Ford Explorer: Hydraulic Brake Actuation / Removal and Installation - Brake Fluid Reservoir

Removal

NOTICE: Siphon the brake fluid from the HCU/EBB reservoir, if the reservoir is not emptied there will be a large amount of brake fluid spilled in the engine compartment.

NOTE: Removal steps in this procedure may contain installation details.

1. Remove the cowl panel grille.
   Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
   

1. Release the tabs and remove the BCMC cover.
   

1. 
   
   1. Remove the nut and position aside the cable aside.
      Torque: 106 lb.in (12 Nm)
   2. Fully loosen the BCMC connector bolts.
      Torque: 48 lb.in (5.4 Nm)

1. Release the tabs and remove the BCMC.
   

1. Remove the bolts, detach the wiring retainers and then remove the BCMC support bracket.
   Torque: 106 lb.in (12 Nm)

1. NOTICE: If the brake fluid is spilled on any component, the affected area must be immediately washed down with cold water.

   NOTE: Be prepared to collect escaping fluid.

   Disconnect the remote brake fluid reservoir tube and drain the fluid into a suitable container.
   

1. Disconnect the electrical connectors.
   

1. Disconnect the electrical connector.
   

1. Syphon and remove the brake fluid with the help of flexible hose and syringe.
   

1. NOTE: Brake fluid reservoir mounting screws and the sealings plugs are supplied with the brake fluid reservoir kit.

   Remove the screws and the brake fluid reservoir. Discard the screws.
   Torque: 23 lb.in (2.6 Nm)

1. NOTE: Brake fluid reservoir mounting screws and the sealings plugs are supplied with the brake fluid reservoir kit.

   Ensure that old brake fluid reservoir sealing washers are removed before installing new reservoir with new washers.
   

Installation

1. To install, reverse the removal procedure.
   

1. Remove the remote brake fluid reservoir cap.
   

1. Fill the reservoir with clean, specified brake fluid.
   Refer to: Specifications (206-00 Brake System - General Information, Specifications).