Brake Modulator (ABS)

ABS Brake Modulator/Master Cylinder Assembly Components:

DISASSEMBLE
1. Remove gear cover. Refer to "Gear Cover (Antilock Brake System [ABS])".
2. Remove brake motor pack (ABS). Refer to "Brake Motor Pack (ABS)."
3. Two ABS brake modulator to master cylinder banjo bolts; separate brake modulator from master cylinder.
4. Two transfer tubes with O-rings from master cylinder or ABS brake modulator.
5. Banjo bolt O-rings from master cylinder and ABS brake modulator.

Important:
^ If ABS brake modulator is to be replaced, install the three gears in the same location on replacement brake modulator. Refer to GEAR REPLACEMENT.
^ No repair of the ABS brake modulator is authorized. Replace as an assembly.
^ Use new transfer tube assemblies when assembling the ABS brake modulator/master cylinder assembly. Make sure two O-rings are properly installed on each transfer tube.

ASSEMBLE
1. Two transfer assemblies.
- Lubricate transfer tube assembly O-rings with clean brake fluid.
- Install transfer tube assemblies in ports in ABS brake modulator and push in by hand to bottom.
2. Lubricate new banjo bolt O-ring with clean brake fluid and install into the master cylinder and ABS brake modulator.
3. ABS brake modulator to master cylinder.
- Clamp mounting flange of master cylinder in a vise.
- Hold ABS brake modulator and rock into position on master cylinder, inserting transfer tube assemblies into master cylinder ports.
4. Two ABS brake modulator to master cylinder banjo bolts.
- Tighten banjo bolts to 24 Nm (17 ft. lbs.).

Gear Position:

5. With the ABS brake modulator upside down, and the gears facing you, rotate each ABS brake modulator gear counterclockwise until movement stops. This procedure will position the pistons very close to the top of the modulator bore simplifying the brake bleeding procedure.
6. ABS brake motor pack to ABS brake modulator/master cylinder assembly.
7. Gear cover to ABS brake modulator/master cylinder assembly.