RE-Assembly

(1) Coat the O-rings with DOT 3 brake fluid and install them on the choke valve piston.


(2) Assemble the choke valve piston and bushing first; and then install them together into the hydraulic cylinder. Make sure to replace the gasket with a new one.


(3) Install the spring seat, choke valve spring, gasket, and the valve cap in that order into the hydraulic cylinder. Make sure to replace the gasket with a new one.



(4) After tightening the valve cap to the specified torque of 30 to 40 N-m (22-18 ft.lbs.), a clearance of 0.5 mm to 0.1 mm (0.020 in. to 0.040 in.) must remain.



(5) Coat the check valve seal with brake fluid and install it on the check valve piston with the larger inner diameter of the seal facing toward the outside. NOTE:
If the check valve seal is installed upside down, the rear brake lock-up control system will become inoperative.



RE-ASSEMBLY

(6) Install the check valve with the check valve seal end first into the hydraulic cylinder. Next, install the check valve spring. NOTE:

If the check valve is installed upside down, the rear brake lock-up control system will become inoperative.



(7) Coat the O-ring with brake fluid and install it on the bleeder cap. Install the bleeder cap and torque to 20 to 30 N-m (15-22 ft.lbs.).



(8) Coat the cup seal with brake fluid and install it with its lipped side first into the hydraulic cylinder. Next, install the back-up ring, the cup retainer (large outside diameter first) into the hydraulic cylinder. Install the snap-ring into its groove and make sure it is fully seated.



RE-ASSEMBLY


(9) Coat the dust seal with the silicone grease furnished with the kit and with your fingers push the dust seal until it snaps into place on the cup retainer. NOTE:

Do not force the outside edge of the dust seal too far into the hydraulic cylinder, since a certain amount of clearance must be provided between the dust seal and the snap ring.



(10) Install the plunger with the smaller diameter end first into the hydraulic cylinder.
(11) Install the hydraulic cylinder to the vacuum cylinder assembly.


(12) Re-connect the vacuum hose, brake lines, and electrical wiring.


(13) Bleed air from the rear brake system modulator first, and then the rear brakes.
NOTE REGARDING REPLACEMENT PARTS:

No repair or replacement parts, except those in the kit, are available for servicing the rear brake lock-up control system modulator. If a part is lost or damaged, the entire modulator must be replaced.