Removal And Installation

WARNING: This page is about a different car, the 2007 Mercury Mariner and 2007 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: The traction battery and charging system contains high voltage components and wiring. High voltage insulated safety gloves and a face shield must be worn when carrying out any diagnostics on this vehicle. Failure to follow these instructions may result in severe personal injury or death.

WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury.

CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

CAUTION: Electronic modules are sensitive to electrical charges. The anti-lock brake system (ABS) module can be damaged if exposed to these charges.

NOTE: The ABS module is part of the HCU. Do not separate the ABS module from the HCU.

NOTE: When installing a new ABS module, it must be calibrated and configured using the vehicle as-built data. Follow the scan tool directions for the calibration procedures. For additional information on ABS module configuration, refer to MODULE COMMUNICATIONS NETWORK article.

NOTE: The HCU must be depressurized before proceeding with any mechanical repairs to the brake system.

NOTE: Mark the level of the brake fluid in the master cylinder before starting the depressurization of the system. When the brake fluid level has increased approximately 12 mm (0.47 in), the system has fully depressurized.

NOTE: If any of these actions occur the system pressurizes and the procedure must be repeated.

Depressurize the HCU.
- Turn the key to the OFF position and let the vehicle stand for 4 minutes without opening the doors, pressing the brake pedal or activating the key fob.
Disconnect the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
Depower the high voltage battery. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY article.
Remove the battery junction box (BJB) fuses 24 (50A) and 31 (50A).
Remove the HCU heat shield.
- Remove the heat shield pin-type fastener.
- Remove the heat shield bolt.
  - To install, tighten to 8 Nm (71 lb-in).
Disconnect the electrical connector by rotating the protective cover.

Fig 1: Rotating Protective Cover

Courtesy of FORD MOTOR CO.

Release the clamp and remove the brake fluid low pressure feed hose.
- To install, tighten to 3 Nm (27 lb-in).
Release the clamp and remove the brake fluid low pressure return hose.
- To install, tighten to 3 Nm (27 lb-in).

NOTE: Note the order of the brake tubes.

Disconnect the brake tube-to-HCU fittings (10 mm).
- To install, tighten to 18 Nm (13 lb-ft).

NOTE: Note the order of the brake tubes.

Disconnect the brake tube-to-HCU fittings (12 mm).
- To install, tighten to 18 Nm (13 lb-ft).
Remove the 2 ground wire nuts and position the 2 ground wires aside.
- To install, tighten to 12 Nm (9 lb-ft).
Remove the 3 HCU bracket-to-frame studs.
- To install, tighten to 30 Nm (22 lb-ft).
Disconnect the brake tube from the routing clip located at the bottom of the HCU bracket.

Fig 2: Brake Tube Routing Clip

Courtesy of FORD MOTOR CO.

Remove the A/C tube routing to HCU bracket bolt.

Fig 3: HCU Bracket Bolt

Courtesy of FORD MOTOR CO.

Remove the HCU assembly.

NOTE: When installing, use a suitable lubricant.

Remove the 3 HCU grommets.

NOTE: Use care not to cross the tubes during installation. If the brake tubes are crossed, the ABS module will set DTC(s) during an ABS event.

To install, reverse the removal procedure.
- Bleed the brake system. For additional information, refer to BRAKE SYSTEM - GENERAL INFORMATION article.