Brake Modulator Replacement

REMOVAL PROCEDURE
1. Remove the brake modulator assembly.





2. Remove the four Toe head screws (1) that retain both ABS brake solenoids from the hydraulic modulator assembly (4).
3. Remove both brake solenoids (2) from the hydraulic modulator assembly (4).





4. Remove the Torx(R) head screws (5) attaching the gear cover (4).
5. Remove the gear cover (4).
6. Remove the four Torx(R) head screws (6) attaching the motor pack (1) to the hydraulic brake modulator (2).

IMPORTANT:
^ Use care when handling the motor pack to ensure the motor pack connector is not damaged, or accidental intrusion of brake fluid into the motor pack does not occur. This may result in a premature failure of the motor pack.
^ Take care in handling the motor pack. If dropped or damaged during handling, the motor pack must be replaced.

7. Remove the motor pack (1) from the hydraulic brake modulator (2).

INSTALLATION PROCEDURE





1. With the ABS brake modulator positioned upside down, and the gears facing you, rotate each ABS brake modulator gear clockwise until movement stops.
The procedure causes the following conditions:
^ The pistons are positioned very close to the top of the modulator bore.
^ The brake bleeding procedure is simplified.





2. Install the ABS brake motor pack (1) onto the hydraulic brake modulator (2). Aligning the three motor pack gears with the modulator gears.

NOTICE: Refer to Fastener Notice in Service Precautions.

3. Install the four Torx(R) head screws (6) that retain the motor pack (1) to the hydraulic brake modulator (2).
^ Tighten the four Torx(R) head screws to 5 Nm (44 inch lbs.).

4. Install the gear cover (4) to the hydraulic brake modulator/motor pack assembly (2).
5. Install the Torx(R) head screws (5) that retain the gear cover (4).
^ Tighten the Torx(R) head screws to 4 Nm (36 inch lbs.).





6. Install the ABS brake solenoids (2) to the hydraulic brake modulator/motor pack assembly.
^ Lubricate the solenoid seals (3) with clean brake fluid.
^ Verify that the solenoid seal (3) is properly positioned to each solenoid.
^ Position solenoids so that their electrical connectors will face the same direction prior to removal.
^ By hand, press down firmly on the solenoids until their flanges seat onto the hydraulic modulator.

7. Install the four Torx(R) head bolts (1) that retain the brake solenoids.
^ Tighten the Torx(R) head screws to 5 Nm (44 inch lbs.).

8. Install the brake modulator assembly.
9. Perform the ABS Diagnostic System Check