Hydraulic Control Assembly - Antilock Brakes: 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.

NOTICE: 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. Remove the degas bottle. For additional information, refer to Cooling System &/or Engine Block Heater.

2. Remove the Thermostatic Expansion Valve (TXV) manifold and tube assembly.

3. Disconnect the ABS module electrical connector.

4. Disconnect the brake tube fittings.
- To install:
- tighten the front and rear brake tube fittings to 20 Nm (177 lb-in).

- tighten the master cylinder brake tube fittings to 27 Nm (20 lb-ft).

5. Remove the Hydraulic Control Unit (HCU) bracket-to-frame nut.
- To install, tighten to 23 Nm (17 lb-ft).

6. NOTE: If installing a new bolt, use only the Torx head type for vehicles equipped with a 3.5L engine.

Remove the HCU bracket-to-frame bolt.

- To install, tighten to 23 Nm (17 lb-ft).

7. Remove the HCU bracket-to-frame stud bolt.
- To install, tighten to 23 Nm (17 lb-ft).

8. Remove the HCU and bracket.

9. Remove the HCU bracket-to-HCU bolt and remove the bracket.
- To install, tighten to 9 Nm (80 lb-in).

10. NOTE: Make sure the HCU and ABS module are clean and free of any brake fluid or foreign material before separating the components.
To install, reverse the removal procedure.
- Bleed the brake system. For additional information, refer to Brakes and Traction Control.