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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.
NOTE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.
    NOTE: This step is only necessary if a new ABS module is being installed on a vehicle equipped with AdvanceTrac®.
  1. Connect the scan tool and upload the module configuration from the ABS module. For additional information, refer to MODULE CONFIGURATION .
  2. Remove the Air Cleaner (ACL). For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  3. Remove the brake fluid reservoir cap and using a suitable clean suction device, remove the brake fluid from the brake fluid remote reservoir.
  4. Remove the transaxle support insulator. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - 4F27E .
  5. Disconnect the PCM electrical connectors.
  6. Detach the wiring harness retaining clips from the PCM bracket.
    Fig 1: Locating Wiring Harness Retaining Clips At PCM Bracket
    G06256246Courtesy of FORD MOTOR CO.
  7. Remove the 3 bolts and the ACL bracket with the PCM bracket and PCM attached.
    • To install, tighten to 25 Nm (18 lb-ft).
      Fig 2: Locating Bolts Of ACL Bracket And PCM Bracket
      G06256247Courtesy of FORD MOTOR CO.
  8. Remove the ground cable bolt and position the cable aside.
    • To install, tighten to 9 Nm (80 lb-in).
      Fig 3: Locating Ground Cable Bolt
      G06256155Courtesy of FORD MOTOR CO.
  9. Loosen the Battery Junction Box (BJB) mounting screw.
    • To install, tighten to 5 Nm (44 lb-in).
      Fig 4: Locating Battery Junction Box Mounting Screw
      G06256156Courtesy of FORD MOTOR CO.
  10. Press the locking tab, disconnect the BJB from the bracket and position the BJB aside.
    Fig 5: Locating BJB Locking Tab
    G06256157Courtesy of FORD MOTOR CO.
  11. Disconnect the ABS module electrical connector by rotating the connector.
    Fig 6: Disconnecting ABS Module Electrical Connector By Rotating Connector
    G06094605Courtesy of FORD MOTOR CO.
    12. NOTE: Cap the brake tube connections to prevent fluid loss or dirt contamination.
    NOTE: To aid in correct installation, make a note of the position of the brake tubes.
  12. Remove the master cylinder-to-Hydraulic Control Unit (HCU) brake tubes.
    • To install, tighten to 23 Nm (17 lb-ft).
    13. NOTE: Cap the brake tube connections to prevent fluid loss or dirt contamination.
    NOTE: To aid in correct installation, make a note of the position of the brake tubes.
  13. Disconnect the remaining brake tubes and position aside.
    • To install, tighten the LF and RR brake tube fittings to 23 Nm (17 lb-ft).
    • To install, tighten the RF and LR brake tube fittings to 20 Nm (177 lb-in).
  14. Remove the LF brake tube from the retaining clip on the LH inner frame rail.
    Fig 7: Removing LF Brake Tube From Retaining Clip On LH Inner Frame Rail
    G06256252Courtesy of FORD MOTOR CO.
  15. Remove the 3 HCU bracket-to-frame nuts and remove the HCU and bracket assembly from the vehicle.
    • To install, tighten to 25 Nm (18 lb-ft).
  16. Remove the 2 HCU-to-bracket bolts and separate the HCU from the support bracket.
    • To install, tighten to 12 Nm (106 lb-in).
  17. To install, reverse the removal procedure.
    1. If a new ABS module was installed on a vehicle equipped with AdvanceTrac® with Roll Stability Control (RSC®), download the module configuration information from the scan tool. For additional information, refer to MODULE CONFIGURATION .
    2. If a new ABS module or HCU was installed on a vehicle equipped with AdvanceTrac® with RSC®, carry out the IVD Initialization sequence for all 4 stability control sensors (roll rate, yaw rate, lateral acceleration, longitudinal acceleration), the steering angle sensor and the brake fluid pressure sensor. Follow the scan tool directions.
    3. Bleed the brake system. For additional information, refer to BRAKE SYSTEM - GENERAL INFORMATION .
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