ATC event detected. ATC off-road switch activation detected. Service brake intervention due to parking brake application request during vehicle driving detected. Before disposing of used components, verify the warranty status. For vehicle equipped with manual parking brakes, apply the parking brakes.
Ensure that the ignition is turned off. Block the front and rear wheels to prevent the vehicle from moving. The full power brake system is a pressurized system that achieves pressures of up to psi. This pressure is not reduced by switching the ignition off or removing battery power. Prior to servicing this system, the depressurization procedures must be performed exactly as presented.
Failure to depressurize the system may result in serious personal injury. Release all air from the air systems before you remove any components. Pressurized air can cause serious personal injury. Failure to depressurize the system may result in personal injury or death. Thoroughly clean the area around the HCU fittings before beginning the removal procedure to avoid contaminating the system. As hoses and brake lines are removed, plug all open ports and lines.
Contamination may cause loss of braking force or brake failure, and result in serious personal injury. If the system sustains damage, or a component malfunctions and requires replacement, the replacement procedures provided by Meritor WABCO must be followed exactly with the associated steps performed in the order presented.
Hydraulic brake fluid is a caustic substance. Contact with the hydraulic brake fluid can cause skin irritation. Do not let hydraulic brake fluid touch any painted surfaces, as it will remove the paint. Hydraulic brake fluid may also damage certain non-metal surfaces.
Do not let fluid contact brake pads, shoes, rotors or discs. If your vehicle is equipped with manual parking brakes, refer to the manual parking brake procedures. To determine the type of parking brake on the vehicle, refer to the vehicle specification sheet. Bleed procedures appear in Section 5 of this manual.
Park the vehicle on a level surface. Apply the parking brake. Ensure that the ignition is turned OFF. Block the front and rear tires to prevent the vehicle from moving.
Disconnect the battery. Use a clean rag to carefully clean the surface of the HCU and the surrounding area. Apply the brake pedal a minimum of 30 times to decrease pressure in the system. To ensure the system is depressurized, perform the following check on both the front and rear axles. Remove the protective cover from the end of the bleeder fitting on one brake caliper. Attach hose clamp pliers to the low pressure hose at the HCU reservoir inlet.
Clamp the rubber hose at least 3 inches 76 mm away from the entrance to the HCU reservoir. Use care to avoid damage to the plastic reservoir nipple inside the hose. Figure 4. Attach a bleeder bottle hose to the bleeder fitting at the wheel end. Submerge the free end of the bleeder hose into the bleeder bottle. Both the tubing and container must be able to withstand the effects of hydraulic brake fluid.
Apply and hold the brake pedal down until no more brake fluid runs out. Do not release the brake pedal. With the brake pedal still applied, use a torque wrench to tighten the bleeder fitting screw to the torque value specified by the component manufacturer.
Repeat Steps A-E for the second axle. If damaged, it will need to be replaced. Loosen the two support brackets and any retaining hardware that holds the middle section of the low pressure hose to the chassis. The bolts must be loose enough to allow movement of the hose during the HCU removal. To help prevent brake fluid from damaging the vehicle or floor paint, or from seeping into the ground, position a container beneath the work area to collect any drained or spilled brake fluid.
Disconnect the low pressure hose from the HCU reservoir. Plug both the low pressure hose and the HCU reservoir inlet to prevent system contamination. To do this: A. Reconnect the battery. Attach a bleeder bottle to one wheel end at the front axle. The pull-down option, Drain Reservoir, will appear. Click on Drain Reservoir to start the drain procedure. Open the bleeder screw.
Apply and hold the brake pedal down until no more fluid runs out. Tighten the bleeder screw. Repeat Steps D-G for the rear axle. Disconnect the brake lines from the HCU. There are at least six brake lines; seven if the system is equipped with power parking brakes. Plug the brake lines and ports on the HCU to prevent system contamination. Mark the brake lines to ensure correct positioning during reassembly.
While supporting the HCU, loosen and remove the four nuts two per side that hold the HCU mounting brackets to the frame rail of the vehicle. Remove the HCU, with mounting brackets attached, from the vehicle. Open the latches on the two-pin power connector and the pin harness attached to the ECU.
After the latch is released, remove the connectors from the ECU. If the vehicle is equipped with hydraulic parking brakes, disconnect the pressure supply valve electrical connector on the HCU. Refer to the Parking Brake Pressure Supply Valve removal and installation procedures in this section. Loosen and remove the two bolts that hold the HCU to the front mounting bracket. Then, loosen and remove the two bolts that hold the HCU to the rear mounting bracket.
Connect the brake lines. Remove the protective cover before attaching the line. Check the line markers to ensure correct installation on the HCU. Remove the mounting brackets from the HCU.
Examine the four bushings inside the brackets for potential deformations. Replace if necessary. Verify the warranty status. To prevent fluid loss, do not remove the protective caps until you are ready to connect the brake lines. Damage to components can result. Refer to the HCU reservoir installation information in this section. Refer to Section 5. Ensure that the ignition is off and the battery is disconnected. Position the HCU between the mounting brackets. Tighten the nuts to Connect the low pressure hose from the master cylinder reservoir to the HCU reservoir and secure the connection with a hose clamp.
Once the connection is secure, remove the pinch clamp installed during the removal of the old HCU. Tighten the two support brackets hose clamps that secure the low pressure hose to the vehicle chassis. Fill the brake system with new brake fluid from a sealed container until the fluid level in the master cylinder reservoir stabilizes at the Max mark. Refer to the vehicle specifications sheet to determine which fluid to use. The open bleeder screw facilitates the expelling of the air from the system.
Close the bleeder screw when filling is complete. Failure to securely connect and correctly latch the connectors could result in loss of braking functions during vehicle operation. Serious personal injury can result. Attach the pin harness and then the two-pin power connector to the ECU.
Push the latch into position to lock the connection. If the vehicle is equipped with a hydraulic parking brake, attach the pressure supply valve connector.
Proceed with pressure filling and bleeding the brake caliper circuits, and the SAHR circuit, if applicable. Refer to Section 5 for procedures. Refer to the hydraulic compact unit removal procedure in this section. Remove the HCU assembly from the vehicle. Inspect the area between the body of the HCU and the HCU reservoir to ensure the area is free from any dirt or other contaminants.
Clean if necessary. Do not allow any contaminants to enter the HCU ports. Use a number 4 Phillips-head screwdriver to remove the four HCU reservoir mounting screws. Then, remove the reservoir from the HCU. With the ports plugged, clean the top of the HCU. Do not reuse the seals or screws from the old reservoir. Inspect the top of the HCU to ensure it is clean and free from debris or other contaminants. Remove the plugs from the reservoir ports on the HCU. Install the four new black rubber grommets from the replacement kit into the ports on the top of the HCU.
Remove the old rubber grommets from the four ports. Do not allow any dirt or other contaminants from these grommets to enter the HCU ports.
If contaminated, the unit must be replaced. Seal the HCU reservoir ports. Refer to the vehicle specification sheet to determine which fluid to use. Position the reservoir on the HCU and verify orientation: The mounting screw holes must line up and the inlet port for the low pressure hose must face the front of the HCU.
Use the four new mounting screws to attach the reservoir to the HCU. Reinstall the HCU assembly on the vehicle. Refer to the hydraulic compact unit installation procedure in this section. Install the new reservoir by pressing it carefully and completely into the grommets in the ports. It is possible for the removed accumulator to retain an internal pressure of up to psi.
To eliminate any removed accumulator from posing a safety hazard, depressurize the accumulator and disable its pressure chamber. If the system sustains damage, or a component malfunctions and requires replacement, the vehicle owner is strongly advised to contact the nearest dealer for professional assistance and repair.
If location and circumstances prevent consulting the dealer, and components must be replaced, the replacement procedures provided by Meritor WABCO must be followed exactly with the associated steps performed in the order presented. Block the front and rear tires to prevent vehicle movement. Use a clean rag to carefully wipe the surface of the HCU and the surrounding area. When replacing an accumulator, note and record the expiration date of the replacement accumulator.
Use a wrench to open the bleeder fitting screw. Follow Steps 10AD to perform this procedure. Drilling accumulators will void the warranty. For vehicles with manual parking brakes, apply the parking brakes. Securely position the accumulator on a drill press table.
Use a vise or clamp that will allow the accumulator to be correctly positioned. The drilling point will be on the opposite side of the welded seam from the threaded port. Center punch the accumulator. Use a strap wrench to remove the accumulator. The accumulator has a right-hand thread. Use a clean rag to clean the counterbore on the HCU.
Inspect the counterbore to ensure that the O-ring seal was removed. Plug the counterbore to prevent contamination from entering the HCU. Determine the warranty status of the accumulators. If the accumulators are under warranty, do not perform Step 11 depressurizing the accumulators.
If the accumulators are not under warranty, the accumulators MUST be depressurized before disposal Step Metal shavings may be blown away from the hole during this procedure.
Wear protective goggles, not glasses, to protect the eyes. Use the following steps to depressurize the accumulator and disable the internal pressure chamber before disposing of the accumulators.
After releasing the internal pressure, correctly dispose of the accumulator. This will prevent the hydraulic pressure in the brake system from rising enough to apply the brakes correctly. This will cause the stopping distance to increase and can result in serious personal injury.
Hydraulic brake fluid that is removed can be contaminated and, if used, can cause damage, loss of braking and serious personal injury. Do not use or mix different types of hydraulic brake fluid. The incorrect hydraulic brake fluid will damage the rubber parts of the brake caliper and can cause damage, loss of braking and serious personal injury. A new accumulator is precharged to a pressure of psi. Do not puncture or pierce the accumulator. Puncturing or piercing the accumulator may result in personal injury or death.
Contact with hydraulic brake fluid can cause skin irritation. Do not let fluid get on brake pads, shoes, rotors or disks. Repeat Steps to replace the second accumulator. Check the fluid level in the master cylinder reservoir. Fluid level should be at the MAX mark.
If not, fill the reservoir to the MAX mark with new brake fluid from a sealed container. Remove the plug from the accumulator counterbore on the HCU. Clean the counterbore and the surrounding area. The old accumulator O-rings should have been removed from the counterbore during removal of the accumulators.
Verify that the O-ring was removed. Use clean brake fluid from a sealed container to lubricate the O-ring on the new accumulator. Place the new accumulator and O-ring into the counterbore. After positioning, use a torque wrench with a strap wrench attachment to tighten to Do not overtighten.
Connect the battery. Turn the ignition to ON. The HCU pump motors will start up and fill the accumulators. Approximate running time is 45 seconds. If there are problems building pressure after bleeding and powering up the system, increase the pressure setting of the pressure bleeder equipment to psi NOTE: Pressure should be left on the system during the first key-on attempt to build pressure. When the pumps stop running and the system is fully charged, the fluid level in the master cylinder reservoir should be between MIN and MAX marks.
Check the accumulator connections for leaks. If there are no leaks, go to Step If there are leaks, depressurize the system before making the necessary repairs.
To ensure that the system is depressurized, perform the following check on both the front and rear axles: A. After making the repairs, check the fluid level in the master cylinder reservoir to make sure it is at the MAX mark when both accumulators are fully depleted. Refer to Section 5 for detailed instructions on how to correctly fill the master cylinder reservoir. Perform the Deplete Accumulators function two times. Refer to the procedure in this section.
Remove the wheel blocks. Test drive the vehicle. Refer to the test drive procedure in Section 3 of this manual. Opening the ECU to gain access to the internal components will void the warranty. Remove the screws in the sequence shown. Refer to Section 3 of this manual for parameter entry procedures. Carefully remove the ECU by lifting straight out.
Determine the warranty status of the ECU. If it is not under warranty, discard the used ECU. The connectors are sensitive and can be damaged by static electrical shock. Use a clean rag to carefully clean the area around the valves formerly covered by the ECU. Do not touch the two pressure sensor connectors. Apply gentle pressure to seat the ECU. Motor connectors must achieve full depth into the housing. Remove and discard the orange seals from the two pressure sensors. Tighten to 14 in-lb 1.
Do not exceed this torque. Tighten the screws using the correct sequence. Install the seals onto the replacement ECU. Do not force the ECU into position. Use a gentle, even pressure when positioning the ECU. Electrical connectors must be correctly installed with the latch pushed in to lock the connection to prevent them from coming loose or disconnecting. Contact Navistar for assistance. For Non-Navistar vehicles, the parameters may be entered manually. Release 1: These ECUs were original equipment on most vehicles built prior to and only have a 5-parameter capability.
Release 2: These ECUs are original equipment on most vehicles built to present and have a parameter capability. If you are able to communicate with the original ECU, try to obtain the parameter data set numbers as follows. If the original ECU was just reinstalled, test drive the vehicle. Turn the ignition on. Connect the computer to the vehicle. A drop-down menu will appear. Click the Download button. Once the Notepad page has been brought up, type the VIN on the first line and press enter to move down to the next line.
Use the data sets that were saved from the original ECU. Verify the Parameters Use the following procedure to verify the parameters were saved correctly. In the File Save window, save the file as follows. Save in: 4.
They should be identical. Refer to the Test Drive procedure in Section 3 of this manual. The parameter file will now be saved to the computer. To correct this issue, perform the following. Press and hold down the Ctrl, Alt and Shift keys, then tap the F12 key.
Release the keys. The lamps may remain on solid until the vehicle sees wheel speed above 4 mph. It has its own Icon and is a separate stand-alone software program. Once the correct HPB programmer has been installed on to the computer, determine if the vehicle has an ammeter. Follow the screen prompts to reflash the ECU. During the reflash the ignition should be off and the brake pedal must be depressed through the entire process, which may take several minutes.
Once the file has been obtained, use the following procedure to install it. Release the brake pedal and wait three seconds. Release the brake pedal and turn the ignition on. If the ammeter fuse was removed, reinstall the fuse. Depending on the version of the HPB Programmer that was used, it may be necessary to download new parameters. Wear safe eye protection.
Block the wheels to prevent the vehicle from moving. With the brake pedal still applied, use a torque wrench to close the bleeder fitting screw. Use a torque wrench to tighten the bleeder fitting screw to the torque value specified by the component manufacturer.
Repeat Step 4 and Step 5 for the other axle. Use hose clamp pliers to clamp the rubber hose at least three-inches 76 mm away from the entrance to the HCU reservoir. Disconnect the two master cylinder brake lines from the relay valve. Plug the two lines to prevent contamination. Use a 4 mm socket wrench to loosen and remove the five Allen-head screws that secure the relay valve to the hydraulic compact unit HCU.
Carefully lower and remove the relay valve. Remove and discard the rubber-coated seal plate. Do not reuse this plate. During installation, use the new seal plate included with the relay valve replacement kit. Tighten each bolt twice. Use denatured alcohol and lint-free rags to clean the valve mounting surface.
Ensure there is no rubber sticking to the HCU. Do not allow rubber or other debris to fall into the HPB bore holes. Place the remaining four screws into the mounting holes on the relay valve. Hand tighten all five screws. Attach the master cylinder brake lines. Remove the hose clamp from the low pressure hose. Fill the brake system with new brake fluid from a sealed container until the fluid level in the master cylinder reservoir stabilizes at the MAX mark.
Place a screw into the center mounting hole of the relay valve. Use a hex-head socket tool for positioning. Place the new relay valve seal onto the relay valve using the screw to align the seal. The orientation should match Figure 4. Position the relay valve against the HCU. Thread the screw into the HCU. Proceed with pressure filling and bleeding the master cylinder circuit. Proceed with pressure filling and bleeding the brake caliper circuits, and the SAHR circuit if applicable. Use hose clamp pliers to clamp the rubber hose at least three-inches For a rear axle pump, proceed to Step 9.
For a front axle pump, carefully remove the relay valve from the HCU to gain access to the pump. Do not kink or bend the brake lines while removing the relay valve. Prepare the replacement pump. Lubricate both pump O-rings with brake fluid. Actuate the pump several times by depressing the spring-loaded pump button by hand. The initial force required to actuate the pump and depress the pump button may be high at first.
However, after the first actuation, the force should be reduced. Use a 6 mm hex-head socket wrench to remove the pump retaining plug from the HCU cavity.
To minimize fluid spill, keep the replacement pump within reach and prepared for installation. Use needle nose pliers with a good grip to remove the pump from the bore. Use care to prevent damage to the O-rings. Avoid sliding the needle nose pliers on the pump.
This can produce metal filings or contaminants which can enter the pump bore. Do not leave any foreign material in the pump bore. Insert the pump retaining plug into the threaded hole. Inspect the bore holes to verify that no foreign material such as rubber, rag lint or metal filings have entered the bore holes. If necessary, remove foreign material with a lint-free swab.
Install the replacement pump. Refer to the installation procedure. If you are replacing both pumps, do not remove the second pump before installing the first replacement pump. Repeat the procedure for removing and installing the second pump if replacing both pumps. Installation 4. If the front axle pump was replaced, install the relay valve. Remove the hose clamp from the rubber hose.
Use care when installing the pump to prevent damage to the O-rings. Use care not to damage the O-rings. If the old reservoir is going to be installed onto the new master cylinder, care must be taken during the removal process not to damage the reservoir. Do not install a damaged reservoir. Use a clean rag to carefully clean the outside of the master cylinder and master cylinder reservoir. Make sure the replacement kit is available before you begin the removal.
If the current reservoir is to be reused, you will need to be careful when removing the master cylinder and reservoir assembly from the vehicle, and when you separate the components. If the reservoir is damaged in any way, it is not reusable. It does not include the master cylinder reservoir. NOTE: Both the foot brake switch and the fluid level sensor switch can be replaced without draining the brake fluid. If you are replacing either of these switches, follow the procedures given in this manual.
Disconnect the foot brake switch on the master cylinder and the fluid level switch on the master cylinder reservoir. Attach a pinch clamp to the low pressure hose near the outlet of the master cylinder reservoir. Do not damage the reservoir outlet. Remove the hose clamp. Disconnect the low pressure hose from the master cylinder reservoir. Sub-package Trailer First License subscription ref.
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