Brake Modulator Replacement

REMOVAL PROCEDURE
1. Remove the brake modulator/master cylinder assembly. Refer to Brake Modulator/Master Cylinder Asm Replacement.
2. Remove the Torx head screws (5) attaching the gear cover (4).
3. Remove the gear cover (4).
4. Remove the four Torx head screws (6) attaching the motor pack (1) to the brake modulator (2).
5. Remove the motor pack (1) from the brake modulator (2).
6. Remove the two brake modulator to master cylinder banjo bolts, separate the brake modulator from the master cylinder.
7. Remove the two transfer tubes with the O-rings from the master cylinder or the brake modulator.
8. Remove the banjo bolt O-rings from the master cylinder and the brake modulator.






INSTALLATION PROCEDURE

IMPORTANT: When replacing the ABS brake modulator, install the three gears in the same location on the replacement brake modulator. Refer to Brake Modulator Gear Replacement in Hydraulic Assembly.

No repair of the ABS brake modulator is authorized. Replace the ABS brake modulator as an assembly.

IMPORTANT: Use new transfer tube assemblies when assembling the ABS brake modulator/master cylinder assembly. Be sure to properly install two O-rings on each transfer tube.

1. Use the following procedure in order to install the two transfer assemblies:
1.1. Lubricate the transfer tube assembly O-rings with clean brake fluid.
1.2. Install the transfer tube assemblies into ports of the ABS brake modulator.
Push the tube assemblies in by hand to the bottom of the ports.
2. Lubricate the new banjo bolt 0-ring with clean brake fluid.
3. Install the banjo bolt 0-ring into the master cylinder and the ABS brake modulator.
4. Use the following procedure in order to install the ABS brake modulator onto the master cylinder:
4.1. Clamp the mounting flange of the master cylinder in a vise.
4.2. Hold the ABS brake modulator and rock the modulator into position on the master cylinder.
4.3. Insert the transfer tube assemblies into the master cylinder ports.
5. Install two ABS brake modulator to master cylinder banjo bolts.

Tighten
Tighten the banjo bolts to 24 Nm (18 ft. lbs.).

6. With the ABS brake modulator positioned upside down, and the gears facing you, rotate each ABS brake modulator gear counterclockwise until movement stops.
The procedure causes the following conditions:
^ The pistons are positioned very close to the top of the modulator bore.
^ The brake bleeding procedure is simplified.
7. Install the ABS brake motor pack (1) onto the brake modulator/master cylinder assembly (2).
8. Install the four Torx head screws (6) that retain the motor pack (1) to the brake modulator (2).

Tighten
Tighten the four Torx head screws to 5 Nm (44 inch lbs.).

9. Install the gear cover (4) to the brake modulator/master cylinder assembly (2).
10. Install the Torx head screws (5) that retain the gear cover (4).

Tighten
Tighten the Torx head screws to 4 Nm (36 inch lbs.).

11. Install the brake modulator/master cylinder assembly. Refer to Brake Modulator/Master Cylinder Asm Replacement
12. Perform the Diagnostic System Check