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Unread 06-05-2012, 07:45 PM   #1
grankin
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Lightbulb Fixing a failed sensor before it fails

The belt sensor has failed repeatedly, and I finally got sick of replacing them. I was going to get a new one and see about replacing the bearing for a real one. Instead, when the new part arrived, I looked at it & thought a bit. There appears, BTW, to be a bearing ID there on the wheel. It says "FAG 626RS NT" That's an actual bearing, findable at <http://www.seekpart.com/bearings/FAG+Deep+Groove+Ball+Bearing+626-RS.html>, but that won't do you much good when it is the shaft it runs on that fails.

There was a nice hole down the center of the shaft the sensor wheel rides on, what looks like a bolt head pressed-in to the forward side, and the shaft peened-over on the aft side. <thinks to self> Betcha I could find me a bolt that'd go through there, a couple of washers to bear any loads and a nylock to pull it all together. </thinks to self> So I went to a local hardware store and bought a button-head cap screw, M3 in size, 20mm long, 0.50 pitch. Then two M3 0.50 fender washers and a M3 50-pitch nylock. The cap screw doesn't fit a 2.5mm Allen, as the photo purports, but really a 9/64 Allen key.

So here are some photos. First, what it looks like from above:
Click the image to open in full size.

And from closer-in and from above (with zip-tie):
Click the image to open in full size.

And closer-in from another direction:
Click the image to open in full size.

Note that the wheel's gone and the end of the shaft looks pretty rough. That's what contacts your belt when the wheel takes off. Not good.

Here're the parts from Ace Hardware, a total of $1.31 worth:
Click the image to open in full size.

The new part, from the peened-over aft side:
Click the image to open in full size.

And from the pressed-in bolt forward side:
Click the image to open in full size.

Cap screw & washer on the bolt side:
Click the image to open in full size.

Nyloc nut and washer on the peened-over (aft) side:
Click the image to open in full size.

Tightened-down:
Click the image to open in full size.

And now seeing both sides:
Click the image to open in full size.

My theory: the washers will keep the wheel from wobbling (as I assume it does) which causes the peened-over end of the shaft to fail. The whole thing is not drawn up all that tightly, just enough to hold it together, so as not to add new stresses.

Any thoughts or observations before I install it?
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