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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 372 (Anti-Lock Brake System - Vehicle Dynamic Systems) >> Removal And Installation >> Hydraulic Control Unit (HCU) - Hybrid >> Removal and Installation

Removal and Installation

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 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.
  • 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.
  • 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.
  • When installing a new ABS module, it must be calibrated and configured using the vehicle as-built data. Follow the diagnostic tool directions for the calibration procedures. For additional information on ABS module configuration, refer to MODULE CONFIGURATION .
  • The HCU must be depressurized before proceeding with any mechanical repairs to the brake system.
  1. Depressurize the HCU.
    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.
    • If any of these actions occur the system pressurizes and the procedure must be repeated.
    • 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.
  2. Disconnect the battery. For additional information, refer to BATTERY DISCONNECT .
  3. Depower the high voltage battery. For additional information, refer to HIGH-VOLTAGE TRACTION BATTERY SYSTEMS DEPOWERING .
  4. Remove the battery junction box (BJB) fuses 24 (50A) and 31 (50A).
  5. Remove the HCU heat shield.
    • Remove the heat shield pin-type fastener.
    • Remove the heat shield bolt.
      • To install, tighten to 8 N.m (71 lb-in).
  6. Disconnect the electrical connector by rotating the protective cover.
    Fig 1: Identifying Electrical Connector By Rotating Protective Cover
    G04617740Courtesy of FORD MOTOR CO.
  7. Release the clamp and remove the brake fluid low pressure feed hose.
  8. Release the clamp and remove the brake fluid low pressure return hose.
    9. NOTE: Note the order of the brake lines.
  9. Disconnect the brake line-to-HCU fittings (10 mm).
    • To install, tighten to 18 N.m (13 lb-ft).
    10. NOTE: Note the order of the brake lines.
  10. Disconnect the brake line-to-HCU fittings (12 mm).
    • To install, tighten to 18 N.m (13 lb-ft).
  11. Remove the 2 ground wire nuts and position the ground wires aside.
    • To install, tighten to 12 N.m (9 lb-ft).
  12. Remove the 3 HCU bracket-to-frame studs.
    • To install:
      • tighten to 23 N.m (17 lb-ft) on vehicles built through 9/2005.
      • tighten to 30 N.m (22 lb-ft) on vehicle built after 9/2005.
  13. Disconnect the brake line from the routing clip located at the bottom of the HCU bracket.
    Fig 2: Locating Brake Line From Routing Clip
    G04617741Courtesy of FORD MOTOR CO.
  14. Remove the A/C line routing to HCU bracket bolt.
    Fig 3: Locating A/C Line Routing To HCU Bracket Bolt
    G04617742Courtesy of FORD MOTOR CO.
  15. Remove the HCU assembly.
    16. NOTE: When installing, use a suitable lubricant.
  16. Remove the 3 HCU grommets.
    17. NOTE: Use care not to cross the lines during installation. If the brake lines are crossed, the ABS module will set DTC(s) during an ABS event.
  17. To install, reverse the removal procedure.
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