Brake Modulator Gear Replacement

REMOVAL PROCEDURE





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

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. 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.

IMPORTANT: Do not repair damaged motor packs or brake modulators. Other than modulator drive gears replacement, repair of the motor pack and brake modulator assemblies is not authorized. Do not oil or lubricate the gears on the motor pack.

1. Remove the modulator/master cylinder assembly. Refer to Brake Modulator Replacement.
2. Remove the Torso head screws that attach the gear cover.
3. Remove the four motor pack to modulator Torx head screws.

IMPORTANT: Use care when handling the motor pack. Replace the motor pack if the motor pack is dropped or damaged during handling.

4. Separate the motor pack from the modulator.
5. Remove three modulator drive gears from the modulator drive shaft retaining nuts.
6. Remove the gears from the modulator.

INSTALLATION PROCEDURE





1. Position the modulator drive gears onto the modulator drive shaft.

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. 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.

NOTICE: Refer to Fastener Notice in Service Precautions.

2. Install three gear retaining nuts.
^ Tighten the nuts to 8.5 Nm (75 inch lbs).

3. With either of the modulators positioned upside down, and the gears facing your, rotate each ABS brake modulator gear counterclockwise until movement stops.

Rotating the modulator gears will cause the following conditions:

^ The pistons on the ABS brake modulator will be positioned very close to the top of the modulator bore.
^ The brake bleeding procedure is simplified.

IMPORTANT: Use care when handling the motor pack. Replace the motor pack if the motor pack is dropped or damaged during handling.

4. Position the motor pack onto the modulator, aligning the three motor pack gears with the modulator gears.
5. Install four motor pack to modulator Torx head screws.
^ Tighten the Torx head screws to 4.5 Nm (40 ft lbs).

6. Install the gear cover onto the modulator with Torx head screws.
^ Tighten the Torx head screws to 4 Nm (45 inch lbs).

7. Install the modulator-master cylinder assembly. Refer to Brake Modulator Replacement.