Getting a tool made - full ABS disassembly

[BMGM3]

I'm looking to rebuild an M3 ABS pump. I know there is a couple of people in the US offering this service, but it's a fair chunk of money for the service and involves sending a pump back and forth overseas etc. I also don't particularly like the idea of vapour blasting the main pump body parts.

I've bought a Bosch ABS pump from a Merc, which is near identical, to play with first before attempting the M3 part. This was £15 from eBay and will have lots of components shared with E30/M3 ( M3 is different to E30 ) pumps , important because nothing is available and there's several unique seals and bits.

I've got it apart but struggling with the solenoid disassembly. They are staked in and even with opening this up and using a brass punch , the locking ring is proving hard to shift without doing damage , one slip and you'll puncture the mesh filter.

I was wondering if anyone has any experience , or the ability, to make a custom tool to do the job properly. Any ideas on cost of making such a tool ?
Linked here is a pic of the solenoid with the locking ring

[onthames]

I think maybe mart could help you here

[martauto]

I think maybe mart could help you here

Let me think about this one, when you say "staked in" do you mean the bit of the outer diameter which seems to have two "dimples" in ?
Is the locking ring screwed in ?

Mart.

[BenHar]

You need something like a grinder spanner but bigger.

Ben

[YODI]

You need a motorbike engine bolt socket, measure up the gap and try find one of the same size.

[paultv]

If I remember correctly they screw in and the crimps lock them - when I did mine I ended up not removing these filters but cleaned them by flushing and reverse flushing -
just left some staining on the screens - thats my image from the first strip down I did. Getting the solenoids out of their casing is a pig - just flush in place or you risk damaging so much,
and as suggested - before dissasembly flush in and out and make sure you have good flow from the inputs to the outputs using syringes to push fluid through - only if badly restricted consider a strip
down, or as suggested, buy a second hand unit to play with.

Remember, mixing ABS pumps with incorrect ABS ECU versions including the wiring harness will cause problems - incorrect cable resistances will unbalance an ABS system.

Paul

[BMGM3]

I think maybe mart could help you here

Let me think about this one, when you say "staked in" do you mean the bit of the outer diameter which seems to have two "dimples" in ?
Is the locking ring screwed in ?

Mart.

The locking ring screws in , then staked , or crimped if you prefer, to stop it backing out.
You may be able to modify a bike socket , as was mentioned, but the two drive pins are not square cut outs, but a angled design. So even if you did find one similar, you still need to fettle it a bit.

[martauto]

[quote=BMGM3 post_id=2988850 time=1635955477 user_id=77816
The locking ring screws in , then staked , or crimped if you prefer, to stop it backing out.
You may be able to modify a bike socket , as was mentioned, but the two drive pins are not square cut outs, but a angled design. So even if you did find one similar, you still need to fettle it a bit.
[/quote]

You could always grind the staked in bits away and loctite it back in but it could leave you a mess near the filters.

Mart.

[BMGM3]

[quote=BMGM3 post_id=2988850 time=1635955477 user_id=77816
The locking ring screws in , then staked , or crimped if you prefer, to stop it backing out.
You may be able to modify a bike socket , as was mentioned, but the two drive pins are not square cut outs, but a angled design. So even if you did find one similar, you still need to fettle it a bit.

You could always grind the staked in bits away and loctite it back in but it could leave you a mess near the filters.

Mart.
[/quote]

I've punched the staking out to where it shouldn't be a problem. Trying to drift the locking ring around is damaging it though.
Everything else is part. Not the easiest job to do , you'd think being aluminium there would be few problems, but everything was stuck hard and needs careful work not to damage the ally bits.

[flybynite]

I've punched the staking out to where it shouldn't be a problem. Trying to drift the locking ring around is damaging it though.
Everything else is part. Not the easiest job to do , you'd think being aluminium there would be few problems, but everything was stuck hard and needs careful work not to damage the ally bits.

Have you looked at any of the stripdown photos of ones already done to get an idea of the thread? Warming the outer cylinder in hot water should help expand the outer cylinder without damage to the plastic.

Mig a couple of teeth to a flat bar and file to size would be my method, grip with a leather strap jar opener or filter tool

[BMGM3]

I've bought the bike socket as mentioned, as I found one that's 20mm and this is pretty much what the solenoid is.
Ideally you'd turn it down a bit, then cut the two prongs down to the correct depth and angle on a lathe. Problem being I lack the lathe part.
The bottom filter pops off rather easily. The top ones and amazingly tight and I've destroyed one on the donor Merc pump.

[YODI]

I've bought the bike socket as mentioned, as I found one that's 20mm and this is pretty much what the solenoid is.
Ideally you'd turn it down a bit, then cut the two prongs down to the correct depth and angle on a lathe. Problem being I lack the lathe part.
The bottom filter pops off rather easily. The top ones and amazingly tight and I've destroyed one on the donor Merc pump.

Motorbike one I mentioned?

[BMGM3]

I've bought the bike socket as mentioned, as I found one that's 20mm and this is pretty much what the solenoid is.
Ideally you'd turn it down a bit, then cut the two prongs down to the correct depth and angle on a lathe. Problem being I lack the lathe part.
The bottom filter pops off rather easily. The top ones and amazingly tight and I've destroyed one on the donor Merc pump.

Motorbike one I mentioned?

Yep.
Solenoid is approx 20mm and found a socket listed being the same.
If you could turn it down and get the ramp angle to match the cut outs on the ring, it really should be easy.

[YODI]

Wicked, how good am I . . . .