Removal and Installation

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury.

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 serious personal injury.

NOTE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

NOTE: This step is necessary only if a new ABS module is being installed.

Connect the scan tool and upload the module configuration information from the ABS module. For additional information, refer to MODULE CONFIGURATION -- FUSION MILAN & MKZ article.
Remove the Thermostatic Expansion Valve (TXV) manifold and tube assembly. For additional information, refer to CLIMATE CONTROL -- FUSION, MILAN & MKZ article.
Remove the 2 engine cover studs from the valve cover stud bolts.

Fig 1: Locating Engine Cover Studs Bolts
Courtesy of FORD MOTOR CO.
Disconnect the ABS module electrical connector.
Detach the wire harness push-type fastener from the Hydraulic Control Unit (HCU) bracket and position the harness aside.
Disconnect the brake tube fittings.
- To install, tighten to 20 Nm (177 lb-in).
With the vehicle in NEUTRAL, position it on a hoist. For additional information refer to JACKING & LIFTING article.
Remove the HCU bracket-to-frame bolts.
- To install, tighten to 23 Nm (17 lb-ft).
Remove the HCU and bracket assembly.

NOTE: Make sure the HCU and ABS module are clean and free of any brake fluid or foreign material before separating the components.

To install, reverse the removal procedure.
- Bleed the brake system. For additional information, refer to BRAKE SYSTEM - GENERAL INFORMATION article.
If a new ABS module was installed, download the module configuration information from the scan tool. For additional information, refer to MODULE CONFIGURATION -- FUSION MILAN & MKZ article.
If a new ABS module and/or a new HCU was installed, carry out the Multi-Calibration routine, follow the scan tool directions.