Electric Brake Controller Installation in a 2005 Ford Expedition

The Ford Expedition is a full-size sport utility vehicle (SUV) that has been in production since 1997. It was originally a mid-size SUV, but has been Ford's largest SUV since the 2005 model year. The 2005 Ford Expedition has an anti-lock braking system (ABS), which requires a controller known specifically as a hydraulic control unit, or HCU. The HCU reduces the braking force on a wheel when it senses the wheel is rotating more slowly than the other wheels. This allows the vehicle to stop more effectively when the wheels lose traction.

Instructions

1

Remove the cables to the battery terminals with a socket wrench. This precaution avoids the possibility of an electrical discharge, which can damage the HCU. Disconnect the air cleaner and evaporative emissions (EVAP) canister in the engine compartment to gain access to the HCU under the air cleaner.

2

Label the five brake lines one through five, going from left to right. This will ensure you connect the brake lines correctly when you install the new HCU. Disconnect the brake lines from the HCU with a socket wrench. Plug the open ends of the brakes lines with clean cloth to keep brake fluid from leaking out.

3

Detach the electrical connector from the HCU, and disconnect the mounting bolts for the HCU with a socket wrench. Remove the HCU from its bracket.

4

Install the new HCU to its bracket, and tighten the bracket bolts to 22 foot-pounds with a torque wrench. Connect the brake lines to the correct ports on the HCU, according to the labels you made in step two. Tighten the fittings for brake lines one and three to 13 foot-pounds. Tighten the fittings for brake lines two, four and five to 18 foot-pounds.

5

Attach the electrical connector to the HCU. Connect the EVAP canister and the air cleaner with a socket wrench. Connect the cables to the battery terminals, and bleed the brake system.