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Bleeding Modulator Assembly

CAUTION: Perform MANUAL BLEEDING procedure before bleeding modulator assembly.
  1. To gain access to 6 bleed screws located on modulator assembly, remove battery, battery tray and acid shield. Connect battery to vehicle using jumper cables.
  2. Ensure all fluid lines are installed and correctly torqued. Bleed base brake system using standard manual procedure.
  3. Connect scan tool to CCD data link connector, located behind fuse access cover on lower section of dash panel, left of steering column. See Fig 1.
    Fig 1: Locating CCD Data Link Connector
    G92B03546Courtesy of CHRYSLER CORP.
    WARNING: When bleeding modulator assembly, wear safety glasses. Attach bleed tube to bleed screw. Place other end of hose in clean transparent container. Direct fluid away from painted surfaces. High-pressure brake fluid comes out when bleed screw is opened.
  4. Using scan tool, ensure CAB has no trouble codes stored. If trouble codes are stored, erase codes using scan tool.
  5. Install bleed tube on primary check valve circuit bleed screw. See Fig 2. Have assistant pump brake pedal several times and then hold pedal, applying medium constant pressure. Loosen primary check valve circuit bleed screw 1-2 full turns. After pedal bottoms, tighten bleed screw. Release pedal. Repeat bleeding procedure until clear, air-free fluid comes out of primary check valve circuit. Tighten bleed screw to 80 INCH lbs. (9 N.m).
  6. Install bleed tube on secondary check valve circuit bleed screw. Have assistant pump brake pedal several times and then hold pedal, applying medium constant pressure. Loosen secondary check valve circuit bleed screw 1-2 full turns. After pedal bottoms, tighten bleed screw. Release pedal. Repeat bleeding procedure until clear, air-free fluid comes out of secondary check valve circuit. Tighten bleed screw to 80 INCH lbs. (9 N.m).
  7. Install bleed tube on primary sump circuit bleed screw. Have assistant pump brake pedal several times and then hold pedal, applying medium constant pressure. Loosen primary sump circuit bleed screw 1-2 full turns. Using scan tool, select BLEED BRAKES mode and then PRIMARY CIRCUIT. Right front and left rear solenoids should alternately actuate for 5 seconds. Continue selecting PRIMARY CIRCUIT until clear, air-free fluid comes out of bleed screw or until brake pedal bottoms. After pedal bottoms, tighten bleed screw. Release pedal. Repeat bleeding procedure until clear, air-free fluid comes out of bleed screw. Tighten bleed screw to 80 INCH lbs. (9 N.m).
  8. Install bleed tube on primary accumulator circuit bleed screw. Have assistant pump brake pedal several times and then hold pedal, applying medium constant pressure. Using scan tool, select BLEED BRAKES mode and then select PRIMARY CIRCUIT VALVES. Right front and left rear solenoids should actuate for 5 seconds. Loosen primary accumulator circuit bleed screw 1-2 full turns. Continue selecting PRIMARY CIRCUIT VALVES until clear, air-free fluid comes out of bleed screw or until brake pedal bottoms. After pedal bottoms, tighten bleed screw. Release pedal. Repeat bleeding procedure until clear, air-free fluid comes out of bleed screw. Lightly tighten bleed screw.
  9. Have assistant pump brake pedal several times and then hold pedal, applying medium constant pressure. Without actuating solenoids, loosen primary accumulator circuit bleed screw 1-2 full turns. After pedal bottoms, tighten bleed screw. Release pedal. Repeat bleeding procedure until clear, air-free fluid comes out of primary accumulator bleed screw. Tighten bleed screw to 80 INCH lbs. (9 N.m).
  10. Install bleed tube on secondary sump circuit bleed screw. Have assistant pump brake pedal several times and then hold pedal, applying medium constant pressure. Loosen secondary sump circuit bleed screw 1-2 full turns. Using scan tool, select BLEED BRAKES mode and then select SECONDARY CIRCUIT. Left front and right rear solenoids should alternately actuate for 5 seconds. Continue selecting SECONDARY CIRCUIT until clear, air-free fluid comes out of bleed screw or until brake pedal bottoms. After pedal bottoms, tighten bleed screw. Release pedal. Repeat bleeding procedure until clear, air-free fluid comes out of bleed screw. Tighten bleed screw to 80 INCH lbs. (9 N.m).
  11. Install bleed tube on secondary accumulator circuit bleed screw. Have assistant pump brake pedal several times and then hold pedal, applying medium constant pressure. Using scan tool, select BLEED BRAKES mode and then select SECONDARY CIRCUIT VALVES. Left front and right rear solenoids should actuate for 5 seconds. Loosen secondary accumulator circuit bleed screw 1-2 full turns. Continue selecting SECONDARY CIRCUIT VALVES until clear, air-free fluid comes out of bleed screw or until brake pedal bottoms. After pedal bottoms, tighten bleed screw. Release pedal. Repeat bleeding procedure until clear, air-free fluid comes out of bleed screw. Lightly tighten bleed screw.
  12. Have assistant pump brake pedal several times and then hold pedal, applying medium constant pressure. Without actuating solenoids, loosen secondary accumulator circuit bleed screw 1-2 full turns. After pedal bottoms, tighten bleed screw. Release pedal. Repeat bleeding procedure until clear, air-free fluid comes out of secondary accumulator bleed screw. Tighten bleed screw to 80 INCH lbs. (9 N.m).
Fig 2: Identifying Modulator Assembly Bleed Screws
G50G12365Courtesy of CHRYSLER CORP.
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