Gear Replacement

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".

NOTICE: The following service procedures shall be performed only after the hydraulic modulator/master cylinder assembly has been removed from the vehicle. Do not perform these procedures with the unit installed on the vehicle. Complete overhaul of the hydraulic modulator/master cylinder assembly is not authorized only the following steps. These steps will break the unit down into major components for replacement purposes.

GEAR REPLACEMENT

IMPORTANT: Do not attempt to repair damaged motor packs or hydraulic modulators. Other than modulator drive gear replacement, repair of these assemblies is not authorized. Do not lubricate or oil gears or motor pack.

CAUTION: The modulator drive gears are under spring load and will turn during disassembly. After removing hydraulic modulator drive gear cover, exercise extreme care not to place fingers into the gear set, since fingers can be pinched by rotating gears.

DISASSEMBLE
1. Hydraulic modulator/master cylinder assembly.
2. Torx head screws attaching gear cover.
3. Four motor pack to hydraulic modulator Torx head screws.

IMPORTANT: Take care in handling the motor pack. If dropped or damaged in the handling, the motor pack must be replaced.

4. Separate motor pack from hydraulic modulator.
5. Three modulator drive gear to modulator drive shaft retaining nuts.

Gear Removal:

6. Gears from modulator.

NOTICE: Do not allow gear to turn while removing the retaining nut, since the modulator piston can hit the top of the modulator bore, damaging the piston. Turn the modulator gear to position the piston in the center of its travel. Place a screwdriver through the holes in the gears (not between the gears) into the recessed hole in the modulator base. This will prevent the gear from turning, aiding in gear removal.

ASSEMBLE

NOTICE:
^ Do not allow gear to turn while tightening the retaining nut, since the modulator piston can bottom out in the modulator bore damaging the piston.

Gear Removal:

^ Turn the modulator gear to position the piston in the center of its travel. Place a screwdriver through the holes in the gears (not between the gears) into the recessed hole in the modulator base. This will prevent the gear from turning, aiding in gear installation.

1. Position hydraulic modulator drive gears onto hydraulic modulator drive shaft.
2. Three gear retaining nuts.

TIGHTEN
^ Nuts to 8.5 Nm (76 lb. in.).

Gear Positioning:

3. 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 the top of the hydraulic modulator bore, simplifying the brake bleeding procedure.
4. Position motor pack onto hydraulic modulator, aligning the three motor pack gears with the modulator gears.

IMPORTANT: Take care in handling the motor pack. If dropped or damaged during handling, the motor pack must be replaced.

5. Four motor pack to hydraulic modulator Torx head screws.

TIGHTEN
^ Torx head screws 5 Nm (44 lb. in.).

6. Gear cover onto hydraulic modulator with Torx head screws.

TIGHTEN
^ Torx head screws to 4 Nm (36 lb. in.).

7. Hydraulic modulator/master cylinder assembly.