ABS Hydraulic Modulator

Hydraulic Modulator







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.

NOTICE: The following service procedures shall be performed only after the ABS 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 ABS hydraulic modulator-master cylinder assembly is not authorized. These steps will break the unit down into major components for replacement purposes.


Remove or Disconnect

ABS Brake Modulator/Master Cylinder Assembly Components:

1. Hydraulic modulator-master cylinder assembly. Refer to "Hydraulic modulator-master cylinder Assembly" in this section.
2. Torx head screws attaching gear cover.
3. Remove gear cover.
4. Four Torx� head screws attaching motor pack to hydraulic modulator.
5. Remove motor pack.
6. Two hydraulic modulator to master cylinder banjo bolts; separate hydraulic modulator from master cylinder.
7. Two transfer tubes with 0-rings from master cylinder or hydraulic modulator.
8. Banjo bolt 0-rings from master cylinder and hydraulic modulator.

Important

^ If ABS hydraulic modulator is to be replaced, install the three gears in the same location on replacement hydraulic modulator.
^ No repair of the ABS hydraulic modulator is authorized. Replace as an assembly.
^ Refer to Brake Master Cylinder for service and repair.
^ Use new transfer tube assemblies when assembling the ABS hydraulic modulator-master cylinder assembly. Make sure two O-rings are properly installed on each transfer tube.

ABS Brake Modulator/Master Cylinder Assembly Components:

Install or Connect

1. Two transfer assemblies.
^ Lubricate transfer tube assembly O-rings with clean brake fluid.
^ Install transfer tube assemblies in ports in ABS brake modulator and push in by hand to bottom.
2. Lubricate new banjo bolt O-ring with clean brake fluid and install into the master cylinder and ABS hydraulic modulator.
3. ABS hydraulic modulator to master cylinder.
^ Clamp mounting flange of master cylinder in a vise.
^ Hold ABS hydraulic modulator and rock into position on master cylinder, inserting transfer tube assemblies into master cylinder ports.
4. Two ABS hydraulic modulator to master cylinder banjo bolts.

Tighten

^ Banjo bolts to 24 Nm (17 ft. lbs.).

Gear Position:

5. With the ABS hydraulic modulator upside down, and the gears facing you, rotate each ABS hydraulic modulator gear counterclockwise until movement stops. This procedure will position the pistons very close to the top of the modulator bore simplifying the brake bleeding procedure.
6. ABS motor pack to ABS hydraulic modulator/master cylinder assembly.
7. Four Torx head screws.


Tighten


^ Torx� head screws to 5 N.m (44 lb.in.).

8. Gear cover to hydraulic modulator-master cylinder assembly.


Tighten


^ Torx� bolts to 4 N.m (36 lb.in.).