Disassembly

IMPORTANT: Do not attempt to repair damaged motor packs or modulator assemblies. Other than modulator drive gear replacement, repair of these assemblies is not authorized. Do not lubricate or oil motor pack assembly.

CAUTION: THE MODULATOR DRIVE GEARS ARE UNDER SPRING LOAD AND WILL TURN DURING DISASSEMBLY. AFTER REMOVING MODULATOR DRIVE GEAR COVER, EXERCISE EXTREME CARE NOT TO PLACE FINGERS INTO THE GEAR SET, SINCE FINGERS CAN BE PINCHED BY ROTATING GEARS.





1. Remove two-gear cover-to-modulator TORT head screws and separate gear cover from modulator.

IMPORTANT:
^ If only the motor pack is being replaced, perform step 3 of this disassembly procedure then perform steps 6 through 9 of the assembly procedures. If removing the master cylinder, perform steps 3 through 6 of this disassembly procedure then perform steps 1 through 5 and 8 and 9 of the assembly procedures.
^ If the modulator is the only unit being replaced, mark the modulator drive gears before removal so that they can be installed onto new modulator in the same location.





2. Remove three modulator drive gear-to-modulator drive shaft retaining nuts and remove gears from modulator.

NOTICE: Do not allow gear to turn while removing retaining nut, since the modulator piston can hit the top of the modulator bore, damaging the piston. 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.





3. Remove two motor pack-to-modulator TORT head screws and separate motor pack from modulator.
4. Remove two modulator-to-master cylinder through-bolts and separate modulator from master cylinder.
5. Remove two transfer tubes with O-rings from master cylinder or modulator.
6. Remove through-bolt O-rings from master cylinder and modulator.

IMPORTANT: For repair of brake master cylinder, refer to "Base Brake Master Cylinder".