Page 321 of 2438

(4) If equipped, remove the 2 bolts (Fig. 4) attaching
speed control vacuum reservoir to battery tray. Then
remove vacuum reservoir (Fig. 4) from the battery tray.
Vacuum lines (Fig. 4) do not need to be removed
from vacuum reservoir. (5) Remove the 4 bolts attaching battery tray (Fig.
5) to frame rail and fender shield of the vehicle.
Then remove battery tray.
(6) Remove battery acid shield, (Fig. 6) from the
ABS modulator assembly.
(7) Remove the 6 tube nuts (Fig. 7), attaching hy-
draulic brake line tube bundle to modulator assem-
bly, thread savers and proportioning valves. Then
remove the 6 hydraulic brake lines as an assembly,
from the modulator assembly. (8) Remove electrical connector from the brake
pressure differential warning switch on hydraulic
junction block (Fig. 8). (9) Remove the primary and secondary hydraulic
brake tubes (Fig. 9) going from the master cylinder
to the junction block, from both master cylinder and
junction block. (10) Remove the brake hydraulic tube going to the
vehicle's left front wheel from the junction block. (11) Remove the 6 hydraulic brake tubes at the hy-
draulic junction block, coming from the antilock mod-
ulator assembly.
Fig. 5 Battery Tray And Attaching Bolts
Fig. 6 ABS Modulator Assembly Acid Shield
Fig. 2 Battery Heat Shield And Hold Down Clamp
Fig. 3 Battery Tray Shield
Fig. 4 Speed Control System Vacuum Reservoir
Ä ANTILOCK 4 BRAKE SYSTEM 5 - 35
Page 322 of 2438

(12) Remove hydraulic brake tube assembly rout-
ing bracket, from the engine mounting bracket (Fig.
10). (13) Remove the 6 hydraulic brake tubes and rout-
ing bracket as an assembly from the vehicle.
INSTALL (1) Install the 6 hydraulic brake tubes, clips and
routing bracket as an assembly into the vehicle. (2) Align the 6 hydraulic brake tubes with their
correct locations on the junction block. Thread the 6
brake line tube nuts by handinto the junction block
tube ports. Then torque all 6 brake tube nuts to 18
N Im (159 in.lbs.).
(3) Install the primary and secondary hydraulic
brake tubes, from master cylinder to junction block
(Fig. 9). Then torque the brake line tube nuts at both
the master cylinder and junction block to 18 N Im
(159 in. lbs.). (4) Install the hydraulic brake tube assembly rout-
ing bracket onto the engine mounting bracket (Fig. 10). Torque the brake tube routing bracket attaching
bolt to 11 N
Im (95 in. lbs.).
(5) Align the 6 hydraulic brake lines with their ap-
propriate fitting locations on the modulator assembly
(Fig. 11). Thread the 6 brake line tube nuts by hand
into proportioning valves and thread savers on mod-
ulator assembly. (6) Using a crow foot and torque wrench (Fig. 12),
torque the 6 hydraulic brake line tube nuts to 18
N Im (159 in. lbs.).
(7) Using approved battery jumper cables, attach
battery, to the vehicles negative and positive battery
cables (Fig. 13). (8) Bleed the vehicles base brake and Antilock
brake hydraulic systems. Refer to Bleeding Bendix
Fig. 7 Hydraulic Brake Line Connections To Modulator Assembly
Fig. 8 Pressure Differential Switch Assembly
Fig. 9 Brake Tubes From Master Cylinder To Junction Block
Fig. 10 Brake Tube Routing Bracket
5 - 36 ANTILOCK 4 BRAKE SYSTEM Ä
Page 323 of 2438

Antilock 4 Brake System in this service manual
supplement for required bleeding procedure.(9) Install battery acid shield (Fig. 14) onto the ABS
modulator assembly. Be sure acid shield is securely
attached to modulator assembly before installing
battery tray. (10) Install battery tray into vehicle. Then install
the 4 bolts (Fig. 15) attaching battery tray to inner
fender and frame rail. Torque the 4 battery tray attach-
ing bolts to 20 N Im (175 in.lbs.).
(11) If equipped, install speed control vacuum reser-
voir on battery tray. Install the 2 speed control vacuum
reservoir attaching bolts (Fig. 16). Torque the 2
vacuum reservoir attaching bolts to 4 N Im (30 in. lbs.).
(12) Install battery tray access cover (Fig. 17) on
bottom of battery tray. The access cover MUST be
on battery tray, before battery is installed. (13) Install battery on battery tray. Then install
and securely tighten the battery hold down clamp
(Fig. 18). Then install battery heat shield, on battery
(Fig. 18). (14) Install battery cables on battery. Securely
tighten clamping bolts on battery cable terminals. (15) Reset any electrical components of the vehicle
which were affected by the removal of the battery. (16) Road test vehicle to verify correct operation of
the vehicles's base and Antilock brake systems.
Fig. 13 Battery Connected To Vehicle For Bleeding Modulator Assembly
Fig. 14 Modulator Assembly Acid Shield Installed
Fig. 11 Hydraulic Brake Line Connections atModulator Assembly
Fig. 12 Torquing Brake Line Connections To Modulator Assembly
Ä ANTILOCK 4 BRAKE SYSTEM 5 - 37
Page 324 of 2438

MASTER CYLINDER AND POWER BOOSTER
REMOVAL AND INSTALLATION If the Master Cylinder or Power Booster need to be
removed for replacement or servicing of other vehicle
components. Refer to Master Cylinder or Power
Brake Service section in group 5 of the 1993 M.Y.
Front Wheel Drive Car service manual. After servicing master cylinder, refer back to this
service manual supplement for the appropriate proce-
dure and sequence used to bleed the base and Anti-
lock portion of the brake system.
PROPORTIONING VALVES (FIG. 1)
CAUTION: Proportioning valves should never be
disassembled.
REMOVAL (1) Disconnect and remove both battery cables
from battery. (2) Remove heat shield (Fig. 2) from the battery.
Then remove battery hold down clamp (Fig. 2) and
battery from battery tray.
Fig. 15 Battery Tray Installation And Attaching Bolts
Fig. 16 Vacuum Reservoir Installation And Attaching Bolts
Fig. 17 Battery Tray Access Shield Installed
Fig. 18 Battery Hold Down Clamp And Heat Shield Installed
Fig. 1 ABS Proportioning Valve Identification
5 - 38 ANTILOCK 4 BRAKE SYSTEM Ä
Page 325 of 2438

(3) Remove battery tray access cover (Fig. 3) from
battery tray. Do not discard, access cover MUST be
put back on battery tray, when battery is rein-
stalled.
(4) If equipped, remove the 2 bolts (Fig. 4) attaching
speed control vacuum reservoir to battery tray. Then
remove speed control vacuum reservoir (Fig. 4) from
the battery tray. Vacuum lines (Fig. 4) do not need
to be removed from vacuum reservoir. (5) Remove the 4 bolts attaching battery tray (Fig. 5)
to frame rail and fender shield of vehicle. Then remove
battery tray from vehicle. (6) Remove battery acid shield, (Fig. 6) from the ABS
modulator assembly. (7) Remove brake tube from the proportioning valve,
requiring removal from modulator assembly (Fig. 7). (8) Remove proportioning valve (Fig. 7) requiring
replacement from the modulator assembly. INSTALL
(1) Slightly moisten proportioning valve to modulator
assembly sealing O-Ring with fresh clean brake fluid.
(2) Install proportioning valve into modulator as-
sembly by hand, until O-Ring seal is fully seated
Fig. 4 Speed Control System Vacuum Reservoir
Fig. 5 Battery Tray And Attaching Bolts
Fig. 6 ABS Modulator Assembly Acid Shield
Fig. 2 Battery Heat Shield And Hold Down Clamp
Fig. 3 Battery Tray Shield
Ä ANTILOCK 4 BRAKE SYSTEM 5 - 39
Page 326 of 2438

against modulator assembly. Then torque proportion-
ing valve to 35 N Im (26 ft. lbs.) torque.
(3) Install hydraulic brake line on proportioning
valve and hand start tube nut into proportioning valve.
Torque tube nut to 18 N Im (159 in. lbs.) torque.
(4) Using approved battery jumper cables, attach
battery, to the vehicles negative and positive battery
cables (Fig. 8). (5) Bleed the vehicles base brake and Antilock brake
hydraulic systems. Refer to Bleeding Bendix Antilock 4
Brake System in this service manual supplement for
required bleeding procedure. (6) Install battery acid shield (Fig. 9) onto the ABS
modulator assembly. Be sure acid shield is securely
attached to modulator assembly before installing
battery tray.
(7) Install battery tray in vehicle. Then install the 4
bolts (Fig. 10) attaching battery tray to inner fender
and frame rail. Torque the 4 battery tray attaching
bolts to 20 N Im (175 in.lbs.).
(8) If equipped, install speed control vacuum reser-
voir on battery tray. Install the 2 speed control vacuum
reservoir attaching bolts (Fig. 11). Torque the 2
vacuum reservoir attaching bolts to 4 N Im (30 in. lbs.).
(9) Install battery tray access cover (Fig. 12) on
bottom of battery tray. The access cover MUST be
on battery tray, before battery is installed in
battery tray.
Fig. 8 Battery Connected To Vehicle For Bleeding Modulator Assembly
Fig. 7 Proportioning Valve Removal From Modulator Assembly
Fig. 9 Modulator Assembly Acid Shield Installed
Fig. 10 Battery Tray Installation And Attaching Bolts
5 - 40 ANTILOCK 4 BRAKE SYSTEM Ä
Page 327 of 2438

(10) Install battery on battery tray and install and
securely tighten the battery hold down clamp (Fig.
13). Then install heat shield, on battery (Fig. 13). (11) Install battery cables on battery. Securely
tighten clamping bolts on battery cable terminals. (12) Reset any electrical components of the vehicle
which were affected by the removal of the battery. (13) Road test vehicle to verify correct operation of
the vehicles's base and Antilock brake systems.
ELECTRONIC COMPONENTS
CONTROLLER ANTILOCK BRAKE CAB
REMOVE
(1) Turn vehicle ignition off.
(2) Disconnect the wiring harness connector from
the Antilock system relay (Fig. 1). Relay will be re-
moved as part of the CAB bracket.
CAUTION: BEFORE REMOVING 60 WAY CONNEC-
TOR FROM THE CAB VERIFY THAT THE VEHICLE'S
IGNITION IS IN THE OFF OR LOCK POSITION. IF IG-
NITION IS ON WHEN 60 WAY CONNECTOR IS RE-
MOVED FROM THE CAB DAMAGE TO THE
CONTROLLER COULD OCCUR.
(3) Loosen bolt (Fig. 2) retaining the wiring har-
ness 60 way connector to the CAB. Then disconnect
the 60 way connector (Fig. 2) from the CAB by pull-
ing it straight out, do not twist connector when re-
moving. (4) Remove the 2 bolts (Fig. 3) attaching the CAB
module mounting bracket, to the frame rail of the ve-
hicle. (5) Remove the CAB and its mounting bracket as
an assembly from the vehicle from the vehicle. (6) Remove the 3 screws (Fig. 4) attaching the
CAB to the CAB mounting bracket. Then separate
CAB from mounting bracket.
Fig. 11 Vacuum Reservoir Installation And Attaching Bolts
Fig. 12 Battery Tray Access Shield Installed
Fig. 13 Battery Hold Down Clamp And Heat Shield Installed
Fig. 1 CAB Location
Ä ANTILOCK 4 BRAKE SYSTEM 5 - 41
Page 328 of 2438

INSTALL (1) Install CAB and system relay/bracket assembly
on CAB mounting bracket (Fig. 4). Install the 3 CAB
to CAB mounting bracket attaching screws (Fig. 4). Torque the 3 CAB to mounting bracket attaching
screws to 12 N Im (106 in. lbs.).
(2) Install the CAB, system relay and mounting
bracket on the frame rail of the vehicle. Install the 2
bolts (Fig. 3) attaching the CAB mounting bracket to
the frame rail of the vehicle. Torque the 2 CAB mount-
ing bracket attaching bolts (Fig. 3) to 28 N Im (250 in.
lbs.).
CAUTION: BEFORE INSTALLING 60 WAY CONNEC-
TOR ON THE CAB VERIFY THAT THE VEHICLE'S
IGNITION IS IN THE OFF OR LOCK POSITION. IF
IGNITION IS ON WHEN 60 WAY CONNECTOR IS
INSTALLED ON THE CAB, DAMAGE TO THE CON-
TROLLER COULD OCCUR.
(3) Install the wiring harness 60 way connector (Fig.
2) into the CAB electrical connector as far as possible
by hand. After 60 way connector is installed as far as
possible by hand, use the 60 way connector retaining
bolt (Fig. 2) to fully seat connector into the CAB. Then
torque the wiring harness 60 way CAB connector
retaining bolt to 4 N Im (38 in. lbs.).
(4) Install the wiring harness connector onto the
Antilock system relay (Fig. 1). Be sure locking tab
on wiring harness connector is fully engaged
with lock on system relay. (5) Road test vehicle to verify correct operation of the
vehicles's Antilock brake system.
REMOVAL/INSTALLATION OF SYSTEM RELAY
The antilock brake system, system relay is serviced
as an assembly, with the mounting bracket. The sys-
tem relay is mounted to a separate bracket which is
attached to the CAB and mounting bracket assembly
(Fig. 5).
Fig. 2 CAB 60 Way Connector And Retaining Bolt
Fig. 3 CAB Bracket To Frame Rail Mounting Bolts
Fig. 4 CAB Removal From Mounting Bracket
Fig. 5 Antilock Brakes System Relay Location
5 - 42 ANTILOCK 4 BRAKE SYSTEM Ä