Motor Pack

CAUTION: To help avoid personal injury, due to a retained load on the ABS hydraulic modulator, the gear tension relief function of the Tech 1 must be performed prior to removal of the ABS hydraulic modulator/master cylinder assembly. Refer to "Gear Tension Relief Sequence".

NOTICE: The following service procedures shall be performed only after the hydraulic modulator/master cylinder assembly has been removed from the vehicle. Do not perform these procedures with the unit installed on the vehicle. Complete overhaul of the hydraulic modulator/master cylinder assembly is not authorized only the following steps. These steps will break the unit down into major components for replacement purposes.

MOTOR PACK

Hydraulic Modulator/Master Cylinder Assembly:

DISASSEMBLE
1. Remove gear cover.
2. Four Torx head screws attaching motor pack.

IMPORTANT: Use care when handling motor pack to ensure motor pack connector is not damaged, or accidental intrusion of brake fluid into the motor pack does not occur. This may result in a premature failure of the motor pack. Take care in handling the motor pack. If dropped or damaged during handling, the motor pack must be replaced.

3. Remove motor pack.

IMPORTANT:
^ If disassembly of the hydraulic modulator/master cylinder assembly was due to a ABS hydraulic functional test that did not pass, the "Automated Motor Pack Diagnosis Test" should he performed at this time to isolate the motor pack or hydraulic modulator.
^ No repair of the motor pack is authorized. Replace as an assembly.

ASSEMBLE

Gear Positioning:

1. With the hydraulic modulator upside down, and the gears facing you, rotate each hydraulic modulator gear counterclockwise until movement stops. This procedure will position the pistons very close to the top of the hydraulic modulator bore .
2. Motor pack to hydraulic modulator/master cylinder assembly.

IMPORTANT:
^ Take care in handling the motor pack. If dropped or damaged during handling the motor pack must be replaced.
^ Align each of the three motor pack pinions with the hydraulic modulator gears.

3. Four Torx head screws.

TIGHTEN
^ Torx head screws to 5 Nm (44 lb. in.).

4. Gear cover to hydraulic modulator/master cylinder assembly.