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Home >> Chevrolet >> 1996 >> Cavalier L4-2.2L VIN 4 >> Repair and Diagnosis >> Brakes and Traction Control >> Antilock Brakes / Traction Control Systems >> Hydraulic Control Assembly - Antilock Brakes >> Service and Repair >> Hydraulic Modulator Assembly Unit Repair >> Gear Replacement

Gear Replacement


GEAR REPLACEMENT







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 -only the following steps. These steps will break the unit down into major components for replacement purposes.


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

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

Remove or Disconnect

1. Hydraulic modulator/master cylinder assembly. Refer to "Hydraulic modulator/master cylinder Assembly" in this section.
2. Torx� head screws attaching gear cover.
3. Four motor pack to hydraulic modulator Torx� head screws.


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

ABS Brake Modulator/Master Cylinder Assembly Components:






4. Separate motor pack from hydraulic modulator.

Gear Position:





Gear Removal:







5. Three modulator drive gears from modulator drive shaft retaining nuts.
6. Gears from modulator.

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 gear (not between the gears) into the recessed hole in the modulator base. This will prevent the gear from turning, aiding in gear removal.

INSTALL OR CONNECT

Gear Removal:





Gear Position:






1. Position ABS brake modulator drive gears onto brake modulator drive shaft.
2. Install three gear retaining nuts.

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 hole 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

Tighten
^ Nuts to 8.5 Nm (76 inch lbs.).

Gear Position:






3. With the ABS hydraulic modulator 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.

ABS Brake Modulator/Master Cylinder Assembly Components:






4. Position the motor pack onto brake modulator, aligning the three motor pack gears with the modulator gears.

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

5. Four motor pack to brake modulator Torx head screws.

Tighten
^ Torx head screws 4.5 Nm (40 inch lbs.).

6. Gear cover onto brake modulator with Torx head screws.

Tighten
^ Torx head screws 4 Nm (35 inch lbs.).

7. Hydraulic modulator/master cylinder assembly.
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