TCS Motor Pack Replacement

Removal Procedure

Important: Use care when handling the motor pack. Replace the motor pack if the motor pack are dropped or damages during handling. No repair of the motor pack is authorized. Replace as an assembly.





1. Remove the 4-way motor pack electrical connector (3) from TCS modulator (2).
1.1. Use the following procedure in order to remove all four brake pipes (1):

Important: Use care when handling the motor pack to avoid damaging the motor pack connector. Make sure brake fluid does not accidentally intrude into the motor pack. Brake fluid in the motor pack may cause a premature failure of the motor pack.

1.2. Place a shop cloth on top of the TCS motor pack in order to catch any dripping fluid.
1.3. Plug the open brake pipes in order to prevent fluid loss and contamination.
2. Remove the bolt (4) attaching the front of the TCS hydraulic modulator/motor pack assembly (2) to the mounting bracket.
3. Lean the TCS modulator assembly (2) forward then remove from vehicle.
4. Remove the three Torx (R) head screws that attach gear cover to TCS hydraulic modulator.
5. Remove gear cover.
6. Remove the two Torx (R) head screws that attach the motor pack (1) to TCS modulator.
7. Remove the motor pack assembly (1).

Installation Procedure
1. With TCS modulator positioned upside down rotate each TCS modulator gear clockwise until movement stops.





2. The above procedure will cause the following conditions:
^ The pistons on the TCS modulator will be positioned very close to the bottom of the modulator bore.
^ The brake bleeding procedure becomes simplified.

3. Install the motor pack assembly to TCS modulator.

NOTICE: Refer to Fastener Notice in Service Precautions.

Important: Use care when handling the motor pack. Replace the motor pack if the motor pack are dropped or damages during handling.

4. Install the two Torx (R) head screws that attach the motor pack (1).
^ Tighten the Torx (R) head screws to 4.5 Nm (40 inch lbs.).
5. Install gear cover onto the TCS hydraulic modulator.
6. Install the three Torx (R) screws.
^ Tighten the Torx (R) head screws to 4 Nm (35 inch lbs.).





7. Install the TCS hydraulic modulator/motor assembly (2) to the mounting bracket.
8. Install the bolt (4) attaching the TCS assembly (2) to the mounting bracket.
^ Tighten the bolt to 9 Nm (80 inch lbs.).
9. Install the four brake pipes (1) to the TCS modulator assembly (2).
^ Tighten all four brake tube nuts to 24 Nm (18 ft. lbs.).
10. Connect the TCS motor pack 4-way electrical connector (3).
11. Bleed the system.