Sidekick JS 2D Soft Top 2WD L4-1.6L (1997)
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
ABS Hydraulic Modulator Gears
Do not attempt to repair defective motor packs or modulator assemblies. Modulator drive gear replacement is the only service that can be
performed on these assemblies. The modulator drive gears are under spring load and will turn during disassemble. After removing hydraulic
modulator drive gear cover, do not place fingers into the gear set.
1. Remove ABS hydraulic modulator assembly as outlined under ABS Hydraulic Modulator and Master Cylinder Assembly.
2. Remove six Torx head screws attaching gear cover.
3. Remove four motor pack to modulator assembly Torx head screws, then separate motor pack assembly from hydraulic modulator assembly. Use
care not to drop or damage motor pack assembly. If motor pack assembly is dropped or damaged during handling, it must be replaced.
4. Turn modulator gear to position piston in the center of its travel.
5. Place a screwdriver through the holes in gears into recessed hole in the modulator base. Do not allow gear to turn while removing retaining nut
.
6. Remove three modulator drive gear to modulator driveshaft retaining nuts, then the gears from modulator.
7. Reverse procedure to install, noting the following:
a. Do not allow gears to turn when tightening retaining nuts.
b. Torque retaining nuts to 75 inch lbs.
c. Rotate each modulator gear counterclockwise until movement stops, before positioning motor pack assembly onto hydraulic modulator.
d. Torque motor pack assembly to hydraulic modulator assembly Torx head screws to 40 inch lbs.
e. Torque gear cover Torx screws to 27 inch lbs.
