Disassembly

(1) Disconnect the vacuum hose, brake lines and electrical wiring from the modulator.


(2) Remove the two mounting bolts of the hydraulic cylinder and pull the hydraulic cylinder from the vacuum cylinder. Seal the hole of the vacuum cylinder to prevent dirt from entering.



(3) Pull the plunger from the hydraulic cylinder and protect the surfaces of the plunger from damage. With a pointed piece of plastic or similar tool, remove the dust seal from the bottom of the hydraulic cylinder.



(4) With the snap-ring plier tips as shown, remove the snap-ring, being careful not to damage the inner surface of the hydraulic cylinder. Then pull outthe cup retainer and back-up ring. If necessary use a long nose pliers to lightly hold the cup retainer and pull it out.



DISASSEMBLY


(5) Remove the cup seal with a brass wire with an L-shaped end.



(6) Put black painted portion of the hydraulic cylinder into a soft jaw vise and remove the bleeder cap. Remove the O-ring from the bleeder cap with a pointed piece of plastic or trim tool.



(7) Remove check valve spring, check valve piston, and check valve seal from the hydraulic cylinder. Using a shop towel and thumb, pull the check valve seal off the check valve piston.



DISASSEMBLY


(8) Re-position the hydraulic cylinder in the vise and remove the valve cap, gasket, choke valve spring, and spring seat.



(9) Hold the end of the choke valve piston with long nose pliers and pull the choke valve piston and bushing from the hydraulic cylinder. Push the choke valve piston out of the bushing with your fingers.



(10) Remove the O-rings from the choke valve with a pointed piece of plastic or trim tool.
(11) Clean all parts and inspect for wear and damage.