Hydraulic Modulator Assembly Removal and Instalation

Master Cylinder-Modulator Assembly

WARNING: To avoid personal injury, due to a retained load on the modulator assembly, the "Gear Tension Relief" function of the TECH 1 scan tool must be performed prior to removal of the brake control and motor assembly.

Remove or Disconnect

ABS Hydraulic Modulator Assembly Removal:

1. Battery.
2. Air box.
3. Using Tech 1, perform "Gear Tension Relief Sequence".

Fluid Level Sensor:

4. Electrical connector from fluid level switch (1).
5. Electrical connectors from both solenoids.
6. 3-pin and 6-pin motor pack electrical connectors.

Brake Pipe Connections:

ABS Hydraulic Modulator Assembly Removal:

7. Brake pipe tube nuts from master cylinder and modulator assembly.
^ Plug open brake pipes to prevent brake fluid loss and contamination.
8. Master cylinder mounting nuts (5).
9. Master cylinder and modulator assembly (6).

Install or Connect

ABS Hydraulic Modulator Assembly Removal:

1. Master cylinder and modulator assembly (6) to power booster assembly.
Tighten
^ Master cylinder and modulator assembly mounting nuts (5) to 27 N.m. (20 lbs.ft.).

ABS Hydraulic Modulator Assembly Removal:

2. Brake pipes tube nuts (4) to master cylinder and modulator assembly (6).
Tighten
^ Brake pipe tube nuts to 23 N.m. (17 lbs. ft.).

ABS Hydraulic Modulator Assembly Removal:

3. Electrical connector to fluid level switch (2).

ABS Hydraulic Modulator Assembly Removal:

4. Electrical connectors from both solenoids (1).
5. 3-pin and 6-pin motor pack electrical connectors (3).
For more information refer to CAUTIONS and NOTICES pertaining to these systems.
6. Fill master cylinder to proper level with clean brake fluid.
7. Bleed hydraulic system.
8. Battery.
9. Air box.