Brake Control Assembly

WARNING: Do not drive or operate the vehicle with the ABS brake control assembly in the tension released position. Excessive brake pedal travel and reduced brake effectiveness could occur with the tension released. Always perform special test run ABS motors, pistons up-home, before driving the vehicle.

NOTE: The antilock brake control module drive gears are under spring tension and will turn during disassembly if not unloaded. To remove tension, use the PDT or equivalent to perform special test, RUN ABS MOTOR, PISTONS DOWN-REL, before removing brake control assembly.





REMOVAL
1. Remove air induction system.





2. Disconnect negative battery cable from battery.
3. Disconnect positive battery cable from battery.
4. Remove hold-down retaining nut and screw, and lift off battery hold-down retainer.
5. Lift the battery off vehicle, and place in a safe location.
6. Disconnect two electrical connectors from solenoid valves.
7. Disconnect brake fluid level sensor electrical connector from master cylinder reservoir.
8. Remove Connector Position Assurance (CPA) retainer from six-way motor pack electrical connector.
9. Disconnect six-way electrical connector from motor pack.

CAUTION: Place a shop cloth on top of the motor pack assembly to catch any dripping brake fluid.

Fig. 63 Removing Anti-lock Brake Control & Master Cylinder Assembly:

10. Disconnect brake line fitting nuts from modulator.

CAUTION:
^ After removing brake line fitting nuts, do not excessively pull or bend brake lines away from brake control assembly.
^ Plug open lines and fittings to prevent brake fluid loss and contamination.





11. Remove two brake control assembly-to-brake booster attachment nuts.
12. Remove brake control assembly.

CAUTION: Be careful not to excessively bend brake lines.





INSTALLATION
1. Position brake control assembly onto brake booster studs and install fastening nuts.
^ Torque: 27 Nm (20 ft.lbs.)

CAUTION: Be careful not to bend brake lines.

Fig. 63 Removing Anti-lock Brake Control & Master Cylinder Assembly:

2. Position brake lines into the brake control assembly and secure brake line fitting nuts.





^ Torque to 32 Nm (24 ft. lbs.)

3. Install the six-pin electrical connector onto motor pack assembly.
4. Check to be sure that connector is fully seated and install CPA retainer.
5. Install electrical connector onto brake fluid level sensor switch.
6. Install two electrical connectors onto solenoid valves.

NOTE: Check to be sure that all electrical connectors are fully seated and latches are engaged.





7. Make sure battery tray is clean.
8. Make sure that the battery cable ends are clean and free of corrosion. (Clean with a wire brush.)
9. Make sure that the battery is in good physical condition (e.g., no cracks, or obvious damage) and that the terminals are clean.
10. Install battery carefully in the battery tray; make sure that the terminals do not short against any metal during the installation.
11. Install the battery hold-down retainer, locking the battery into the tray. Install and tighten the hold-down retainer nut and screw.
^ Torque to 9 Nm (80 inch lbs.)
12. Install the positive battery cable first.
^ Torque 17 Nm (151 inch lbs.)
13. Install the negative battery cable last.
^ Torque to 17 Nm (151 inch lbs.)





14. Install air induction system.
15. Fill brake fluid reservoir with clean brake fluid up to the base of the reservoir filler neck.
16. Bleed brake system. Service and Repair
17. Check brake fluid level.