2004 S80 T6 Is this brake pressure pedal sensor repairable?

jmlorey · Post by **jmlorey** » 17 Jun 2014, 11:36

I am interested in repairing the brake pedal position sensor for my 2004 S80 2.9L T6. I have the error message "Brake Assist Service Required" and "Engine Service Required" and I think this sensor may be the culprit. I was trying to follow the repair guide found here: http://www.volvoforums.org.uk/showthrea ... 192&page=5

When I was able to locate the brake pedal pressure sensor I noticed that it looked different than all the ones I had seen repaired so here is the picture, it is the first and second attachment. Third picture is to show how tight it is getting in there.

Notice that the plug seems to be in the center of the sensor compared to others that I've seen being off to one side. Also, the end of the plug seems to be one solid piece of plastic that doesn't have the rubber seal that is normally cut into to access the inner workings of the sensor.

Any of you ever came across this type of sensor and repaired it? Do you guys think I would be able to cut this open with a Dremel possibly or might it be different entirely inside? Also, how do you get to the snap ring or curclip that holds this in place, I have no idea how to get in there and get it off? I assume that I remove the strut bar to start but any advice at all would be greatly appreciated!

Post by **jimmy57** » 17 Jun 2014, 18:08

The three wire versions fail because the potentiometer track wears through. No way to repair that I know of.

jmlorey · Post by **jmlorey** » 17 Jun 2014, 18:30

So my plug is different than others that are shown being repaired? I noticed the different location of the plug on my sensor but I figured it might still be the same connector.

And opening it up to resolder the joints would fail most likely if I were able to get in without completely destroying the casing? (Because the potentiometer track is just worn through)

I can't even seem to find a replacement online that has the same exact BPPS as mine, most are the same as the ones shown being repaired. Anybody have a clue where to find one that fits or have a donor car?

Post by **jimmy57** » 17 Jun 2014, 21:01

Two wire ones are different. They are metal conductors with resistance in steps and aren't really a pot.

jmlorey · Post by **jmlorey** » 18 Jun 2014, 18:44

Ok so I was able to stop by an awesome import junk yard near my town and I found a replacement BPPS for $25. It is the correct 3 wire version so I'm hoping it should work. This is from a 2005 S80 that has most likely sat for some time so not sure if it will still be in good working shape.

Whats interesting is that this sensor looks as if it can be opened up like the other two wire versions. If this one doesn't work right think I can open it up and resolder something or is the inside totally different for the three wire version?

jmlorey · Post by **jmlorey** » 11 Jul 2014, 23:42

"Brake assist service required" popped up again today. The replacement BPPS was working great and I got rid of the error message and cruise control was working great up until this.

I hit a pot hole and it appeared shortly after this so maybe just jarred it loose, have to check in the morning.

Back to my original question, can the three wire plug version of the BPPS be opened up and resoldered for a solid repair???? Or is it totally different and irreparable??

Thanks