My Copen also failed it's MOT on the wheel bearing. I had a new one put in as it was making a grinding noise. BUT the new one has now started making the same grinding noise and my ABS light came on. I collared my mechanic about it and he say the sesor was knackered as he had to take it out of the hub to get the bearing out. Anyway I've ended up ordering a second hand hub with bearing and sensor in it as Daihatsu want £180 for the sensor alone!! But why would my wheel start grinding again and they fail it on the bearing when its a brand new one!!
How long ago did you get the bearing changed & is it the same mechanic your using? Did they use genuine Daihatsu parts?
Just been reading up. If you look at section E3-4 of the service manual. You can see the diagram on how to remove the ABS sensor. The sensor was probably damaged when it was removed & re-fitted the last time the bearing was changed. Section D2-3 to D2-5 shows the wheel bearing. I'd guess they didn't use a genuine part & had some cheap bearing that has failed early. I would've thought parts should have some sort of warranty on them. As your swaping out the entire hub you won't get anywhere with a claim. Sounds like a plan to use the second hand hub assembly. See if you can get the CV joint too. Try a different mechanic. Check out the good garage scheme to find a trusted mechanic in your area. http://www.goodgaragescheme.co.uk/
