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TSB 06-22-1

11/13/06

ABS LIGHT ON AND DTC C1475 - HYBRID VEHICLES
BUILT FROM 8/2/2004 - 3/30/2006.

FORD:
2005-2006 Escape Hybrid

MERCURY:
2006 Mariner Hybrid

This article supersedes TSB 06-10-14 to update the Service Procedure.

ISSUE
Some 2005-2006 Escape Hybrid and 2006 Mariner Hybrid vehicles built from 8/2/2004 to 3/30/2006 may exhibit an amber ABS light with a red brake light and an accompanying diagnostic trouble code (DTC) C1475. When this code is set the hydraulic pump motor will run any time the brakes are applied, so brake assist is maintained. Some customers may report an audible noise from the pump motor when brakes are applied.

ACTION
Use the following Service Procedure to retrieve subfault data to determine if the hydraulic control unit (HCU) needs to be replaced, or if the HCU can be reprogrammed instead. If the HCU is reprogrammed, it will also be necessary to add grease to the high pressure accumulator (HPA) connector terminals.

SERVICE PROCEDURE
NOTE
DO NOT CLEAR CODES DURING DTC RETRIEVAL.

1. Run ABS module self test using IDS release B45.3 and higher. Do not clear DTCs.

2. If DTC C1475 is NOT present, refer to Workshop Manual (WSM), Section 206-06, Hydraulic Brake Actuation, of the appropriate year Workshop Manual. No further actions are required from this TSB.

3. If a DTC C1475 is present, using IDS, a question mark (?) will be displayed next to the DTC (Figure 1). Follow the screen prompts to retrieve the data stored in EEPROM Location Ox6B (Figure 2). Write down value stored at EEPROM Location Ox6B. The bitmap displayed below the line which includes the Ox6B and subfault can be ignored.



4. If DTC list includes other DTCs in addition to the C1475, all Non-C1475 DTCs should be diagnosed first.
a. If pinpoint tests for other DTCs lead to replacement of the HCU replace HCU per procedure in WSM, Section 206-09, and continue with normal diagnosis as needed. No further actions are required from this TSB.
NOTE
THE REPLACEMENT HCU AVAILABLE FROM SERVICE WILL ALREADY CONTAIN THE LATEST SOFTWARE UPDATES, AND WILL ALREADY HAVE GREASE IN THE HPA CONNECTOR TERMINALS.
b. If C1475 is the only DTC present, or the pinpoint test for the other DTCs did not lead to HCU replacement, then repair any faults identified by the pinpoint test for the other DTCs and proceed to Step 5.

5. Analyze the BSCM C1475 EEPROM information.
a. If EEPROM Ox6B = "Ox10" or "Ox11", then proceed to TSB service procedure for adding grease to HPA connector and reprogramming the ABS module.
b. If EEPROM Ox6B is equal to any other value and DTC C1475 is present, replace the HCU per procedure in WSM, Section 206-09. No further actions are required from this TSB.

PROCEDURE TO ADD GREASE TO THE HPA CONNECTOR
NOTE
INDIVIDUAL GREASE PIPETTES, PROVIDE A MEASURED QUANTITY OF GREASE FOR EACH TERMINAL AND SHOULD BE USED FOR THIS REPAIR, ONE (1) FOR EACH TERMINAL, A TOTAL OF THREE (3) FOR EACH CONNECTOR. THE USE OF TOO MUCH GREASE MAY PREVENT THE CONNECTOR FROM SEATING FULLY WHEN RECONNECTING.

1. After parking vehicle in repair bay and opening the hood, wait at least 5 minutes or until you hear the electro hydraulic brake (EHB) system shut down completely (ignition switch off) before beginning repairs.

2. Disconnect 12 volt battery.

3. Remove the 47-way EHB system connector from the HCU, by pushing the locking mechanism and pulling the lever/cover up. Move the connector back and out of the way.

4. Remove the 4-way high pressure accumulator (HPA) connector, (located directly below the 47 way connector you disconnected in step 3), from the HCU by pushing the connector slightly forward to the ECU, releasing the locking mechanism underneath on the bottom side and pulling the connector backwards. Do not disconnect or attempt to add grease to the connector on the accumulator canister.

5. Carefully position the HPA connector upwards so you can look into the terminals of the connector. One of the four possible pin locations is empty. Only add grease to those locations which contain terminals, Pin locations 1, 3, and 4.

6. Remove cap from grease pipette (tube) and squeeze the contents of the tube into one of the three (3) terminals (1, 3, or 4); use one (1) pipette (tube) for each terminal. All three (3) terminals need to be greased.
NOTE
THE GREASE MUST BE INJECTED INTO THE FEMALE TERMINAL ENDS AND NOT SIMPLY SMEARED AROUND THE CONNECTOR FACES. TAKE CARE NOT TO SPREAD THE FEMALE TERMINAL ENDS WITH THE PIPETTE TUBE. (FIGURE 3)


7. Push the 4-way HPA connector back onto the ECU and make sure that the locking mechanism closes properly (audible click).

8. Install the 47-way connector back onto the ECU and make sure that the locking mechanism closes properly (audible click).

9. Reconnect the 12 volt battery.

10. Turn on the ignition then step on the brake pedal once and release it all the way to calibrate the brake pedal travel sensor. This step is required any time the 12 volt battery is disconnected for any reason.

11. Clear DTCs. This will eliminate DTCs set during the Grease Procedure.

PROCEDURE TO REPROGRAM THE ABS MODULE
1. Reprogram the ABS module to the latest calibration using IDS release IDS 45.3 and higher. This new calibration is not included in the VCM 2006.9 DVD. Calibration files may also be obtained at the website. Choose "ABS module" from the menu.
NOTE
THE RED BRAKE LIGHT WILL BE ILLUMINATED AND DTCS C1525 AND C1473 WILL BE SET AFTER REPROGRAMMING HAS COMPLETED.

2. After completion of reprogramming procedure, run an "Air Bleed Check" followed by an "ACU Bleed Check' to complete the repair and clear the DTCs C1525 and C1473.

Parts Block
PART NUMBER
PART NAME
7M6Z-2C286-BHCU
6U7Z-8042-AGrease
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

OPERATION
DESCRIPTION
TIME
062201A2005-2006 Escape Hybrid, Mariner Hybrid: Check Diagnostic Trouble Codes, Add Grease To The ABS Module Connector, And Reprogram The ABS Module (Do Not Use With 2219D, 2219D11, 12651D, 12651D4)
0.7 Hr.​
062201B2005-2006 Escape Hybrid, Mariner Hybrid: Check Diagnostic Trouble Codes, And Replace HCU, Bleed Brakes, (Module Configuration Not Required) (Do Not Use With 2219D, 2219D11, 12651D, 12651D4)
2.1 HrS.​
MT062201Claim Additional Labor Required As Actual Time Or Use SLTS Operation If Available
Actual Time​
DEALER CODING
BASIC PART NO.
CONDITION CODE
2C286
04​
 
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