This procedure covers the removal and replacement of the ABS hydraulic control unit (HCU) pump assembly on a 2015-2020 Ford F-150 with the 5.0L Coyote V8 engine.

Warnings

Tools required

Parts

• ABS hydraulic control unit (HCU) pump assembly × 1 — Use OEM specification
• Brake line crush washers/seals × 6 — Use OEM specification
• Shop towels × 1 — Generic

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 1 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Open hood and locate brake fluid reservoir - remove cap and use turkey baster to remove old fluid down to minimum line (dispose properly)
4. Disconnect negative battery terminal and wait 2 minutes for airbag system to discharge
5. Locate ABS pump assembly on driver side frame rail forward of driver door area
6. Spray all brake line fittings at ABS pump with penetrating oil and let soak 10-15 minutes

Procedure

1. 1

   Access ABS pump assembly
   The ABS pump is mounted to the driver side frame rail. Remove any plastic covers or shields that obstruct access to the pump. On some models, the driver side front wheel may need to be removed for easier access. If removing wheel, raise vehicle with floor jack, support on jack stands, and remove wheel.
2. 2

   Disconnect electrical connector
   Locate the main electrical connector on the ABS pump assembly. Press the release tab and carefully disconnect the connector. Inspect connector pins for corrosion or damage. Move connector away from work area to prevent brake fluid contamination.
   ⚠Do not pull on wiring - press release tab fully before separating connector.
3. 3

   Label and disconnect brake lines
   There are six brake lines connected to the ABS pump (four wheel circuits plus inlet and return). Use a marker or tape to label each line location before removal. Place drain pan beneath pump. Using line wrenches to prevent rounding, loosen each brake line fitting at the pump. Work slowly and expect brake fluid to drain. Have caps or safety wire ready to immediately seal each line opening to prevent contamination.
   ⚠Use only line wrenches - standard wrenches will round off soft brass fittings.
   ℹ️Brake fluid will drain from lines - have catch pan positioned and plug lines immediately.
   Torque spec

   Line Fittings26 Nm (19 lb-ft)
4. 4

   Remove mounting hardware
   The ABS pump assembly is secured to the frame bracket with mounting bolts (typically three). Remove these bolts using appropriate socket. Support the weight of the pump with one hand as the final bolt is removed as the assembly is relatively heavy.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
5. 5

   Remove ABS pump assembly
   Carefully lower the ABS pump assembly from its mounting location. Keep assembly upright to minimize additional fluid spillage. Place old pump on workbench with drain pan underneath. Inspect mounting bracket for damage or corrosion and clean mounting surfaces with wire brush.
6. 6

   Prepare new ABS pump
   Remove new ABS pump from packaging. Verify part number matches old unit. Remove all protective caps from brake line ports. Install new crush washers/seals on all six brake line ports. Compare old and new units to ensure identical configuration.
   ℹ️New pump may come pre-filled with fluid or dry - verify manufacturer instructions.
7. 7

   Install new ABS pump assembly
   Position new ABS pump assembly onto mounting bracket on frame rail. Align mounting holes and thread bolts by hand first. Once all bolts are started, torque mounting bolts to specification in a crossing pattern to ensure even seating.
   Torque spec

   Mounting Bolts34 Nm (25 lb-ft)
8. 8

   Connect brake lines
   Remove caps from brake lines. Verify crush washers are properly seated in pump ports. Thread each brake line fitting by hand first according to your labels to ensure correct routing. Once all fittings are hand-started, use line wrench to torque each fitting to specification. Double-check all six connections are tight and properly seated.
   ⚠Cross-threading brass fittings will require line replacement - thread by hand first to verify alignment.
   Torque spec

   Line Fittings26 Nm (19 lb-ft)
9. 9

   Reconnect electrical connector
   Wipe electrical connector clean of any brake fluid. Align connector with ABS pump and press firmly until release tab clicks into locked position. Verify connection is secure by gently pulling on connector.
10. 10

    Fill brake fluid reservoir
    Fill brake fluid reservoir to MAX line with fresh Motorcraft DOT 4 LV brake fluid. Keep reservoir topped off throughout bleeding process - check level frequently.
    ⚠️Only use DOT 4 LV brake fluid - other fluid types will damage ABS components and seals.
11. 11

    Reconnect battery and perform ABS bleeding
    Reconnect negative battery terminal. Connect ABS-capable scan tool to vehicle OBD-II port. Turn ignition to ON position (do not start engine). Using scan tool, navigate to ABS system bleeding function. Follow scan tool prompts to activate ABS pump cycles while manually bleeding brakes at each wheel in sequence: right rear, left rear, right front, left front. Have assistant monitor fluid level and add fluid as needed. Each wheel requires multiple cycles to purge all air from ABS hydraulic unit.
    ⚠Scan tool activation is mandatory - the ABS pump must cycle to purge internal valves that cannot be bled manually.
    ℹ️This process typically requires 15-30 minutes and may consume significant brake fluid.
12. 12

    Manual brake bleeding
    After ABS pump bleeding cycles are complete, perform conventional two-person brake bleeding at each wheel (same sequence: RR, LR, RF, LF). At each wheel, have assistant pump brake pedal three times and hold, then open bleeder screw until fluid stops flowing, close bleeder screw, and repeat until no air bubbles appear in fluid. Torque bleeder screws to specification.
    ⚠Do not overtighten bleeder screws - they are easily stripped.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
13. 13

    Reinstall wheel and components
    If wheel was removed for access, reinstall wheel and torque lug nuts to specification in star pattern. Reinstall any plastic covers or shields removed during access. Top off brake fluid reservoir to MAX line.
    Torque spec

    Wheel Lug Nuts204 Nm (150 lb-ft)

Reassembly

1. Verify all brake line fittings are torqued and not leaking
2. Confirm electrical connector is fully locked
3. Ensure brake fluid reservoir is at MAX line with cap properly installed
4. Verify no tools or parts are left in engine compartment or wheel well

Verification

• Start engine and verify ABS warning light turns off after 2-3 seconds
• With engine running, press brake pedal firmly - it should feel solid with no sponginess
• Perform test drive in safe area at low speed - verify normal brake operation and no warning lights
• Test ABS activation on dry pavement at low speed (if safe to do so) - pedal should pulsate normally
• Return to shop and inspect all brake line connections at ABS pump for any signs of leakage
• Use scan tool to verify no ABS fault codes are present
• Re-check brake fluid level after test drive and top off if needed

More procedures for this vehicle