164 Brake Fluid Sensor Problem

["Rich Lasner" <richlasner@domain.elided>]

After wrestling with clutch hydraulic troubles over the last month, I was
relieved to have my 164S back in good shape. One day after the clutch
hydraulics were fixed, both the Brake and Brake Pad Wear warning lights
began to come on on bumpy roads, then go off. Yesterday, both lights came on
and stayed on when I started the car.

Since the brake system and clutch hydraulics share one fluid reservoir, I
assumed either the electrical contacts or the sensor float had a problem. I
had removed the brake/clutch fluid reservoir cap/sensor over a dozen times
while sorting out the clutch hydraulics. As its the original part, I
figured it had died. Theres a removable small rubber cap on top of the
sensor. When I removed it, a small metal washer, which normally sits on the
top of the float shaft and touches two contacts to complete the sensor
circuit, had fallen off into the cap. It appeared to me that it should sit
under the contacts, so that the fluid level would push it up to complete the
sensor circuit. This seemed right to me, since putting the metal washer
above the contacts meant the circuit was open when the level was right- a
situation that could be duplicated by one of the electrical connectors
falling off. Just my guess, but it has some logic to it.

Well, neither positioning of the washer resulted in the lights on the dash
shutting off. The really strange thing is that I accidentally got the dash
lights to go off by removing either of the electrical connections. Didnt
matter which one. I left it with one connector off, and the lights havent
come back. I ordered a new sensor today, but Id love to hear from anyone
else who has experienced this problem.

Rich Lasner
1992 164S
ARA
AROC
Mill Valley CA
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