This procedure covers the removal and replacement of the ABS hydraulic control unit (HCU) pump assembly on a 2011-2014 Ford F-150 3.5L EcoBoost 4WD, including brake line disconnection, bleeding, and system verification.

Warnings

Tools required

Parts

• ABS hydraulic control unit (HCU) assembly × 1 — Use OEM Ford specification
• Brake fluid × 1 — Motorcraft DOT 4 LV
• Brake line sealing washers × 6 — Use OEM specification

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind rear wheels.
2. Disconnect negative battery cable and wait 2 minutes to allow airbag system capacitors to discharge.
3. Remove engine cover if equipped by pulling upward on cover clips.
4. Locate ABS hydraulic control unit on driver side frame rail near master cylinder.
5. Clean area around ABS unit and brake line connections with brake cleaner to prevent contamination.
6. Label all brake line connections with tape or marker for proper reinstallation reference.
7. Prepare brake line caps or plugs to seal lines immediately after disconnection to minimize fluid loss and contamination.

Procedure

1. 1

   Relieve brake system pressure and disconnect battery
   With engine off, pump brake pedal 20-25 times until pedal becomes firm and no further assist is present. This depletes vacuum assist and relieves residual pressure in ABS system. Disconnect negative battery cable and secure away from battery terminal.
2. 2

   Disconnect ABS module electrical connector
   Locate the main electrical connector on the ABS hydraulic control unit. Press the connector locking tab and carefully pull connector straight off the module. Do not twist or bend connector pins. Secure connector away from work area to prevent damage or contamination.
3. 3

   Disconnect brake lines from ABS unit
   Using flare nut wrenches, carefully loosen each of the six brake line fittings on the ABS hydraulic control unit. Work slowly to avoid rounding off brass fittings. Allow brake fluid to drain into drain pan. Immediately cap or plug each brake line and port on ABS unit after disconnection to prevent fluid loss and air intrusion. Keep track of which line connects to which port using labels from preparation.
   ⚠Brake fluid will drain from lines. Position drain pan to catch fluid and prevent spills on frame or components.
4. 4

   Remove ABS unit mounting fasteners
   Locate the mounting bolts securing the ABS hydraulic control unit to the mounting bracket on the frame rail. Remove mounting bolts using appropriate socket. Support the ABS unit while removing final bolt to prevent it from falling.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
5. 5

   Remove ABS hydraulic control unit
   Carefully lift ABS unit from mounting bracket and remove from vehicle. Keep unit upright to minimize fluid spillage. Place unit in drain pan and allow remaining fluid to drain. Inspect mounting bracket for corrosion or damage and clean with wire brush if necessary.
6. 6

   Prepare new ABS unit for installation
   Remove protective caps from new ABS hydraulic control unit ports. Inspect all ports for debris or damage. Verify new unit matches original unit configuration and connector orientation. Install new brake line sealing washers on all brake line fittings that will connect to ABS unit.
7. 7

   Install new ABS unit to mounting bracket
   Position new ABS hydraulic control unit onto mounting bracket on frame rail, ensuring proper orientation with electrical connector accessible. Install mounting bolts finger-tight initially. Verify unit sits flush on bracket before torquing. Torque mounting bolts to specification.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
8. 8

   Reconnect brake lines to ABS unit
   Remove caps from brake line ports on ABS unit. Using your reference labels, reconnect each brake line to correct port on ABS hydraulic control unit. Thread fittings by hand first to prevent cross-threading. Use flare nut wrenches to carefully tighten each fitting. Do not overtighten brass fittings. Tighten securely but avoid excessive force that could damage sealing surfaces.
   ⚠Ensure brake lines are routed correctly and not kinked, twisted, or in contact with sharp edges or heat sources.
9. 9

   Reconnect electrical connector
   Align electrical connector with ABS module connector and push firmly until connector locking tab clicks into place. Verify connector is fully seated and locked. Gently tug on connector to confirm secure attachment.
10. 10

    Fill brake fluid reservoir
    Locate brake fluid reservoir on master cylinder. Clean area around reservoir cap before opening. Fill reservoir to MAX line with fresh Motorcraft DOT 4 LV brake fluid only. Do not use any other type of brake fluid. Keep reservoir filled above MIN line throughout bleeding process.
11. 11

    Perform manual brake bleeding
    Begin bleeding brakes in this sequence: right rear, left rear, right front, left front. At each wheel, attach bleeder hose to bleeder screw and submerge other end in clean brake fluid in clear container. Have assistant pump brake pedal 3-4 times and hold pressure. Open bleeder screw to release fluid and air, then close before pedal reaches floor. Repeat until fluid flows clear with no air bubbles. Torque bleeder screw to specification after bleeding each wheel. Monitor and refill reservoir frequently to prevent introducing air.
    ⚠️Never allow brake fluid reservoir to run empty during bleeding or air will enter ABS unit requiring complete rebleeding procedure.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
12. 12

    Perform ABS module bleeding with scan tool
    Connect scan tool to vehicle OBD-II port. Reconnect battery negative cable. Turn ignition to ON position (do not start engine). Navigate to ABS bleeding function in scan tool. Follow scan tool prompts to cycle ABS solenoid valves. This will purge air from ABS hydraulic control unit internal passages. During this process, monitor brake fluid level and refill as needed. After scan tool cycling is complete, perform one additional manual bleed at each wheel using sequence from previous step.
    ℹ️Some scan tools may require engine to be running during ABS bleeding cycle. Follow specific instructions for your scan tool model.
13. 13

    Verify brake pedal feel and system operation
    With engine running, pump brake pedal several times. Pedal should feel firm with normal travel. If pedal feels spongy or travels too far, repeat bleeding procedure. Turn ignition off and on several times to verify ABS warning light illuminates briefly during bulb check then extinguishes. If ABS light remains on, use scan tool to check for diagnostic trouble codes and address any issues.

Reassembly

1. Reinstall engine cover by aligning clips and pressing down firmly until secured.
2. Verify all brake line connections are tight and properly routed with no contact to moving or hot components.
3. Ensure brake fluid reservoir is filled to MAX line with proper Motorcraft DOT 4 LV brake fluid.
4. Double-check that battery negative cable is securely reconnected.
5. Inspect area under vehicle for any brake fluid leaks from ABS unit or brake line connections.

Verification

• Start engine and verify ABS warning light extinguishes after initial bulb check (approximately 3-5 seconds).
• With engine running, apply firm brake pedal pressure and verify pedal is firm with no excessive travel or sponginess.
• Perform a low-speed test drive (5-10 mph) in safe area and apply brakes firmly to verify proper braking action and no ABS warning light activation.
• Perform ABS function test at low speed (approximately 20 mph) on safe surface by applying firm brake pressure to activate ABS. Verify ABS pulses are felt and vehicle stops properly without warning lights.
• After test drive, inspect all brake line connections at ABS unit for any signs of leakage. Tighten if necessary.
• Use scan tool to verify no ABS diagnostic trouble codes are present in system memory.
• Recheck brake fluid level after test drive and top off if needed. Level may drop slightly as fluid distributes through system.
• Document repair with date and mileage for vehicle service records.

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