Antilock Brake (ABS) and Pad Wear Connector for Porsche Boxster 986

The anti-lock brake speed sensor and brake pad wear cable both plug into a common connector mounted just behind the brake disc on the Porsche Boxster 986.  The goal of this build was to replace the connector housing, reusing the pins and center metal lug of the original cable.

It turns out that the connector is so brittle that it cracks and falls off of the original wires and pins leaving them fully intact and reusable.  Rather than replace the entire cable my goal was to simply replace the connector body.  

So far I'm not completely happy with the design but I thought I would share.

What works:

• pins fit and line up perfectly
• plugs insert securely
• metal capture (not shown) comes off the original and fits on the round pivot points of this body

What I don't like:

• Top to bottom capture is not as secure as I would like.  The ‘clip’ capture points are too small
• The full body is too wide by just a few millimeters at the top to mount properly behind the brake disc.  It mounts but doesn't lay flush due to a piece of metal on the side.

This is currently installed and I'm driving with it!

I've installed this on the front right wheel and it's working. I used a dab of superglue to keep the top and bottom shell together (placing it only on the 4 plastic corners) so that it can be replaced in the future when I print another version.

What to print with?  I'm using a Nylon Carbon Fiber.  I needed heat resistance, chemical resistance, and strength.  So far I'm very happy with the material and we'll see how it survives.

How to Print?  I print it face down with a 0.2mm layer height and supports from build plate only on a Prusa MK3+.  I'm super happy with the print quality and it looks so nice.

My plan is for this part to be fully removable and to not glue anything in… so that I can keep iterating on this.  

The only destructive part of this is to crush the original connector with a pair of pliers which for me was easy because it was already fractured into 20 pieces that were barely holding together as-is.

For the left side I don't have this installed, just zip tied the cables and connector pins together so this modification is not limiting to my ability to drive.

Feedback and suggestions welcome!

(Waring:  ABS and brakes are a safety system in your car so work with this at your own risk.)

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Break off the original connector and you're left with bare wires.

You need to know which two pins are for the Speed Sensor and which two pins are for Brake Pad Wear… but there is not polarity to worry about (since the plugs can be plugged is reversible)

Here is the wiring diagram. You see references to brown-black // brown-white and brown-black//grown-green in the official schematics.

Carefully insert the pins in the connector and you may need a toothpick or something non destructive to push the pins into place.  Then insert the metal ground lug in the center.  There is a slot in the back for the cable.