1. Remove the gear cover (3). Refer to Modulator Gear Cover Replacement .
2. Remove the brake motor pack (ABS) (1). Refer to ABS Motor Pack Replacement .
3. Remove two ABS brake modulator to master cylinder banjo bolts (2).
4. Separate the brake modulator (6) from the master cylinder (8).
5. Remove two transfer tubes (7) with O-rings from the master cylinder (8) or the ABS brake modulator (6).
6. Remove banjo bolt O-rings from the master cylinder (8) and the ABS brake modulator (6).

Important: When replacing the ABS brake modulator, install the three gears in the same location on the replacement brake modulator. Refer to ABS Motor Pack Replacement .

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 (7) into ports of the ABS brake modulator (6).

Push the tube assemblies in by hand to the bottom of the ports.

Important: Refer to Master Cylinder Overhaul in Hydraulic Brakes for repair of the master cylinder.

2. Lubricate the new banjo bolt O-ring with clean brake fluid.
3. Install the banjo bolt O-ring into the master cylinder (8) and the ABS brake modulator (6).
4. Use the following procedure in order to install the ABS brake modulator (6) onto the master cylinder (8):

4.1.	Clamp the mounting flange of the master cylinder in a vise.

4.2.	Insert the transfer tube assemblies (7) into the master cylinder ports.

4.3.	Hold the ABS brake modulator and rock the modulator into position on the master cylinder.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install two ABS brake modulator to master cylinder banjo bolts (2).

Tighten
Tighten the banjo bolts to 24 N·m (17 lb ft).

6. With the ABS brake modulator positioned upside down, and the gears facing you, rotate each ABS brake modulator gear clockwise 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 ABS brake modulator/master cylinder assembly.
8. Install the gear cover (3) to the ABS brake modulator/master cylinder assembly. Refer to Modulator Gear Cover Replacement .
9. Bleed the system. Refer to Hydraulic Brake System Bleeding in Hydraulic Brakes.