Hydraulic Assembly: Service and Repair

Hydraulic Control Unit (HCU)











Removal and Installation

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 it with water.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Remove the battery tray.
3. Disconnect the ABS module electrical connector.

4. NOTE: The brake tubes must be installed in the same location as removed.

Remove the 2 master cylinder primary and secondary brake tube-to-hydraulic control unit (HCU) fittings and position both brake tubes aside.
^ To install, tighten to 23 Nm (17 lb-ft).

5. NOTE: The brake tubes must be installed in the same location as removed.

Remove the 4 brake tube-to-HCU extension tube fittings.
^ To install, tighten to 18 Nm (13 lb-ft).
6. Remove the 3 HCU bracket-to-frame nuts.
^ To install, tighten to 23 Nm (17 lb-ft).
7. Remove the HCU assembly.

8. NOTE: The brake tubes must be installed in the same location as removed.

Remove the 4 HCU extension tube-to-HCU fittings.
^ To install, tighten to 18 Nm (13 lb-ft).
9. Remove the 2 HCU bracket-to-HCU extension tube retainer nuts and the extension tube retainer assembly.
^ To install, tighten to 9 Nm (80 lb-in).
10. Remove the HCU bracket-to-HCU bolt and the HCU bracket.
^ To install, tighten to 9 Nm (80 lb-in).
11. To install, reverse the removal procedure.
^ Bleed the brake system.