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    Ford Excursion, Expedition, Lincoln Navigator 2000-2005

    Hydraulic Control Unit (HCU)

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    Removal & Installation




    WARNING
    Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.

    1. Disconnect the battery.
      2.  
    2. Remove the air cleaner.
      3.  
    3. Remove the EVAP canister.
      CAUTION
      Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.


      WARNING
      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.


      WARNING
      Only authorized inlet hydraulic brake tubes should be used. These tubes are of specific design and only authorized parts should be used when installing new inlet brake tubes.


      NOTE
      Plug each open port to prevent brake fluid from spilling.

      4.  
    4. Disconnect the hydraulic brake tubes.
      5.  
    5. Disconnect the electrical connections.
      6.  
    6. Remove the Hydraulic Control Unit (HCU) and bracket.
      7.  

    To install:

    1. To install, reverse the removal procedure. Observe the following tightening specifications:
      1. HCU bracket bolts: 22 ft. lbs. (30 Nm).
        2.  
      2. Hydraulic brake tube fittings: see accompanying illustration.

        Click image to see an enlarged view

        Fig. Tighten the hydraulic brake tube fittings as shown\

        3.  

      2.  
    2. Bleed the brake system.  
      3.  


    WARNING
    Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.

    1. Disconnect the battery.
      2.  
    2. Disconnect the Anti-lock Brake System (ABS) module electrical connector.
      CAUTION
      Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instruction may result in personal injury.


      WARNING
      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.


      WARNING
      Only authorized inlet hydraulic brake tubes should be used. These tubes are of specific design and only authorized parts should be used when installing new inlet brake tubes.


      NOTE
      Plug each open port to prevent brake fluid from spilling.



      Click image to see an enlarged view

      Fig. Disconnect the Anti-lock Brake System (ABS) module electrical connector

      3.  
    3. Disconnect the hydraulic brake line nuts.

      Click image to see an enlarged view

      Fig. Disconnect, then plug the hydraulic brake lines

      4.  
    4. Remove the 3 bolts and the Hydraulic Control Unit (HCU).

      Click image to see an enlarged view

      Fig. Remove the bolts and the HCU

      5.  

    To install:

    1. Installation is the reverse of the removal procedure. Please note the following tightening specifications:
      1. HCU mounting bolts: 12 ft. lbs. (16 Nm)
        2.  
      2. Hydraulic brake line nuts: 13 ft. lbs. (18 Nm)
        3.  

      2.  
    2. Bleed the brake system.  
      3.  

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