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 intor 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 brake modulator/master cylinder assembly. Refer to Brake Modulator Replacement in Hydraulic Assembly.
2. Remove the Torx head screws that attach the gear cover.
3. Remove the 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 gear 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: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part number for that application. The manufacturer will call out those fasteners that require a replacement after removal. The manufacturer will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
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 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 brake modulator/master cylinder assembly. Refer to Brake Modulator Replacement in Hydraulic Assembly.
8. Perform the Motor Rehome Procedure.
9. Perform the Diagnostic System Check