Gear Replacement (ABS)

CAUTION: The modulator drive gears are under spring load and will turn during disassembly. After removing brake modulator drive gear cover, exercise extreme care not to place fingers into the gear set, since fingers can be pinched by rotating gears.

NOTICE: Do not allow gear to turn while removing the retaining nut, since the modulator piston can hit the top of the modulator bore, damaging the piston. Place a screwdriver through the holes in the gears (not between the gears) into the recessed hole in the modulator base. This will prevent the gear from turning, aiding in gear removal.

Important: Do not attempt to repair damaged motor packs or brake modulators. Other than modulator drive gears replacement, repair of these assemblies is not authorized. Do not lubricate or oil gears on motor pack.

REMOVE OR DISCONNECT
1. Antilock Brake System (ABS) brake modulator/master cylinder assembly. Refer to ABS BRAKE MODULATOR or MASTER CYLINDER. Brake Modulator (ABS)/Master Cylinder Assembly
2. Torx(R) head screws attaching gear cover.
3. Four ABS brake motor pack to ABS brake modulator Torx(R) head screws.

Important: Take care in handling the motor pack. If dropped or damaged in the handling, the motor pack must be replaced.

4. Separate motor pack from brake modulator.
5. Three modulator drive gears from modulator drive shaft retaining nuts.

Gear Removal:

6. Gears from modulator.

Gear Position:

NOTICE: Do not allow gear to turn while tightening the retaining nut, since the modulator piston can bottom out in the modulator bore damaging the piston. Turn the modulator gear to position the piston in the center of its travel. Place a screwdriver through the holes in the gears (not between the gears) into the recessed hole in the modulator base. This will prevent the gear from turning, aiding in gear installation.

INSTALL OR CONNECT
1. Position ABS brake modulator drive gears onto brake modulator drive shaft.
2. Install three gear retaining nuts.
- Tighten nuts to 8.5 Nm (76 inch lbs.).
3. With either of the brake modulators upside down, and the gears facing you, rotate each ABS brake modulator gear counterclockwise until movement stops. This procedure will position the pistons on the ABS brake modulator very close to the top of the modulator bore. This will simplify the brake bleeding procedure.
4. Position the motor pack onto brake modulator, aligning the three motor pack gears with the modulator gears.

Important: Take care in handling the motor pack. If dropped or damaged during handling, the motor pack must be replaced.

5. Four motor pack to brake modulator Torx(R) head screws.
- Tighten Torx(R) head screws 4.5 Nm (40 inch lbs.).
6. Gear cover onto brake modulator with Torx(R) head screws.
- Tighten Torx(R) head screws to 4 Nm (35 inch lbs.).
7. Brake Modulator (ABS) and Master Cylinder assembly. Refer to BRAKE MODULATOR (ABS) and MASTER CYLINDER. Brake Modulator (ABS)/Master Cylinder Assembly