Brake Pad Wear Sensor (Right Rear) Wire Breaking.

[Jehu]

The past many replacements have mysteriously had the wire breaking... I can not visualize how this is happening.. the Brake Caliper operates normally and is actually a recent rebuilt replacement .

Anyone have any ideas?

Had brand new Michelin Pilot Super sports 235-45-17 mounted on the M-Systems today and nothing to do with the connector from the harness or the insertion of the probe end appeared amiss yet the wire was broken as if the caliper spread too far at some point and just ripped it.

These are OE calipers and as far as I know I am getting the right part for this model and year.

Also have a (Right) Fog lamp that must have a wire break somewhere down into the harness bundle.

New bulb in fairly new Hella lamp, all wires visible from inside the lamp, the plug and up till it enters the large wiring loom routing across the front end.. maybe an object impacted at a high rate of speed and damged it? Ever seen that happen?

[shogun]

First to the foglights: easiest is a swop of the bulbs from right to left to see if the fault moves. From my experience with E32 some hints to check, but I am not sure if that is the same set-up on E34
This big round plug is on my E32 behind the bumper left side, it is for the foglights and the outside temp. sensor, oxidation occurs http://bmwe32.masscom.net/johan/OBC_temp/OBC_temp.html
Then I once had the wire melted just close to the connector of the foglight, bare wires, but that was my fault, because I installed 100W H1 bulbs.
Use for all connections contact cleaner / contact enhancer, I fixed in the past years some problems just with such spray, for example the aux fan was not running, the spades of both aux fan relays were oxidized, just sprayed the parts, problem solved.
I also sprayed all fuse sockets with contact enhancer.

As for the wear pad sensor wire I just can imagine that it is not correct installed, is that clip there for the wire as shown on the last pic? http://bmwe32.masscom.net/sean750/rear_brake_pads/ReplacingRearBrakePads.htm

[Jehu]

8546

if this is the clip you mention then no the wire was not held between the two ends. Must be that when free the wire can travel and become trapped during operation of the caliper.

I'll recheck the bulbs... being that the first thing I did was replace the bulb I assumed it was good. The old bulb did appear darkened so I'll try a swap. Thanks .

[shogun]

just checked on realoem for your 01/95 540 it might look a bit different, http://www.realoem.com/bmw/enUS/showparts?id=HE53-USA-01-1995-E34-BMW-540i&diagId=34_0443
might be 11 Cable holder D=13MM 61136784633 http://www.realoem.com/bmw/photos/61136784633

[Jehu]

just checked on realoem for your 01/95 540 it might look a bit different, http://www.realoem.com/bmw/enUS/showparts?id=HE53-USA-01-1995-E34-BMW-540i&diagId=34_0443
might be 11 Cable holder D=13MM 61136784633 http://www.realoem.com/bmw/photos/61136784633


Interestingly while the issue is happening on the rear caliper the missing clip I circled in the picture appears to be the no longer available #10 which appears only for the front. The rear shows no clip for the rear other than the one in your pic which I do have and hold the connectors.
http://www.realoem.com/bmw/enUS/showparts?id=HE53-USA---E34-BMW-540i&diagId=34_0443


I'll examine the caliper and see if there is a hole in it where such a middle clip could be fitted and then hunt at some junk yards.. I just got a cruise control module for $35 from a '95 525

[632 Regal]

Interestingly while the issue is happening on the rear caliper the missing clip I circled in the picture appears to be the no longer available #10 which appears only for the front. The rear shows no clip for the rear other than the one in your pic which I do have and hold the connectors.
http://www.realoem.com/bmw/enUS/showparts?id=HE53-USA---E34-BMW-540i&diagId=34_0443


I'll examine the caliper and see if there is a hole in it where such a middle clip could be fitted and then hunt at some junk yards.. I just got a cruise control module for $35 from a '95 525

That clip is a rubber deal that goes on the bleeder. It connects to the end of the bleeder and around the base. Without it on there the wire is most likely wearing against the wheel.

It's called a dust cap, #6 in your link. 34111153198

[Jehu]

That clip is a rubber deal that goes on the bleeder. It connects to the end of the bleeder and around the base. Without it on there the wire is most likely wearing against the wheel.

It's called a dust cap, #6 in your link. 34111153198

Ahhh..now that you point it out I think I have a vague recollection of seeing this once upon a time .. must have either broke off or was never replaced after the caliper swap..

Excellent work Holmes.

[632 Regal]

Ahhh..now that you point it out I think I have a vague recollection of seeing this once upon a time .. must have either broke off or was never replaced after the caliper swap..

Excellent work Holmes.

Lots of cars have them so you should be able to grab a pocketful as you wander aimlessly around the junk yard ;)