Hello ...

My front driver side ABS sensor broke when I was trying to remove it from the Knuckle. The cylinder part of the sensor is now stuck in the knuckle, I wanted to know if I can just drill it out so I can slide in the new ABS sensor without damaging the knuckle?

 

Yes its possible, be careful.

 

Yes you an drill it out mark you drill bit with tape so you don't go to far and hit the axle, and when installing the new one install some grease on the plastic so the same doesn't happen. Just don't get it on the tip

 

Great ... Thanks ...

Should I use a bit that is the same width as the sensor or smaller?

 

certainly smaller.

 

I just did this on my own car. Are you planning on taking the knuckle off to do this? If not, I would highly recommend you reconsider. It will make the job immeasurably easier and it is not that difficult. It's a few bolts, take the shock off and pop the ball joint loose. You shouldn't have to separate the wheel bearing if you don't want to. I ended up finding a lightly used knuckle/wb/sensor for $150 and just swapped the whole thing in, took a couple hours taking my time. You'll spend almost that much on a replacement sensor. Just some food for thought, best of luck!

 

I was finally able to get out the broken part out of the knuckle. I wanted to know if the new ABS sensor is suppose to slide in easily or do I have to hammer it into place?

 

The sensor is suppose to slide in easily, although the clearance should be extremely tight.

Now since your old sensor had an issue coming out you may have to clean the bore a little bit with a pipe cleaner or something.... (small stainless steel cylinder brush)

 

You do not want to hammer the sensor in. It should fit in there snugly with nothing more than pressure from you sliding it in. It shouldn't be forced in there.

 

Maybe lube up the shaft it slides into a little with a bit of motor oil or WD40?