Service manual

TC Series Hydraulic Brake ABS System
030.1-8
8. Replace tire and drum if required. Remove
safety stands, lower the vehicle, and remove the
chocks from front tires.
9. Perform a voltage output check to ensure proper
installation, refer to Sensor Output Voltage Test
in troubleshooting section.
Modulator Assembly
Modulator Assembly Removal
BRAKE FLUID IS FLAMMABLE AND
TOXIC TO SKIN, EYES AND
RESPIRATORY TRACT. SKIN AND EYE
PROTECTION IS REQUIRED. AVOID
REPEATED OR PROLONGED CONTACT.
DRAIN FLUID IN A WELL-VENTILATED
AREA.
1. Apply the parking brakes. Chock the front and
rear tires to prevent vehicle movement.
2. Place a container under the modulator assembly
to catch brake fluid.
3. Disconnect the electrical harness connector from
the modulator assembly.
4. Mark the six brake lines for ease of installation.
5. Disconnect the lines from the modulator
assembly.
Whenever any hydraulic system fitting is
loosened or disconnected, the entire system
must be bled to remove any air.
6. Remove three (3) mounting capscrews, washers,
and nuts that attach the modulator assembly and
bracket assembly to vehicle.
Modulator Assembly Installation
1. Position the modulator assembly and bracket in
place on the vehicle, see Figure 2.2—Modulator
Position.
Figure 2.2—Modulator Position
2. Torque three (3) mounting nuts to 132 inch-
pounds.
3. Connect and torque two (2) small brake line
adapters to 108 inch-pounds.
4. Connect and torque four (40) large brake line
adapters to 132 inch-pounds.
FAILURE TO BLEED THE SYSTEM
WHENEVER ANY HYDRAULIC SYSTEM
FITTING IS LOOSENED OR
DISCONNECTED WILL ALLOW AIR TO
REMAIN IN THE BRAKE SYSTEM. THIS
WILL CAUSE THE STOPPING
DISTANCE TO INCREASE AND CAN
RESULT IN SERIOUS INJURY.
PROPERLY DISCARD HYDRAULIC
FLUID THAT IS REMOVED FROM THE
BRAKE SYSTEM. HYDRAULIC FLUID
THAT IS COMTAMINATED CAN CAUSE
DAMAGE, LOSS OF BRAKING AND
SERIOUS INJURY.
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