Hydraulic Control Assembly - Antilock Brakes: Service and Repair

(Part 1 Of 2):

REMOVAL
1. Remove battery.
2. Remove power distribution box-to-battery tray retaining bolt.
3. Remove battery tray.
4. Disconnect 16-pin valve body to wire harness connector.
5. Raise and support vehicle and remove LH front tire and wheel assembly.
6. Remove LH inner fender splash shield.
7. Disconnect 3-pin fluid level switch connector, 4-pin pump motor connector, 4-pin pump motor relay connector and 55-pin ABS control module connector.

CAUTION: The brake master cylinder will drain if the feed hose is not pinched off. DO NOT allow brake fluid to come in contact with wiring or paint. Immediately rinse any paint or wiring with water if brake fluid comes in contact with them.

8. Remove low pressure feed hose from hydraulic control unit reservoir. Clamp or plug hose.
9. Disconnect LH front brake tube from hose at the hose mounting bracket.
10. Remove the two lower hydraulic control unit assembly mounting bracket attaching screws.
11. Lower vehicle and disconnect the five brake tube connections at the junction block. Remove the two junction block retaining nuts.

CAUTION: Do not allow the two upper bushings to turn in the bracket while loosening the two upper mounting bolts. Hold the bushings with a pair of vise grips necessary. If the bushings turn in the bracket, they must by replaced with new parts before installation.

12. Remove the two upper hydraulic control unit assembly mounting bracket attaching bolts.

INSTALLATION
1. Position hydraulic control unit assembly and place mounting bracket hook through slot in outer frame rail. Hand-start the two lower mounting screws.
2. Lower vehicle and install the two upper mounting bolts. Tighten bolts to 12.5-15.5 Nm (9.5-11.5 ft. lbs.).
3. Raise and support vehicle and tighten two lower mounting screws to 12.5-15.5 Nm (9.5-11.5 ft. lbs.).
4. Install low pressure feed hose to hydraulic control unit reservoir.
5. Reconnect LH front brake tube to hose at the mounting bracket.
6. Reconnect 55-pin ABS control module connector, 4-pin pump motor relay connector, 4-pin pump motor connector and 3-pin fluid level switch connector.
7. Lower vehicle and install the two junction block retaining nuts and tighten to 4.0-5.5 Nm (35-49 inch lbs.).
8. Reattach the five tube connections at the junction block. Tighten to 14-24 Nm (11-17 ft. lbs.).
9. Reconnect 16-pin valve body-to-wire harness connector. Install battery tray.
10. Install power distribution box to battery tray retaining bolt.
11. Install battery.
12. Bleed brake system. Service and Repair
13. Install inner fender splash shield.
14. Install tire and wheel assembly.
15. Tighten lug nuts. Refer to Steering and Suspension.