Attachment III - Technical Information

CERTAIN 2001-2002 ESCAPE VEHICLES EQUIPPED WITH AN ANTI-LOCK
BRAKE SYSTEM (ABS) - FUSED RELAY INSTALLATION AND BRAKE MASTER
CYLINDER RESERVOIR CAP REPLACEMENT

OVERVIEW

Some of the affected vehicles may have a master cylinder reservoir cap that could allow brake fluid to leak and potentially reach the ABS module connector. If the module connector is not sealed properly,
brake fluid may enter the module connector, creating a potential for an electrical short. An electrical short might cause an ABS malfunction that could illuminate the ABS warning light, and in some cases, the
module may overheat resulting in burning odor, smoke, and/or fire. This condition could occur either when the vehicle ignition switch is in the off position or while the vehicle is being operated.

Dealers are to:
^ ensure Safety Recall 07S51 is completed

^ install a revised brake master cylinder reservoir cap

^ disable the original ABS circuits which were powered at all times
- Remove and discard original fuses (reference "A" below)
- Cut wires that lead to the fuses (reference "B" below)
- Splice the two red wires together (reference "C" below)





^ install a new fused ABS relay to provide "Key-On" power only (reference "D" below)

SERVICE PROCEDURE

Install Revised Brake Master Cylinder Reservoir Cap

1. Remove and discard the brake master cylinder reservoir cap.





2. Install revised brake master cylinder reservoir cap. See Figure 1.

NOTE:
The revised brake master cylinder reservoir cap package also contains two (2) black adhesive dots that will be used in the next step.

Remove the Original ABS Fuses





1. Remove the Power Distribution Box (PDB) cover. Apply the two black adhesive dots over fuse location F1.14 and F1.24, located on the inside of the PDB cover. See Figure 1.





2. Ensure fuses F1.14 and F1.24 were removed. If not, remove and discard the 25A fuse from cavity F1.14 and the 60A fuse from cavity F1.24. See Figure 2.

Disable Original ABS Circuits

NOTE:
In the absence of the 25A and 60A ABS fuses, the ABS fused relay will supply power to the ABS module and is only powered in the "Key-On" position. The circuit would be restored to "powered at all times" if an individual reinstalled the fuses. To prevent this, the original ABS wires that lead to the PDB must be cut and "dead ended".

1. Disconnect the negative battery cable. For additional information refer to Workshop Manual (WSM), Section 414-013.

2. Open the wire harness convolute between the PDB and the tie down strap and locate the 12 gauge YE/LG wire. See Figure 1.

3. Locate the two 16 gauge RD wires that run next to each other and are factory spliced to a single RD wire near the PDB. See Figure 1.

NOTE:
Ignore the RD wire that is not factory spliced.

4. Cut the 12 gauge YE/LG wire and the two 16 gauge RD wires.





5. Using a non-insulated butt connector, splice the two 16 gauge RD wires together that lead to the ABS module. See Figure 2.





6. Apply heat shrink tubing to spliced wires and "dead end" all remaining cut wires by applying heat shrink tubing over the cut end. See Figure 3.

7. Secure the wires in the convolute and wrap convolute with electrical tape.

Install ABS Fused Relay





1. Wet a clean shop towel with brake cleaner and wipe the side of the PDB to remove all traces of oil and dirt. See Figure 1.





2. Wipe the side of the PDB again with a clean dry shop towel and apply the supplied adhesive promoter to the cleaned area. See Figure 2.

IMPORTANT!
Adhesive promoter is required in order to make a strong bond between the ABS fused relay and the PDB.

IMPORTANT!
The adhesive promoter requires 2 minutes of drying time.

3. While the adhesive promoter is drying:

^ Position the relay housing next to the PDB. (Do not attach relay to PDB at this time.)





^ Connect the red relay wire eyelet to the B+ terminal inside the PDB. See Figure 3.

^ Torque the B+ terminal nut to 10.5 Nm (7.7 lb-ft).





4. Locate the ABS test connector mounted behind the master cylinder reservoir. Remove and discard the test connector plug and connect the ABS relay connector. See Figure 4.





5. Remove the protective film from the adhesive tape located on the side of the relay housing. Align the top edge of the adhesive tape to the upper edge of the PDB housing. Push the relay housing firmly against the area with the dried adhesive promoter on the PDB. See Figure 5.





6. Route the ABS relay harness along the PDB wire harness and secure with the three attached tie straps. See Figure 6.





7. Reinstall the PDB cover. Bend the supplied tie strap to ease installation. Push the tie strap under and around the PDB box. See Figure 7A. Secure the ABS relay housing to the PDB by tightening the tie strap around the PDB and the relay housing. See Figure 7B.

8. Connect the negative battery cable. For additional information refer to WSM, Section 414-01.