I've been refreshing the brakes on my daughter's R52S, as her front pads were worn. When I also checked the rear brakes, I found one of the RL pads half disintegrated.


The worn FL pad had chewed a little into the rotor, too. After assessing everything (and having new rear rotors I found in the trunk of an R53 on a U-pull run a couple of years ago, anyway), I decided to just put in new pads and rotors front and rear, along with new wear sensors. I'm about halfway through, but I got stalled with one wrong-size front rotor and the wrong front pads. The correct parts are on their way and will arrive early next week.

In the meantime, I am tackling a temporary fix for a broken connector shell on the FL headlight level sensor that's mounted by the inner ball joint on the lower control arm.



My temporary fix was to zip-tie the connector to the sensor body. An important item was to make sure the connector's gasket was seated fully inside the connector cavity of the sensor (to prevent water/dust ingress).


I haven't come across the connector and some of its pigtail at a U-pull, yet. But, if someone has one they'd like to sell, please send me a PM. Thanks!

I have the rear brakes finished (new rotors, pads and wear sensor installed), and will finish the fronts next week.

 

I'm going to run through the local U-Pull yard today and see if I have any luck finding something that will work.

 

And, SCORE!

I successfully sourced the Connector Outer shell and pigtail (just in case) from a -00's Volvo 5cylinder engine! On the Volvo, it is the connector to the throttle body.

I'll remove the zip ties and replace the connector shell this evening.

The outer shell is compatible, but the inner connector housing has different "keying" than the level sensor connector. But, if needed, the terminals/contacts inside the inner connector housing would also be compatible with the Mini's wiring (though the wire colors may be different).

 

I moved the connector shell from the U-Pull pigtail to the Mini and everything is back together and connecting great!


I had to remove the terminals/contacts/wires from the inner connector portion, slip the new connector shell over them and up the harness, reinstall the terminals/contacts/wires into the inner connector, and then slide the connector shell down over it.


Much better! It clicked solidly in place on the sensor 😁