Haas, a former world number two but now down at 302, won 2-6, 7-6 (10/8), 6-4 for just his fourth victory in 17 meetings against his close friend.
Federer, building up for an assault on an eighth Wimbledon title, hadn't played since March and skipped the entire clay court season.
It was just the second defeat of 2017 for 35-year-old Federer, who claimed the Australian Open for his 18th major in January,
"I saved a match point in the second set so was able to play more freely after that.
"I even shocked myself.
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