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Hi Trev,
In the thread Charlie refers to, we discussed the change that was made in '91, at least in the US market. For non-ABS cars in that year, the differential pressure switch was done away with, replaced with the more reliable, less troublesome, level sensing reservoir, and a much less expensive manifold block. Non-ABS. My daughter has one of those cars.
Plugging the switch is impossible. I know the word "impossible" is like waving a red flag at a crowd of bulls, but think about your hydraulic pressure peaks in the braking system, and the fact nothing there is sealed by threads, and what it would take to match those switch threads with a plug and some kind of brake-fluid-proof sealant. If there is fluid at the switch, the hydraulic seals inside the octopus have failed, and no "new switch" or plug will fix it. Most of us just live with a slow leak.
ABS are still dual systems, just not split at the front calipers like the pre-ABS. The same switchless manifold is used. Anything resulting in a pressure differential, as reported by the old system, would wind up lighting the brake failure light through the level switch, when the fluid fails to return to the rez.
Lots of "progress" was made in the 19 years of 240 production. Some of it was actually implemented on our 240s.
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Art Benstein near Baltimore
Women and cats will do as they please, and men and dogs should relax and get used to the idea. -Robert A. Heinlein
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