Chrysler Caravan/Voyager/Town n Country 1984-1995

Modulator Assembly

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8 and 9



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Fig. Fig. 1: Controller Anti-lock Brake (CAB) module-to-battery tray mounting bracket



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Fig. Fig. 2: Battery tray support bracket-to-modulator bracket attaching bolt



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Fig. Fig. 3: Hydraulic brake line connections to the modulator assembly



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Fig. Fig. 4: Vehicle wiring harness connection to the modulator assembly



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Fig. Fig. 5: Speed control servo-to-modulator bracket attaching bolt



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Fig. Fig. 6: Modulator bracket-to-frame rail rear mounting bolt



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Fig. Fig. 7: Modulator bracket-to-frame rail front mounting bolt



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Fig. Fig. 8: Removing the modulator and bracket assembly from the vehicle



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Fig. Fig. 9: Modulator assembly-to-mounting bracket attaching bolts

  1. Raise vehicle on jackstands or position vehicle centered on a frame contact hoist.
  2.  
  3. Disconnect and remove both battery cables from battery.
  4.  
  5. Remove the battery hold-down clamp and battery from battery tray.
  6.  
  7. Unfasten the 2 bolts attaching battery tray to battery tray support bracket and frame rail. Remove battery tray from vehicle.
  8.  
  9. Unfasten the bolt attaching CAB to battery tray support bracket, and remove CAB from battery tray support bracket.
  10.  

The CAB does not require removal from vehicle when removing modulator assembly.

  1. Loosen but do not remove (bracket is slotted) bolt attaching battery tray support bracket to modulator assembly mounting bracket.
  2.  
  3. Loosen but do not remove bottom bolt, (bracket is slotted) attaching battery tray support bracket to side of frame rail. Then loosen top bolt attaching battery tray support bracket to side of frame rail. Remove battery tray support bracket from vehicle.
  4.  
  5. Remove the acid shield, from the ABS modulator assembly.
  6.  
  7. Unfasten the 6 tube nuts attaching hydraulic brake line tube bundle to modulator assembly, thread savers and proportioning valves. Then remove hydraulic brake lines as an assembly, from the modulator assembly. Brake lines do not need to be loosened at junction block.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove vehicle's wiring harness 10-way connector from modulator assembly.
  12.  
  13. If vehicle is equipped with speed control, remove bolt attaching speed control servo assembly to modulator assembly bracket.
  14.  
  15. The speed control servo does not need to be removed from vehicle, but should be moved out of the way.
  16.  
  17. Loosen but do not remove the 2 bolts at front of modulator assembly bracket, attaching it to frame rail.
  18.  
  19. Loosen, but do not remove bolt at rear of modulator bracket, attaching bracket to frame rail.
  20.  
  21. Lower the vehicle.
  22.  
  23. Remove the modulator assembly and the mounting bracket as an assembly from vehicle.
  24.  
  25. Remove the modulator assembly from the mounting bracket.
  26.  
  27. The mounting bracket will need to be transferred to replacement modulator assembly, if a new modulator is to be installed.
  28.  

To install:

Before installing modulator assembly back on mounting bracket, inspect the 3 modulator assembly to bracket isolators for any signs of deterioration or damage. Replace all 3 isolators if any show signs of damaged or deterioration, before mounting modulator assembly on bracket. Install the modulator assembly on mounting bracket.


CAUTION
Be sure mounting isolators are correctly positioned on mounting bracket and modulator assembly, before installing and torquing modulator mounting bolts.

Install the 3 bolts attaching anti-lock modulator assembly to mounting bracket. Then tighten the 3 modulator assembly to mounting bracket bolts to 21 ft. lbs. (28 Nm).

  1. Mount the modulator and the mounting bracket assembly, on the 3 mounting bolts on the side of the frame rail.
  2.  
  3. Tighten rear bolt attaching modulator assembly mounting bracket to frame rail to 125 inch lbs. (14 Nm)
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Tighten the 2 front modulator assembly to frame rail mounting bolts to 125 inch lbs. (14 Nm)
  8.  
  9. Mount the speed control servo and bracket, on the modulator assembly mounting bracket.
  10.  
  11. Install mounting bolt for speed control servo, then tighten to 21 ft. lbs. (28 Nm).
  12.  
  13. Install vehicle's wiring harness 10-way connector onto modulator assembly. Be sure lock on vehicle wiring harness connector is fully engaged with tab on modulator assembly electrical connector.
  14.  
  15. Lower the vehicle.
  16.  
  17. Align the 6 disconnected hydraulic brake lines with their appropriate fitting locations on modulator assembly. Then thread the 6 brake line tube nuts by hand into the proportioning valves and thread savers on modulator assembly.
  18.  
  19. Using a crow foot and torque wrench, tighten the 6 hydraulic brake line tube nuts to 13 ft. lbs. (18 Nm). When torquing the tube nuts, hold the thread savers and proportioning valves with an open end wrench to prevent them from turning.
  20.  
  21. Using approved battery jumper cables, attach battery, to the vehicles negative and positive battery cables.
  22.  
  23. Bleed the vehicles base brake and anti-lock brake hydraulic systems. Refer to the Bendix Anti-lock 4 Brake bleeding procedure in this section for the required bleeding procedure.
  24.  
  25. Install the acid shield onto modulator assembly. Be sure the acid shield is securely attached to the modulator assembly before installing the battery tray support bracket.
  26.  
  27. Install the battery tray support bracket in the vehicle.
  28.  
  29. Install the 1 attaching bolt support bracket to the frame rail and tighten the 3 bolts attaching the battery tray support bracket to the frame rail and the modulator bracket to 125 inch lbs. (14 Nm).
  30.  
  31. Install the CAB module/mounting bracket assembly, on battery tray support bracket.
  32.  
  33. Install the CAB assembly mounting bolt, then tighten to 14 inch lbs. (6 Nm).
  34.  
  35. Install the battery tray. Fasten the 2 bolts mounting the battery tray to the battery tray support bracket and the fender shield.
  36.  
  37. Install the battery on battery tray. Fasten and securely tighten the battery hold down clamp.
  38.  
  39. Install the battery cables on the battery. Securely tighten the clamping bolts on the battery cable terminals.
  40.  
  41. Reset any electrical components of the vehicle which were affected by the removal of the battery.
  42.  
  43. Road test the vehicle to verify correct operation of the vehicles's base and anti-lock brake systems.
  44.  

 
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