1992 Cavalier Delco VI ABS

caviar emptor

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I have a 1992 Chev Cavalier RS, 2-door, 3.1L, V6, A/T, FWD, two sensor ABS and the driver side front caliper keeps locking up as if the caliper piston was seized and not releasing.

I have replaced the original caliper with a new caliper and bled the brakes. The brake bleeding was difficult, the brake fluid was barely trickling out even if the brake pedal was pushed in hard. Once the brakes were bled, the same problem (caliper not releasing pressure) reoccurred shortly after the car was started and brakes activated.

I get no ABS or BRAKE warning light.

I suspect this might be an ABS problem. I tried to look up some information. There is no visible identification as to what type of ABS system is on this car. The closest to identifying the ABS module was in this article:

http://www.j-body.org/forums/read.php?f=3&i=137251&t=137206

The article tells me the Delco VI ABS has been installed in as an option on Saturn, Buick Skylar, Oldsmobile Cutlass Calais and Pontiac Grand Am models, it soon became standard equipment on most General Motors front-wheel drive passenger cars, including Buick Regal and Century, Chevy Impala, Monte Carlo, Malibu, Cavalier and Silhouette.

However, Delco VI is a four sensor ABS and my cavalier has only two sensors.

questions:
1/ can somebody confirm this is Delco VI ?
2/ how do i reset the ABS module and test it without using any special tools or scanners?
 

zora

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Before blaming the ABS system, have you tried replacing the brake caliper rubber hose? They collapse internally and create the problem you are describing.
 

caviar emptor

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thank you for your suggestion to replace the rubber hose ... unfortunately replacing the rubber hose has not occurred to me even though... while working on the car... i noticed the rubber hose was/is in bad shape and the outer rubber lining broke and the inner insulation is exposed... i hope the rubber hose is not the issue since i already took the ABS module out and started taking it apart...

i may have provided incorrect info in my original post: it would appear the Delco VI ABS system is, indeed, 4 sensor system, not two as i thought previously, since i noticed electrical connectors and wires plugged into the hub behind the rear wheels.. as per attached diagram.

needless to say, since my original post was waiting for "approval" and i was not certain if this "approval" will take days.. weeks... or months, i found similar problem i am experiencing on the jaguar forum so i proceeded with the ABS module cleanup following this procedure:

https://www.jaguarforums.com/forum/x-type-x400-14/stuck-abs-valve-188478/

if there is anything anybody can add to this information... i'd greatly appreciate it
 

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caviar emptor

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Before blaming the ABS system, have you tried replacing the brake caliper rubber hose? They collapse internally and create the problem you are describing.
for those who are not interested in reading my massive rant, the TL;DR bottom line is: the brake caliper flex rubber hose collapsed internally and created the described problem...

in any case, thank you for the suggestion to investigate/replace the caliper flex hose... unfortunately i did not get to act on your suggestion due to delays getting my questions up on this forum... and by the time my first post with questions was visible, i already ripped the ABS module out of the car and started taking it apart...

As i already mentioned above, i replaced the caliper since i had no reason to think it was anything else... at that time. Well, it was not the caliper... so i started searching on this forum and on the web what would be some other reasons why calipers would lock up wheels. Pretty much all sources suggested it was the ABS system so i focused on the ABS module and found sources which reinforced and confirmed my theory and played into my own bias. The post (below) on the jaguar forum totally convinced me it was faulty ABS - stuck ABS valve:

https://www.jaguarforums.com/forum/x-type-x400-14/stuck-abs-valve-188478/

based on that ^, i found everything related to my Delco VI ABS system:

the principles of ABS and how it works:
http://faculty.ccbcmd.edu/~smacadof/Books/A5StudentWorkBooks126/SWB_a5_m10a_Final.pdf

how to service Delco ABS:
https://www.motor.com/magazinepdfs/062001_04.pdf

and how to bleed Delco VI ABS:
https://www.brakeandfrontend.com/bleeding-abs-systems/

https://www.autozone.com/repairguid...-Bleeding-The-ABS-System/_/P-0900c152802180b2

Turns out that after many hours of reading, researching, taking ABS out of the car, taking the ABS module apart, cleaning all ABS module components (and not finding any faults... the internals were clean as a whistle) ... and then putting the ABS back in, bleeding all brakes and the ABS module... the problem with brakes locking up persisted.

What was the problem.. you ask? Well, the fault was in 28yo flex brake hose which cost $15 and 20min to replace (Dorman H38905). It appears the hose collapsed internally and the obstruction inside the hose prevented the release of applied brake pressure; thus, the calipers remained clamped and the wheel locked.

so..., that's it... a problem that should've taken no more than 1hr to fix ended up being close to 30hr effort all together... sad and :mad:

i hope those ABS links ^ help somebody with their ABS trouble...
 
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