Gear Replacement

CAUTION: Do not attempt to repair damaged motor packs or hydraulic modulators. Other than modulator drive gear replacement, repair of these assemblies is not authorized. Do not lubricate or oil gears on motor pack.

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

DISASSEMBLE OR REMOVE
1. Hydraulic modulator.
2. TORX (R) head screws attaching gear cover.
3. Motor pack to hydraulic modulator TORX (R) head screws. Take care in handling the motor pack. If dropped or damaged in the handling, the motor pack must be replaced.
4. Separate motor pack from hydraulic modulator.
5. Three ABS modulator drive gears to modulator drive shaft retaining nuts.

Gear Removal (Typical):

Gear Positioning (Typical):

6. Gears from modulator.

CAUTION: 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. Turn the modulator gear to position the piston in the center of its travel. 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. Do not allow gear to turn while tightening the retaining nut, since the modulator piston can bottom out in the modulator bore damaging the piston. Turn the modulator gear to position the piston in the center of its travel. 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 installation.

ASSEMBLE OR INSTALL
1. Position hydraulic modulator drive gears onto hydraulic modulator drive shaft.
2. Three ABS gear retaining nuts. Tighten nuts to 8.5 Nm (75 inch lbs.).
3. With the hydraulic modulator upside down, and the gears facing you, rotate each hydraulic modulator gear counterclockwise until movement stops. This procedure will position the pistons very close to their home position of the hydraulic modulator bore, simplifying the brake bleeding procedure.
4. Position motor pack onto hydraulic modulator, aligning the three ABS motor pack gears with the modulator gears. Take care in handling the motor pack. If dropped or damaged during handling, the motor pack must be replaced.
5. Motor pack to hydraulic modulator TORX (R) head screws. Tighten TORX (R) head screws 4.5 Nm (40 inch lbs.).
6. Gear cover onto hydraulic modulator with TORX (R) head screws. Tighten TORX (R) head screws to 4 Nm (35 inch lbs.).
7. Hydraulic modulator.

NOTE: Bleeding is not part of the gear replacement procedure but it should be performed after installation of the hydraulic modulator. Service and Repair