Complete replacement of all brake lines from master cylinder to all four wheels, including front and rear hard lines and flexible hoses.

Warnings

Tools required

Parts

• Complete brake line kit (3/16" steel tubing pre-bent or straight stock) × 1 — Use OEM specification or aftermarket complete kit
• Front brake hoses (left and right) × 2 — Use OEM specification
• Rear brake hose × 1 — Use OEM specification
• Brake line clips and retainers × 1 — Assorted frame mount clips
• Brake line fittings (inverted flare) × 1 — 3/16" and 1/4" assortment

Fluids

• DOT 4 Brake Fluid — 2 qt

Preparation

1. Park vehicle on level, solid surface and set parking brake firmly
2. Place wheel chocks behind rear wheels
3. Loosen all four wheel lug nuts while vehicle is on ground
4. Raise vehicle and support securely on four jack stands at frame rail points
5. Remove all four wheels
6. Place drain pans under master cylinder and all four wheel cylinders/calipers
7. If working with pre-bent line kit, lay out all lines and verify fitment before beginning removal
8. If fabricating lines from straight stock, take detailed photographs and measurements of existing line routing before removal
9. Apply penetrating oil to all brake line fittings at least 30 minutes before attempting removal

Procedure

1. 1

   Drain master cylinder reservoir
   Using a turkey baster or fluid transfer pump, remove as much brake fluid as possible from the master cylinder reservoir. Wipe up any spills immediately to prevent paint damage. This minimizes fluid loss during line removal.
2. 2

   Disconnect lines at master cylinder
   Locate the two brake line fittings at the master cylinder (front and rear circuits). Using appropriate line wrenches, carefully loosen and remove both lines from the master cylinder ports. The front line typically feeds the front disc brakes, and the rear line feeds the rear drum brakes through a distribution block. Cap or plug the master cylinder ports immediately to prevent contamination. Allow remaining fluid to drain into catch pan.
3. 3

   Remove front brake lines
   Starting at the master cylinder, trace the front brake line to the distribution block on the frame. Disconnect the line at the distribution block using a line wrench. Follow each line forward to where it connects to the flexible brake hose near each front wheel. Disconnect the hard line from the flexible hose at each front wheel location. Remove all frame clips and retainers securing the front lines to the frame and body. Extract the complete front hard line assembly. Note routing, clip locations, and clearances from exhaust, suspension, and steering components.
4. 4

   Remove front flexible brake hoses
   At each front wheel, locate where the flexible brake hose connects to the caliper. Using a line wrench, disconnect the hose from the caliper. Remove the bracket bolt securing the flexible hose to the frame or suspension component. Remove both front flexible hoses completely. Inspect caliper ports for damage or corrosion.
5. 5

   Remove rear brake line
   From the master cylinder distribution point, trace the rear brake line along the frame toward the rear axle. Disconnect the line at the distribution block using a line wrench. Follow the line rearward to where it connects to the rear flexible hose or distribution block on the rear axle housing. Disconnect the hard line at this junction. Remove all frame clips securing the rear line. Extract the complete rear hard line assembly, noting routing and clip positions.
6. 6

   Remove rear flexible hose and axle lines
   Disconnect the flexible brake hose from the frame-mounted bracket. At the rear axle housing, disconnect the hose from the axle-mounted distribution block or tee fitting. Remove the flexible hose. If present, disconnect the hard lines running along the rear axle housing to each wheel cylinder. Remove the retaining clips securing lines to the axle housing. Extract all rear axle lines completely.
7. 7

   Clean all fittings and mounting points
   Using a wire brush, clean all fittings at the master cylinder, distribution blocks, calipers, and wheel cylinders. Remove rust, old thread sealant, and debris. Inspect all threaded ports for damage. Chase threads with appropriate tap if necessary. Clean all frame-mounted clip locations. This ensures proper sealing and torque values when installing new lines.
8. 8

   Install new front brake lines
   If using pre-bent lines, route the new front brake lines along the original path, ensuring proper clearance from exhaust, suspension, and steering components. If fabricating from straight stock, bend tubing carefully using a tubing bender to match original routing. Maintain minimum 2-inch clearance from exhaust components and 1-inch clearance from suspension travel paths. Install frame clips loosely to allow final positioning adjustment. Do not fully tighten fittings yet.
9. 9

   Install new front flexible brake hoses
   Install new front flexible brake hoses at each front wheel. Mount the hose bracket to the frame or suspension mount. Connect the hose to the hard line fitting, ensuring the hose is not twisted. The hose should hang naturally without tension or kinking throughout full suspension travel and steering range. Tighten the bracket bolt securely. Snug the line-to-hose fitting but do not fully tighten yet.
10. 10

    Connect front lines to calipers
    Connect the flexible hoses to the front brake calipers. Verify the hose is not twisted and allows full suspension and steering movement without binding or stretching. Tighten the caliper fitting snugly but do not fully torque yet.
11. 11

    Install new rear brake line
    Route the new rear brake hard line from the master cylinder distribution point along the frame to the rear axle area. Follow the original routing path, maintaining proper clearances from exhaust (minimum 2 inches) and suspension components. Install frame clips loosely. If fabricating from straight stock, ensure all bends are smooth without kinks and use a bending spring or tubing bender to prevent collapse.
12. 12

    Install rear flexible hose and axle lines
    Install the rear flexible brake hose from the frame hard line to the rear axle distribution block. Ensure the hose has adequate length to accommodate full axle travel without stretching or binding. Mount any brackets securely. Install the hard lines along the rear axle housing to each wheel cylinder, securing with retaining clips. Verify all lines are clear of rotating components and axle shafts.
13. 13

    Final tightening of all fittings
    Starting at the master cylinder and working toward each wheel, tighten all brake line fittings using line wrenches. Tighten inverted flare fittings firmly, typically 10-12 ft-lbs for 3/16" lines and 12-15 ft-lbs for 1/4" lines, but avoid overtightening which can damage the flare. Tighten flexible hose-to-caliper fittings to 18-20 ft-lbs. Secure all frame clips and verify no lines contact moving or hot components. Check each connection visually for proper flare seating.
14. 14

    Bleed brake system
    Fill the master cylinder reservoir with fresh DOT 4 brake fluid. Bleed the brake system in the correct sequence: right rear, left rear, right front, left front (farthest from master cylinder to nearest). At each wheel, attach clear tubing to the bleeder screw and submerge the other end in a container partially filled with brake fluid. Have an assistant pump the brake pedal 3-4 times and hold pressure. Open the bleeder screw until fluid flows and air bubbles cease, then close the bleeder before the assistant releases the pedal. Repeat until no air bubbles appear in the fluid stream. Keep the master cylinder reservoir full throughout the process. Alternatively, use a pressure bleeder following manufacturer instructions. Repeat the entire sequence a second time to ensure all air is purged.
15. 15

    Final inspection and leak test
    With the vehicle still on jack stands, have an assistant firmly apply the brake pedal while you inspect every fitting, connection, and line for leaks. The pedal should feel firm and hold pressure without sinking. Check for fluid seepage at all fittings, particularly at flare connections and flexible hose junctions. Wipe all fittings dry and recheck after 10 pedal applications. Inspect all lines for contact with frame, suspension, exhaust, or other components throughout the full range of suspension and steering travel. Make any necessary adjustments to line routing or clip positions.

Reassembly

1. Reinstall all four wheels and tighten lug nuts in a star pattern
2. Lower vehicle to ground and torque lug nuts to 80 ft-lbs
3. Top off master cylinder reservoir to proper level with DOT 4 brake fluid
4. Verify brake pedal is firm and does not sink when held under pressure
5. Clean any brake fluid from painted surfaces immediately

Verification

• Start engine and verify brake pedal firmness with power assist active
• Pedal should be firm within upper half of travel and should not sink when held under constant pressure for 30 seconds
• Perform brake tests in safe area: test brakes at 5 mph, 10 mph, and 20 mph to verify proper operation
• Check for pulling to one side during braking which indicates air in system or other issues
• After test drive, re-inspect all fittings and connections for leaks with vehicle on jack stands
• Verify no brake lines contact moving components by having an assistant turn steering lock-to-lock while you observe clearances
• Check brake fluid level in reservoir after test drive and top off if needed
• Pump brakes firmly 20-30 times and re-inspect all connections for any seepage
• Plan to re-inspect all connections after 50 miles and again after 200 miles of driving

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