Brake Modulator

ABS Brake Modulator/Motor Pack Assembly Components:

DISASSEMBLE
1. Remove gear cover. Gear Cover Replacement

2. Remove motor pack. Brake Modulator/Motor Pack Assembly Replacement

3. Two hydraulic modulator to brake combo valve banjo bolts, separate hydraulic modulator from brake combo valve.
4. Two transfer tubes with O-rings from brake combo valve or hydraulic modulator.
5. Banjo bolt O-rings from brake combo valve and hydraulic modulator. If hydraulic modulator is to be replaced, install the three gears in the same location on replacement hydraulic modulator. Refer to Gear Replacement. No repair of the hydraulic modulator is authorized. Replace as an assembly. Use new transfer tube assemblies when assembling the hydraulic modulator/brake combo valve assembly. Make sure two O-rings are properly installed on each transfer tube.

ASSEMBLE
1. Two transfer assemblies. Lubricate transfer tube assembly O-rings with clean brake fluid. Install transfer tube assemblies in ports in hydraulic modulator and push in by hand to bottom.
2. Lubricate new banjo bolt O-ring with clean brake fluid and install into the brake combo valve and hydraulic modulator.
3. Hydraulic modulator to brake combo valve. Hold brake combo valve and rock into position on hydraulic modulator inserting transfer tube assemblies into brake combo valve ports.
4. Two hydraulic modulator to brake combo valve banjo bolts. Tighten Banjo bolts to 16 Nm (12 ft. lbs.)
5. 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 their home position of the modulator bore simplifying the brake bleeding procedure.
6. Motor pack to hydraulic modulator. Brake Modulator/Motor Pack Assembly Replacement

7. Gear cover to hydraulic modulator/motor pack assembly. Gear Cover Replacement