This latest production BOSCH 0 265 200 040 found in 1992+ model years features a fundamental internal solenoid engineering overhaul. The solenoid traveler valve is upgraded and made in polished chromoly steel. The larger traveler has more magnetically reactive mass and this revised design allows for moving the return spring inboard and nearly tripling in size over its predecessor design. The larger spring returns the valve to rest faster and eliminates the possibility of sludge blocking the springs movements. Finally the plastic caged internal bearings present in the earlier design have been completely eliminated as the revised design does not need or benefit from them, providing one less failure point.
The solenoids on this pump are specific to the 040 Super series of pumps. The upper manifold plate has lost the bosses for top facing ports found on other models and now sports a sleek upper top plate.
The primary difference between the late 040 and the mid 040 is the addition of cosmetic sleeves made of aluminum that cover the solenoid frames. These are finished in a polished surface treatment but can be offered in brushed by request. The sleeves are often not salvageable from core pumps due to galvanic corrosion and as such they do carry a modest premium over non sleeved pumps.
The cover shroud and chassis wiring hold down are secured with T15 Torx screws
The youngest of these pumps is 28 years old and has all but undoubtedly suffered from infrequent fluid exchanges.
Solenoids become encumbered with sludge, filter screens obstructed, and shuttle valves seize. ABS function extremely limited.
Lack of fluid flow through the pump to the rear caliper circuit is most common, with a possibility to stick the calipers ON
All components disassembled, ultrasonically cleaned and exampled for wear, damage and fitness for refurbishment.
Aluminum components vapor honed to lustrous finish. Steel parts cleaned, polished and plated in yellow zinc chromate.
Solenoids and drive motor electrically tested with windings and current draw verified inside of normal specified range.
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BOSCH® is a registered trademark of Robert Bosch GmbH, Germany.
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