REPLACED FSA PARTS INSPECTION AND SIGN OFF
Effective March 1st, 2021 all parts replaced as part of an FSA repair with a repair order open date of March
1st, 2021 or later must be inspected and signed off on the repair order by a member of your dealers fixed
operations management team or an employee the task has been delegated to. If the task is to be delegated
to a non-management employee, the employee needs to be someone other than the technician who
completed the repair and needs to understand the importance of completing this task consistently and
accurately.
•

All parts replaced as part of an FSA repair should be returned to the parts department following the
Warranty Parts Retention and Return Policies.

•

Inspect the replaced parts to verify the FSA repair was completed.

•

If the FSA repair is found to be complete, the designated employee signs the repair order line or
parts return stamp area (electronic or hand signed) for the FSA repair indicating the parts were
inspected and validated to have been replaced.

•

After the parts have been inspected, they should be handled based on the guidance in the parts
status report in the Online Warranty System (Hold, Return, CORE, Scrap, etc.).

•

This process is subject to review during warranty audits for FSA repairs with a repair order open
date of March 1st, 2021 or later. Any eligible FSA claims requiring parts replacement, found not to
have been inspected and signed off during a warranty audit will be subject to chargeback and
consideration for enrollment into the Dealer Incomplete Recall Repair Process.
Note: Other approvals (electronic or handwritten) for add-on repair lines, dealer owned vehicle repairs, and
repeat repairs do not qualify as FSA parts inspection approvals. The post repair FSA parts inspection
process (electronic or handwritten) is independent from other warranty approval requirements. The approval
by the designated employee implies that the FSA parts were found to be replaced and must be able to be
clearly identified on the Repair Order. If multiple FSA’s require approval on a single Repair Order, each
applicable occurrence will require individual post repair approval by the designated employee.

© Copyright 2021 Ford Motor Company

ATTACHMENT III
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RECALL 21N11

CUSTOMER SATISFACTION PROGRAM 21N11
CERTAIN 2006-2010 MODEL YEAR FUSION/MILAN/MKZ/ZEPHYR VEHICLES
EQUIPPED WITH ANTI-LOCK BRAKE SYSTEMS — HYDRAULIC CONTROL UNIT
ONE-TIME REPAIR
REGULAR MAINTENANCE & RELATED DAMAGE
A lack of regular maintenance on a vehicle’s brake system may result in poor braking or even a complete
inability to stop. Some of the more common problems are listed below and should be discussed with the
customer before the repair begins, as they are outside the scope of this program.
1. Leaking brake fluid due to cracks in brake lines or hoses
2. Leaking fluid or other problems with master cylinder
3. Unreliable braking due to air in the system
4. Poor braking caused by worn pads or warped rotors
5. Temporary loss of stopping ability due to oil or grease on the pads or rotors
6. Poor braking due to uneven application of hydraulic pressure on all four wheels
7. A chattering or shaking sensation when the brakes are applied due to bent pads
or rotors
8. A screeching or grinding noise caused by worn brake pads gouging the rotors

SERVICE PROCEDURE

A. Pedal Evaluation..................................................................Page 2

B. IDS Service Function - Hydraulic Control Unit (HCU) Valve
Inspection........................................................................... Page 2
C. Inspection Results..............................................................Page 8

D. Valve Activation PASSES IDS Routine...............................Page 9

E. Valve Activation DOES NOT PASS IDS Routine................Page 12

F. Diagnostic Trouble Codes - C1095, B1342, B1483, and

B1676.....................................................................................Page 18

CPR © 2021 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2021

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Pedal Evaluation
1. Perform a pedal/drive evaluation in the dealer parking lot to determine the condition of the brake pedal:
• Make a note of the following on the repair order before beginning the repair:
1. Pedal travel
2. Height from floor board when pressed
3. Overall pedal feel
2. Perform a walk around visual inspection of the vehicles condition, ensuring there are no current brake
fluid leaks or damage to the braking system before performing this procedure.
3. Review any existing brake pedal travel concerns with customer prior to starting repair.

IDS Service Function - HCU Valve Inspection
NOTE: Ensure that your Integrated Diagnostic Software (IDS) is updated with the most current version.
1. Park the vehicle on a flat, level surface.
2. Apply the parking brake.
NOTE: For manual vehicles ensure the vehicle is in neutral.
3. Connect a battery charger to the 12V battery.
4. Connect the IDS and start a new session.
5. Check for existing diagnostic trouble codes (DTCs).
• DTCs C1095, B1342, B1483, and B1676 may be covered as related damage if present in the IDS
session file.
• Other than DTCs C1095, B1342, B1483, and B1676 - any other existing DTCs should be properly
diagnosed and resolved outside of this field service action.
• Other than DTCs C1095, B1342, B1483, and B1676, resolution of any other DTCs cannot be
claimed as part of this program or as related damage.
• Review any existing DTCs with customer prior to starting repair.
6. If DTCs C1095, B1342, B1483, and B1676 are present, proceed to section Diagnostic Trouble Codes -
C1095,B1342, B1483, and B1676 on PAGE 18. If DTCs are not present, proceed to Step 7.
7. Select the "Tool Box" tab then "Chassis", "Braking" then "Valve Activation". See Figure 1.
8. Follow the on screen prompts to complete the procedure. See Figures 2 through 11, for
screenshots of the process, and applicable notes.
• The procedure will complete the activation of the valves a total of four times.

CPR © 2021 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2021

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RECALL 21N11

1729H

FIGURE 1

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1729J

FIGURE 2

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1729K

CPR © 2021 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2021

FIGURE 3

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RECALL 21N11

1729L

FIGURE 4

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1729M

FIGURE 5

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11/2021

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RECALL 21N11

NOTE: Brake pedal must be depresed when prompted to complete the IDS routine, if brake pedal is not
depressed you will recieve a message prompting you to do so. See Figure 6.
NOTE: If brake pedal is depressed properly, Figure 6 will not apply.

1729R

FIGURE 6

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FIGURE 7

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DEARBORN, MICHIGAN 48121
11/2021

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RECALL 21N11

1729O

FIGURE 8

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FIGURE 9

1729P
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FOR
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11/2021

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RECALL 21N11

NOTE: At the end of the IDS routine, after the activation of the valves has completed a total number of
four times, you will receive one of the two possible screens shown below determining if the IDS
routine has passed or failed. The activation of the valves four times is completed within the IDS
service function. Do NOT repeat the IDS Valve Activation routine multiple times - this is recorded
in the IDS log file. SSSC contacts with multiple pass or fail results will not be approved, additional
information will be requested. See Figures 10 and 11.
NOTE: All IDS session files with a fail result must be saved, requests for additional labor or related
damage will be denied if they are not available upon request. Dealers may also be requested
to upload IDS session files upon request to the Ford Technical Hotline server before
SSSC approval is provided.

1729Q

FIGURE 10

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1729G

FIGURE 11

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CPR © 2021 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2021

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ATTACHMENT III
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RECALL 21N11

INSPECTION RESULTS
1. Did the HCU pass inspection after the IDS routine was performed?
HCU Passes inspection - Proceed to Valve Activation PASSES IDS Routine, on Page 9.

HCU Replacement Not Required.
HCU DOES NOT PASS inspection - Proceed to Valve Activation FAILS IDS Routine, on Page 14.

This procedure will include the HCU Replacement procedure,

and Brake Fluid Change Procedure.

CPR © 2021 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2021

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RECALL 21N11

Valve Activation PASSES IDS Routine
NOTE: DOT3 Brake fluid should have previously been flushed from vehicle when completing 19S54 or
20S14. Updated DOT4 Brake Fluid reservoir cap should already be installed. Contact the SSSC if
these are not present on vehicle and programs were previously completed.

Brake Fluid Change Procedure
1. With the vehicle in NEUTRAL, position it on a hoist. Please follow the Workshop Manual (WSM)
procedures in section 100-02.
NOTE: The front and rear wheel tire assemblies will remain on the vehicle while bleeding the brake
calipers.
2. Bleed the brakes. Please follow WSM procedures in Section 206-00.
3. Using a suitable Brake/Clutch System Pressure Bleeder/Filler, such as the Flo-Dynamics®
BrakeMate JR™ brake flush machine, install the bleeder adapter to the brake master cylinder reservoir
and attach the bleeder tank hose to the fitting on the adapter.
NOTE: When using a suitable Brake/Clutch System Pressure Bleeder/Filler ensure that you are using the
correct adapter cap.The cap should fit tight/snug on the brake master cylinder reservoir.To ensure
a proper fit to the brake master cylinder while using the power bleeder, it is recommend to use
adapter 199-40100045 available through Rotunda or adapter BA04 SP available through NORCO
INDUSTRIES©. The cap can be manually adjusted and tightened by moving the bands of the cap
with your hands to further ensure a proper fit. See Figure 12.

BA04 SP

FIGURE 12

CPR © 2021 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2021

1729I

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RECALL 21N11

4. Turn off the pressure bleeding machine and remove the adapter cap from the master cylinder
reservoir – The pressure bleeder will be used one last time for a final bleed after the next
step (IDS Routine).
5. Verify the brake system connections are secure and functioning properly (master cylinder cap,
bleeder screws, etc.) prior to performing the IDS Routine.
NOTICE: The Integrated Diagnostic Software (IDS) ABS service bleed procedure must be performed.
6. Select the "Tool Box" tab then "Chassis", "Braking" then "ABS Service Bleed". See Figure 13.
7. Follow the on screen prompts to complete the procedure.
• Using IDS perform the ABS service bleed a total of TEN times.

1729V

FIGURE 13

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1729W

FIGURE 14
CPR © 2021 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2021

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RECALL 21N11

1729Y

FIGURE 15

8. Repeat the “Brake Fluid Change Procedure” (Steps 1 through 3, above), while bleeding an additional
2 to 3 oz. from each bleeder screw.
• It is not necessary to perform the ABS service bleed during the secondary bleed.
9. Adjust the brake fluid level in the master cylinder reservoir to the "Max" line.
10. Reassemble the vehicle and ensure the vehicle is secure by reversing the removal procedure.
11. Before returning the keys to the customer, perform a road test to determine the status of the brake
pedal. Since the vehicle passed the IDS Valve Activation Routine, there should be no deterioration
in the brake pedal.
12. If the condition of the pedal is worse than experienced during the initial road test, or if the pedal
goesFOR

STUD
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to the floor, this may be an indication that air has been introduced into the brake system. The
followingNUT
steps should be completed:
STUD
FOR
• Complete the IDS Valve Activation Routine. An IDS session file will be required and a video
is
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required to assist in the pedal evaluation.
• If it passes again – then perform the brake bleed procedure following WSM procedures above.
STUD FOR
• If concern is still present proceed to the complete brake system inspection below.
MISSING NUT
• If it fails the valve test – replace the HCU, recall is complete.
PLACE COPY
NOTE: It may be necessary to step outside these technical instructions and complete normal workshop
HERE
manual diagnostics for low or spongy brake pedal in WSM Section 206-00 Brake System –
PLACE COPY HERE
General Information, Diagnosis and Testing to resolve a customer's brake system concern.
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• Brake fluid leaks and/or air in the system: INSPECT the system for leaks. REPAIR as necessary.
HERE
BLEED the system.
• Brake master cylinder CARRY OUT the Brake Master Cylinder Component Test
• Brake calipers and/or guide pins: INSPECT the brake calipers and guide pins
• Brake flexible hose: INSPECT the brake flexible hoses during brake application.
• Complete the Brake System Inspection.
CPR © 2021 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2021

ATTACHMENT III
PAGE 12 OF 21
RECALL 21N11

Valve Activation DOES NOT PASS IDS Routine
NOTE: If the IDS routine ends with a Replace ABS HCU screen, See Figure 11. Documents will be
required to be submitted to the SSSC prior to HCU Replacement.

Required Submission for HCU Replacement Approval
1. Send the following pictures to Special Service Support Center (SSSC) via the SSSC Web Contact Site:
• One picture of the odometer
• One picture of the Vehicle Certification (VC) Label showing the Vehicle Identification Number
(VIN).
• IDS Log file in PDF format. See Figure 16 and 17.

• Due to software and network differences between dealers, consult your IT department
or IT contact in your dealership for additional instructions.

NOTE: All IDS session files with a fail result must be saved, requests for additional labor or related
damage will be denied if they are not available upon request. Dealers may also be requested
to upload IDS session files upon request to the Ford Technical Hotline server before
SSSC approval is provided.
IDS Log File

1729S

FIGURE 16

CPR © 2021 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2021

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RECALL 21N11

1729T

FIGURE 17
2. Proceed to HCU Replacement, after approval is given by the SSSC.

Hydraulic Control Unit (HCU) Replacement
WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer's specification.

Additionally, do not use brake fluid that has been previously drained. Following these
instructions will help prevent system contamination, brake component damage

and the risk of serious personal injury.
WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL
INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft

products call: 1-800-959-3673. For additional information, consult the product
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Material Safety Data Sheet (MSDS) if available. Failure to follow these instructionsMISSING
may
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result in serious personal injury.
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NOTICE: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a MISSING NUT
painted or plastic surface, immediately wash it with water.
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1. Remove the condenser-to-evaporator line and compressor manifold and tube bracket bolts. MISSING NUT
• To install, tighten to 6 Nm (53 lb-in).

PLACE COPY HERE

2. Position the engine coolant degas bottle aside.

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1. If equipped, detach the wiring harness retainer from the degas bottle.
2. Remove the bolt.

• To install, tighten to 9 Nm (80 lb-in).
3. Remove the nut.

• To install, tighten to 9 Nm (80 lb-in).

PLACE COPY HERE

NOTE: It is not necessary to evacuate, recover and remove the Air Conditioning (A/C) lines for this
procedure.
CPR © 2021 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2021

ATTACHMENT III
PAGE 14 OF 21
RECALL 21N11

3. Disconnect the ABS module electrical connector.
4. Disconnect the brake tube fittings.
• To install:

• tighten the front and rear brake tube fittings to 20 Nm (177 lb-in).

• tighten the master cylinder brake tube fittings to 27 Nm (20 lb-ft).
5. Remove the HCU bracket-to-HCU bolt.
• To install, tighten to 9 Nm (80 lb-in).
NOTE: Due to rust and corrosion the HCU bracket-to-HCU bolt and the HCU may be difficult to remove.
6. Remove the HCU.
NOTE: It is not necessary to remove the HCU bracket from vehicle to complete this procedure.
NOTE: Make sure the HCU and ABS module are clean and free of any brake fluid or foreign material
before separating the components.
7. Transfer the ABS module and the two HCU to bracket grommet securement studs to the new HCU
Valve Body.
8. To install the HCU, reverse the removal procedure.
9. Follow the brake fluid change procedure on Page 15.
NOTE: For manual transmission vehicles it is not necessary to bleed the clutch slave cylinder for
this procedure.

CPR © 2021 FORD MOTOR COMPANY
DEARBORN, MICHIGAN 48121
11/2021

ATTACHMENT III
PAGE 15 OF 21
RECALL 21N11

Brake Fluid Change Procedure