ABS Hydraulic Modulator and Master Cylinder Assembly Components

ABS HYDRAULIC MODULATOR AND MASTER CYLINDER ASSEMBLY COMPONENTS

CAUTION: To help avoid personal injury, due to a retained load on the ABS hydraulic modulator, the gear tension relief function of the Tech 1 must be performed prior to removal of the ABS hydraulic modulator/master cylinder assembly. Refer to "Gear Tension Relief Sequence".

ABS Hydraulic Modulator And Master Cylinder Assembly Components:

DISASSEMBLE
1. Six Torx head screws attaching gear cover.
2. Gear cover.
3. Four Torx head screws attaching motor pack assembly.

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

4. Remove motor pack assembly.

IMPORTANT
^ If disassembly of the ABS hydraulic modulator and master cylinder assembly was due to a ABS hydraulic functional test that did not pass, the automated motor pack diagnosis test should be performed at this time to isolate the motor pack or ABS hydraulic modulator.

5. Two modulator assembly to master cylinder thru-bolts and separate modulator assembly from master cylinder.
6. Two transfer tubes with 0-rings from master cylinder or modulator assembly.
7. Thru-bolt 0-rings from master cylinder and modulator assemblies.

IMPORTANT
^ If ABS hydraulic modulator is to be replaced, install three gears in same location on replacement hydraulic modulator. Refer to gear replacement in this section.

IMPORTANT
^ No repair of the motor pack assembly or ABS hydraulic modulator assembly is authorized. Replace as assemblies.
^ Refer to Brakes and Traction Control / Brakes / Antilock Brake System / Master Cylinder, ABS / Service and Repair for repair of master cylinder.Service and Repair
^ Use new transfer tube assemblies when assembling the ABS hydraulic modulator and master cylinder assembly.
^ Make sure two 0-rings are properly installed on each transfer tube assembly.

ASSEMBLE
1. Two transfer tube assemblies.
^ Lubricate transfer assembly 0-rings with clean brake fluid.
^ Install transfer tube assemblies in ports in ABS hydraulic modulator and push in by hand to bottom.
2. Lubricate new thru-bolt 0-rings with clean brake fluid and install into the master cylinder and modulator.
3. ABS hydraulic modulator to master cylinder.
^ Clamp mounting flange of master cylinder in vise.
^ Hold ABS hydraulic modulator and rock into position on master cylinder, inserting transfer tube assemblies into master cylinder ports.

4. Two modulator to master cylinder thru-bolts.

TIGHTEN
^ Bolts to 16 Nm (12 lb. ft.).

NOTICE: With the modulator upside down and the gears facing you, rotate each gear on the ABS hydraulic modulator counterclockwise until movement stops. This will position the pistons very close to the top of their travel, simplifying bleeding procedures.

5. Motor pack assembly to ABS hydraulic modulator and master cylinder assembly.

IMPORTANT
^ Take care in handling the motor pack assembly. If dropped or damaged during handling, the motor pack assembly must be replaced.
^ Align each of three motor pack pinions with ABS hydraulic modulator gears.

6. Four Torx head screws.

TIGHTEN
^ Torx head screws to 5 Nm (40 lb. in.).

7. Gear cover to ABS hydraulic modulator and master cylinder assembly.
8. Six Torx head screws.

TIGHTEN
^ Torx bolts to 3 Nm (27 lb. in.).