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Removal and Installation

WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts the eyes, flush the eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.
WARNING: When installing a new hydraulic control unit (HCU) and stability assist module, the HCU and stability assist module must be removed as a complete assembly. Failure to follow these instructions may result in personal injury.
CAUTION: Use of any other than approved DOT brake fluid will cause permanent damage to brake components and will render the brakes inoperative.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately rinse it off with water.
  1. Disconnect the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Disconnect the low brake fluid warning indicator switch electrical connector.
    1. Pull back the tab.
    2. Press the clips.
    3. Disconnect the electrical connector.
    Fig 1: Disconnecting Electrical Connector
    G03191367Courtesy of FORD MOTOR CO.
    3. CAUTION: Make sure the filler cap does not become contaminated.
    Fig 2: Removing Reservoir Filler Cap
    G03191368Courtesy of FORD MOTOR CO.
  3. Remove the reservoir filler cap.
  4. Remove the front wheels. .
  5. Loosen the bleeder screw.
    1. Remove the bleeder screw cap.
    2. Loosen the bleeder screw.
    Fig 3: Removing Bleeder Screw Cap And Bleeder Screw
    G03191369Courtesy of FORD MOTOR CO.
    6. NOTE: Carry out this process on both the front brake lines.
    Fig 4: Connecting Bleed Tube To Bleeder Screw And Into Suitable Container
    G03191370Courtesy of FORD MOTOR CO.
  6. Drain the brake fluid reservoir.
    1. Connect a bleed tube to the bleeder screw and into a suitable container.
    2. Press the brake pedal until the no more fluid is expelled.
    3. Tighten the bleeder screw.
  7. Lower the vehicle.
  8. Install the brake fluid reservoir cap.
  9. Remove the air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  10. Remove the air cleaner outlet tube.
  11. Disconnect the electrical connector.
    Fig 5: Disconnecting Electrical Connector
    G03191371Courtesy of FORD MOTOR CO.
  12. Remove the battery junction box (BJB).
    Fig 6: Removing Battery Junction Box (BJB)
    G03191372Courtesy of FORD MOTOR CO.
  13. Disconnect the BJB from the bracket and position aside.
    • Press the locking tabs.
    Fig 7: Disconnecting BJB From Bracket
    G03191373Courtesy of FORD MOTOR CO.
  14. Disconnect the ABS module electrical connector.
    1. Release the retainer.
    2. Disconnect the electrical connector.
    Fig 8: Disconnecting ABS Module Electrical Connector
    G03191374Courtesy of FORD MOTOR CO.
    15. CAUTION: Cap the brake tube connections to prevent fluid loss or dirt contamination.
    Fig 9: Disconnecting HCU Brake Tubes
    G03191375Courtesy of FORD MOTOR CO.
  15. Disconnect the HCU brake tubes.
  16. Unclip the brake tubes.
    Fig 10: Removing Brake Tubes
    G03191376Courtesy of FORD MOTOR CO.
    17. CAUTION: Cap the brake tube connections to prevent fluid loss or dirt contamination.
    Fig 11: Removing Master Cylinder To HCU Brake Tubes
    G03191377Courtesy of FORD MOTOR CO.
  17. Remove the master cylinder to HCU brake tubes.
  18. Disconnect the wiring harness from the wheelhouse assembly.
    Fig 12: Disconnecting Wiring Harness From Wheelhouse Assembly
    G03191378Courtesy of FORD MOTOR CO.
  19. Remove the HCU bolts and separate the HCU from the support bracket.
    Fig 13: Removing HCU Bolts And Separate HCU From Support Bracket
    G03191379Courtesy of FORD MOTOR CO.
    20. NOTE: After installation, bleed the brake system. For additional information, refer to BRAKE SYSTEM - GENERAL INFORMATION .
  20. To install, reverse the removal procedure.
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