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Removal And Installation

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
WARNING: Wear high-voltage insulated safety gloves and a face shield when working with high-voltage batteries or cables. The high-voltage insulated safety gloves should be of the appropriate safety and protection rating. Inspect the gloves before use and always wear them with the leather outer glove. Any hole in the rubber insulating glove is a potential entry point for high-voltage. Failure to follow these instructions may result in serious personal injury or death.
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.
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.
NOTE: The ABS module is part of the hydraulic control unit (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.
  1. 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.
  2. Depower the high voltage battery. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY article.
  3. Remove the battery junction box (BJB) fuses 9 (50A) and 18 (50A).
  4. 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).
  5. Disconnect the electrical connector by rotating the protective cover.
    6. Fig 1: Identifying Connector
    GF0042321Courtesy of FORD MOTOR CO.
  6. Loosen the clamp and remove the brake fluid low pressure feed hose.
    • To install, tighten to 3 Nm (27 lb-in).
  7. Loosen the clamp and remove the brake fluid low pressure return hose.
    • To install, tighten to 3 Nm (27 lb-in).
    8. NOTE: Note the order of the brake tubes.
  8. Disconnect the brake tube-to-HCU fittings (10 mm).
    • To install, tighten to 18 Nm (13 lb-ft).
    9. NOTE: Note the order of the brake tubes.
  9. Disconnect the brake tube-to-HCU fittings (12 mm).
    • To install, tighten to 18 Nm (13 lb-ft).
  10. Remove the 2 ground wire nuts and position the 2 ground wires aside.
    • To install, tighten to 12 Nm (9 lb-ft).
  11. Remove the 3 HCU bracket-to-frame studs.
    • To install, tighten to 30 Nm (22 lb-ft).
  12. Disconnect the brake tube from the routing clip located at the bottom of the HCU bracket.
    13. Fig 2: Brake Tube Routing Clip
    GF0024677Courtesy of FORD MOTOR CO.
  13. Remove the A/C tube bracket-to-HCU.
    • To install, tighten to 6 Nm (53 lb-in).
    14. Fig 3: HCU Bracket Bolt
    GF0024678Courtesy of FORD MOTOR CO.
  14. Remove the HCU assembly.
    15. NOTE: When installing, use a suitable lubricant.
  15. Remove the 3 HCU grommets.
    16. NOTE: Use care not to cross the tubes during installation. If the brake tubes are crossed, the ABS module will set DTCs during an ABS event.
  16. To install, reverse the removal procedure.
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