Speed sensor pinion gear

[gesoffen]

2003 EV Westy, 2.8LVR6 and 01P Trans

Troubleshooting symptoms of a somewhat hyperactive speedometer indication, especially on coast down, I found the gears on the speedometer pinion gear chewed up - not surprising as its plastic and 20 years old.

I pulled the housing off of the right side of the differential to clean the pieces of the plastic pinion gear. The ring gear on the output shaft is fine. I have a new pinion gear on the way. I went ahead an replaced the output shaft seal (again) because they're cheap.

Question for the crowd (or for those with access to Bentley or similar factory repair documentation): Is there any lubricant that goes onto the pinion gear/ring gear? Should this housing have any lubricant in it (e.g. differential lube)?

The housing has an o-ring at the inboard end and a shaft seal at the outboard end - not sure if they are there to hold something in (lube) or keep something out (FOD).

[gesoffen]

Perhaps anyone with access to Bentley or similar factory service manual can post any insight? Thanks in advance!

[jjvincent]

There’s a fill plug. Suck out all of the existing fluid. A traditional differential oil will work. Just fill until it runs out and then install the plug.

[kourt]

Is this the area you're working on? (see below)

What I've posted below is what Erwin (the only real repair doc for the 01-03 vans) has available.

Kourt

[gesoffen]

jjvincent: yes, there is a fill plug on the diff (and no drain plug as you indicate). However, on the passenger side of the diff is a “housing” that the speedometer ring and pinion gears reside in. What I’m not sure about is if this housing (and the ring/pinion gears) require lubricant. If so, what kind/how much? Perhaps it is lubricated through the diff?

Kourt: the nomenclature is correct for a 24v VR6 EV. However, the diagram reflects the older style passenger intermediate axle shaft housing. So im not sure if Erwin is providing relevant info.

Regardless, thanks for the community knowledge - keep it coming!

[kourt]

I was probably on the wrong page. There are several diagrams of different years in Erwin. It's pretty dense and not easy to be confident you have the correct information. If I find something better, I'll post it.

kourt

[jjvincent]

[gesoffen]

Done and dusted - thanks for the help gents! No more bouncy speedo (or yo-yo cruise control due to bouncy speedo).

I did add a little diff lube to the pinion gear teeth and the bottom of the housing where the pinion gear is seated.

[kourt]

I did this job yesterday in about an hour on my 2001 Eurovan.

1. drive the van on ramps
2. [option] remove the belly pan. I was able to reach everything without removing the belly pan.
3. find the speed sensor on the passenger side of the transmission, pointing upwards. It should be covered by a radiant shield fabric protector.
4. unsnap the bottom snaps on the protector and work the radiant shield up higher over the speed sensor on the speed sensor wire, so that the connection points are visible.
5. my speed sensor had a plastic cover that was secured with fine wire. Cut the wire and discard it, and slide the plastic cover off horizontally to expose the spring loaded wire connector. They really don't want this connection coming undone while driving.
6. pinch the wire springs on the side of the connector and lift it upwards to release it from the speed sensor. Push the wiring and radiant shield up out of the way for now. Clean the area of debris.
7. use a short adjustable wrench to loosen the speed sensor, and then unscrew it off with your hands--it should come off easily once started.
8. what remains is the (probably aluminum) bushing that contains the plastic speedometer pinion. Use more care with this bushing, as it can be damaged easily. Find a deep 22mm socket or another reliable wrench and loosen it, and unscrew it by hand, take it off, and set it aside.
9. the top of the plastic speedo gear pinion shaft should be visible. It's probably green plastic, turned dark gray with age and gear oil contamination. Lift the entire plastic pinion shaft up and out with your fingers.

I believe the transmission output shaft is bathing in common gear oil shared with the differential. My speedo pinion shaft came out wet with gear oil, and I had changed my gear oil last year, so I did not have any concerns about gear oil capacity or age.

Parts:

Vehicle speed sensor: 357919149
Transmission speedometer pinion: 02B409197
thin wire to secure the speed sensor connector cover

I got my VSS form FCP Euro and the speedo pinion from eBay (shipped from Latvia). Both of these parts were in the $15 range.

Install is reverse of removal. Use light torque on all parts here.

I did this work to address an occasionally jumpy speedometer. My pinion shaft and speed sensor were original, with 245K miles. My pinion shaft came out easily and was not damaged, so I am not sure if this really solved my problem, but it is good to know this essential sender is refreshed.

kourt