnecessary, but when soldering electronics, conductivity is essential. For those that think the idea of melting metal and applying it with a soldering iron sounds dangerous, wire glue is available to do the two main jobs of soldering: joining two components and being conductive.

What is Wire Glue and How it is Used

Wire glue is perfect for using on small electrical jobs that require some, but not a lot of, conductivity. The material is black, and the main ingredient is graphite, which along with the micro carbon technology, gives it the conductivity needed for electrical jobs. Wire glue is lead free, which is untrue of soldering materials, and is also non-toxic, non-flammable, and ecologically friendly. Most importantly, wire glue is conductive, which is necessary for electrical jobs, but not as conductive as soldering, and is appropriate for low voltage AC and DC currents. Wire glue is great for use in potentially high-temperature conditions, like on metal, glass, and ceramic.

The way wire glue works in theory is very much like actual soldering, but very different in application. The material is applied to two components that need to be rejoined after being separated, usually wires, with an electrical current needing to be able to pass between the two. The material can be very thin and tough to work with, so it's best not to pour it out freely, but to handle it with an applicator. Using a toothpick or other small, delicate applicator to apply the wire glue works best (sometimes the glue comes in an easy to use applicator not unlike a syringe), then the material must set and cure overnight. Once the glue has set, the bond is very strong and electricity can flow freely between the two components again. Some users of wire glue have been known to coat the dried glue with a quick setting epoxy to reinforce the bond made by the glue.

Uses and Benefits of Wire Glue

There are many uses for wire glue, especially in the realm of hobbyists, but also for anyone looking to do some small-scale electrical work, especially when repairing things. Heavy duty electrical work is best left for the soldering iron, but wire glue is perfect for the smaller stuff, and great for those with little electrical experience, as well as for the expert. Some examples of the types of jobs that are perfect for wire glue include small repair jobs, like computers, guitars, boats and automobiles, and solar cells, among many others. Hobbyists may get the most use out of wire glue, as the substance could be used for any number of projects, such as remote control cars, boats, or planes, model train sets, robotics, etc.

So why would anyone use wire glue as opposed to soldering? There are many reasons. First off, it's easier and cheaper: not everyone has a soldering iron, nor do many people feel comfortable working with molten metal. A small tube of wire glue is much cheaper and easier to work with than a soldering iron. Second, sometimes the inner workings of the thing needing repair are sensitive to the heat put off by a soldering iron, thus requiring the assistance of the room temperature wire glue. Third, some repairs are physically out of reach of a soldering iron and require the reach and pinpoint accuracy of the wire glue and an applicator such as a toothpick. Fourth, sometimes a repair is required but a soldering iron is not on hand, perhaps on a camping trip, or in the event of a power outage, and the most convenient thing to use is wire glue. Finally, wire glue is just safer than soldering. A little glue on the hands is much better than some molten metal.

 

[chrisp]

Wire glue $10 from Jaycar?

Description
A soldering iron in a jar. Wire Glue is a electrically conductive adhesive that enables you to make solder-free connections when you don't have a soldering iron handy, or aren't able to apply heat for some reason. Hundreds of hobby, trade and electronics uses. Lead-free, cures overnight

I haven't repaired an ABS module, but a couple of general comments on the video. The breaks in the two wires look like fatigue breaks (perhaps due to vibration or some sort of weakness due to distorting the wire in the welding process?). Also, those connection look like they are relatively high current - hence the two heavy wires compared to the standard wire-bonds on the other pins. I have doubts that wire glue will be conductive enough for this application.

Maybe try replacing the aluminium links with a single copper link and very carefully (conventional) solder to the connecting pin and the circuit board?

 

[VT&VX]

I get what you are saying. crazy decision they made to use Aluminium wires. Aluminium will always harden with vibration so it is going to fail.

Planned failure, designed for obsolescence?

I am going to dab a big lump on it and see what happens.

 

[oska]

give it a go, it's not new others have tried it and does work for a while

the wire glue is better suited to repair circuit boards and the like, that gel is a real problem just be careful you don't break the gold wires

 

[VT&VX]

I will give it a go, but I also just bought a second hand ABSmodule still connected to the pump from a "it was working last time we drove it" car. So I have a backup.

I bought the 'wire glue' from Jaycar. Tiny jar,