Removal Procedure
- Check the 12 volt battery voltage with a digital multimeter before disconnecting any battery cables leads. If the voltage is 13.5 volts or above, the Battery Maintenance Mode is active. The technician must wait for the T18 battery charger to deactivate before disconnecting the battery negative cable. Charging System Description and Operation
- Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
- Raise and support the vehicle. Lifting and Jacking the Vehicle (Standard Service) , or Lifting and Jacking the Vehicle (Mobile Service)
High Voltage Battery Tray Reinforcement Nut (1) - Remove [4x]
- High Voltage Battery Tray Reinforcement Bolt (2) - Remove [2x]
High Voltage Battery Tray Reinforcement Bolt (1) - Remove [21x]
With the aid of an assistant, remove the high voltage battery tray lower front reinforcement (1).
Place a drain pan under the vehicle.
- Rear Brake Rear Pipe Nut (1) - Remove
Brake Pedal Push Rod Bolt (1) - Remove
- Brake Pedal Nut (2) - Remove [4x]
Turn the 3 front compartment sight shield retainers (1) a quarter turn counter clockwise to release.
Front Compartment Side Sight Shield (1) - Remove
- Thoroughly clean the brake master cylinder reservoir and the brake master cylinder body to remove any dirt and debris.
- Electrical Connector @ Brake System Control Module - Disconnect
- Electrical Connector @ Brake Fluid Level Indicator Switch - Disconnect
- Place a drain pan under the vehicle.
Remove the 4 rear brake front pipe nuts (1) and position the brake pipes aside.
Brake Master Cylinder Adapter Nut (1) - Remove
Chassis Control Module Bracket Nut (2) - Remove
- Chassis Control Module Bracket Bolt (1) - Remove [2x]
- Chassis Control Module Bracket (3) - Reposition away
Drive Motor Battery Radiator Surge Tank Bolt (1) - Remove
- Drive Motor Battery Radiator Surge Tank (2) - Reposition
Maneuver the brake master cylinder (1) out of the vehicle.
- Brake Master Cylinder Gasket (2) - Remove and DISCARD
- Clean any brake fluid from the underbody area and remove the drain pan from under the vehicle.
Front Brake Front Pipe Clip (1) - Disengage [2x]
- Maneuver the right front brake pipe (2) out of the vehicle.
Always ensure the Battery Maintenance Mode is inactive before disconnecting the low voltage 12 volt battery (or batteries). This mode can be active with the ignition off, regardless of whether the vehicle charging cord is plugged in or not. When this mode is active, the on-board high voltage battery charger(s) will energize the 12 volt battery cables and charge the 12 volt battery (or batteries). Disconnecting any battery cables while this mode is active may result in an electrical shock or a burn from hot battery cable leads.