I have answers! What I suspected was right and the shop mechanic over the phone was defensive though said to bring the car in tomorrow. He said their job was just to press the bearing and that was it, even though it’s like 2mm off causing ABS to not work and the axle nut to not thread in by several more millimeters that it should.
By going through a specific series of steps with the ABS diagnostic connector under the steering wheel and two pins hidden in electrical tape, decoding flashes of the ABS light on the dash I obtained 3 ABS error codes. That was thanks to internet forums and photos within them. By searching online with one of the names of one of the codes in quotes I discovered an official looking “diagnostic chart”.
I already found out about testing the ABS sensor connector with a multi-meter which I did and found it to be at 0.99k Ohms which is within the range of “0.8 and 1.2kΩ” specified on the diagnostic chart. So the sensor appears to be fine. They’re also clearly durable and made to be exposed to the elements.
Another diagnostic test is the gap between the end of the ABS sensor and the face the the ABS tone ring. The diagnostic chart says it should be within “0.9 — 1.4 mm” apart.
After searching online at Walmart, Home Depot, Lowes (for current in-store availability) and in person at Lowes I could not find a feeler gauge which is used to measure small gaps.Eventually I looked on Autozones website and found a “mini” one for only $2.99. Now I see that it is more of if not an automotive specific tool.
After removing the wheel, the brake assembly and the rotor, I had access to the end of the ABS sensor and the tone ring. I put in two about 0.88mm feeler gauges and there was still more space. So that’s over 1.6mm apart which the specs. say there should be a maximum of 1.4 mm in space. This offset also explains why the axle nut sticks off the end of the shaft by about 2-3mm when torqued to 130 ft. lbs.
So it’s clear that the bearing/hub b press is off by several milimiters in one or more areas causing the ABS sensor gap to exceed specs. and the axle nut not being able to go on all the way.
Whether the auto shop will make the adjustment at no additional cost is to be seen. They do have the word “Honest” in auto shops name, which is a franchise.
Like I said the attitude of the mechanic guy on the phone was we did what we were supposed to do which was press a bearing and we have no more responsibility for anything. He even used an example of buying chicken from somewhere not liking the taste, which is ludicrous because it’s not about me not liking it it’s about functionality and being able to use it the way it should, which is with ABS and the axle nut going as far in as it should to indent it for safety.
If they do not want to do the adjustment to the steering knuckle assembly, I will find a place that will and may take the auto shop to small claims court to recover my costs.