New sensor arrived and Sunday was dry enough for me to spend over 6 hours under the car... Ah, the joys of working on 21+ year old cars...
Long and short, the three amigos have once again left the building and a joyous lack of yellow lamps have restored calm to the dashboard.
There was absolutely NO WAY the sensor was coming out the way the Haynes' manual optimistically suggests. And in fact, removing the half shaft from the immediately revealed the problem: the outer part of the CV joint had corroded and the ensuing rust had ballooned and expanded the reluctor ring, such that the ring was shaped more like an egg, and the high part of the reluctor had worn off the tip of the old sensor, effectively killing it.
It has been replaced (and the CV/splined end of the drive shaft cleaned and painted first). The sensor itself came out in parts - the plastic inner first, then the alloy casing (after much chiselling with an old screw driver) and drifting. The copper retaining cage came out after running a 16mm hole drill down the sensor orifice in the hub. Lots of copper grease on reassembly!
I need to go through the process of removing the nearside rear drive shaft as the diff seal has failed. Getting the trailing arm off the hub was fun, but thank goodness for Chinese cheap tools - I had bought an induction loop thingy, which heated up a nut that had started to round off - and after getting that cherry red, it released relatively easily.
Why is it that when you start any job on a car invariably leads to almost your entire tool box lying on the drive next to you (when when you intentionally start with the minimum of tools that you think you'll need)?
I ran out of light, but the three amigos disappeared. However, the sensor is occasionally dropping out a speed signal leading to activation of the traction control. I think I need to push the sensor a little closer to the reluctor ring to get a more reliable signal. I'll do this one evening this week, work and weather permitting!
PS lower arm to subframe bolts - really 36Nm then 360 degrees? That's what Haynes manual says, is that correct?? Thanks!
PPS will upload photos, if I can work out a way of doing this from my phone...