Brake Hose - Front

Replacement of the front brake hose on a 2005 Dodge Viper, including removal of the old hose from the caliper and brake line, installation of new hose with fresh copper washers, and bleeding of the brake system.

Warnings

Tools required

Parts

• Front brake hose (specify left or right side) × 1 — Use OEM specification
• Banjo bolt copper crush washers × 2 — Use OEM specification - 2 required per banjo connection
• Brake line retaining clip (if damaged) × 1 — Use OEM specification

Fluids

• DOT 4 brake fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid ground and apply parking brake firmly
2. Place wheel chocks behind rear wheels
3. Using a turkey baster or fluid pump, remove approximately half the brake fluid from the master cylinder reservoir to prevent overflow during hose replacement
4. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground
5. Lift front of vehicle with floor jack at manufacturer-specified jacking point
6. Install jack stands under manufacturer-specified support points on the side being serviced
7. Remove front wheel completely and set aside
8. Verify vehicle is stable on jack stands before proceeding

Procedure

1. 1

   Locate and inspect brake hose assembly
   Identify the flexible brake hose running from the brake hard line (mounted to the chassis/frame rail) to the brake caliper. The hose will have a banjo fitting at the caliper end and a threaded fitting at the hard line end, with a bracket securing the hose to the chassis or suspension component. Inspect the routing and note the position of any retaining clips or brackets for reinstallation reference.
2. 2

   Clean brake line connections
   Use a wire brush to clean the banjo bolt at the caliper and the threaded fitting at the brake line junction. Apply penetrating oil to both connections if corrosion is present. Allow 5-10 minutes for penetration. Clean away any dirt or debris from the surrounding area to prevent contamination of the brake system.
3. 3

   Position drain pan and prepare for fluid loss
   Place a drain pan beneath the caliper and brake line junction area. Have shop towels ready to catch brake fluid. Be prepared for fluid to drain from both the hose and the brake line once connections are broken.
4. 4

   Disconnect hose from caliper
   Using the appropriate box wrench, loosen and remove the banjo bolt securing the brake hose to the caliper. The bolt passes through the banjo fitting and threads into the caliper body. Once loose, remove the bolt completely along with the brake hose banjo fitting. Brake fluid will drain from both the hose and caliper - control spillage with shop towels. Note the position of the copper crush washers (one on each side of the banjo fitting) and discard them - they must not be reused. Immediately plug the caliper inlet port with a clean shop towel or rubber cap to minimize fluid loss and prevent contamination.
5. 5

   Remove hose from mounting bracket
   Locate the metal bracket that secures the brake hose to the chassis or suspension component (typically near the strut or frame rail). The hose passes through this bracket and is held by a retaining clip or bolt. Remove the retaining clip by sliding it off or remove the bracket bolt, then slide the hose out of the bracket. Note the orientation of any clips or hardware for reinstallation.
6. 6

   Disconnect hose from brake hard line
   Using a flare nut wrench of the correct size for your vehicle, carefully loosen the threaded fitting connecting the flexible brake hose to the hard brake line. The hard line fitting is easily damaged - use a flare nut wrench to avoid rounding the fitting. Hold the brake hose end with another wrench if necessary to prevent twisting the hose. Once loose, unthread the connection completely and separate the hose from the hard line. Additional brake fluid will drain - catch it in the drain pan. Immediately cap or plug the open hard line end to prevent fluid loss and contamination.
7. 7

   Inspect mounting points and clean threads
   With the old hose removed, inspect the caliper banjo bolt hole, hard line threads, and mounting bracket for damage, excessive corrosion, or stripped threads. Clean all threaded connections with a wire brush. Check that the hard line fitting is not cracked or damaged. If any threads are damaged or components are compromised, repair or replace before installing the new hose.
8. 8

   Prepare new brake hose
   Remove the new brake hose from its packaging. Verify that the hose has the correct fittings and length for your application (driver or passenger side). Install one NEW copper crush washer onto the banjo bolt, slide the bolt through the banjo fitting on the hose, then install the second NEW copper crush washer on the opposite side of the fitting. Do not reuse old washers. Ensure any protective caps or plugs are removed from the hose ends.
9. 9

   Connect new hose to brake hard line
   Thread the brake hose fitting onto the hard line by hand, ensuring it starts smoothly without cross-threading. The hose should rotate freely as you thread it on - if resistance is felt, back off and restart. Thread the fitting until hand-tight, ensuring the hose is not twisted and routes naturally toward the caliper and mounting bracket. Do not fully tighten yet.
10. 10

    Install hose in mounting bracket
    Route the brake hose through the chassis/suspension mounting bracket, ensuring proper orientation and clearance from suspension components, steering components, and the wheel. The hose must not contact any moving parts through the full range of suspension and steering travel. Install the retaining clip or bracket bolt to secure the hose in the bracket.
    Torque spec

    Brake Hose Bracket10 Nm (7 lb-ft)
11. 11

    Connect hose to caliper
    Position the banjo fitting against the caliper inlet port, aligning the bolt hole. Ensure one copper crush washer is positioned between the banjo fitting and the caliper, and one is positioned between the fitting and the banjo bolt head. Insert the banjo bolt and thread it by hand into the caliper. Ensure the brake hose has no twists and routes naturally without tension. Hand-tighten the banjo bolt first.
    Torque spec

    Brake Hose Banjo Bolt25 Nm (18 lb-ft)
12. 12

    Torque all connections to specification
    Using a torque wrench, tighten the banjo bolt at the caliper to the manufacturer-specified torque (verify the exact value in the vehicle service manual before tightening). Next, while holding the brake hose stationary to prevent twisting, use a flare nut wrench and torque wrench to tighten the threaded fitting at the hard line connection. If a specific torque value for the hard line fitting is not available, tighten firmly with the flare nut wrench until snug per the manufacturer specification, but do not overtighten as this can damage the flare. Verify the hose has no twists along its length and routes with adequate clearance.
    Torque spec

    Brake Hose Banjo Bolt25 Nm (18 lb-ft)
13. 13

    Bleed brake caliper
    Locate the bleeder screw on the brake caliper (typically on top of the caliper body). Attach clear tubing to the bleeder nipple and submerge the other end in a container partially filled with clean brake fluid of the type specified on the reservoir cap (verify DOT 3 vs DOT 4 for your vehicle). Have an assistant slowly depress the brake pedal while you open the bleeder screw 1/4 to 1/2 turn. Fluid and air will discharge through the tube. Close the bleeder screw before the pedal reaches the floor, then have the assistant release the pedal slowly. Repeat this process until no air bubbles are visible in the discharged fluid - typically 5-10 pump cycles. Check and refill the master cylinder reservoir frequently during bleeding to prevent introducing more air. Tighten the bleeder screw to specification when complete.
    ⚠Never allow the master cylinder reservoir to run empty during bleeding or additional air will enter the system requiring a full system bleed.
    Torque spec

    Bleeder Screw14 Nm (10 lb-ft)
14. 14

    Inspect all connections for leaks
    With the brake system bled, have an assistant apply firm, steady pressure to the brake pedal (approximately 50 lbs of force) and hold for 30 seconds. While pressure is applied, carefully inspect the banjo bolt connection at the caliper and the threaded connection at the hard line for any signs of brake fluid seepage or dripping. Also check around the bleeder screw. If any leaks are detected, release pedal pressure, correct the issue (retorque or replace washers), and rebleed. No leaks should be present.
15. 15

    Verify brake pedal feel and check fluid level
    With the engine off, pump the brake pedal several times. The pedal should become firm after 2-3 pumps and hold steady pressure. If the pedal feels soft or sinks slowly, air remains in the system and additional bleeding is required. Check the master cylinder reservoir and top off with fresh DOT 4 brake fluid to the MAX line. Install the reservoir cap securely.
16. 16

    Reinstall wheel and lower vehicle
    Clean the wheel mounting surface on the hub. Reinstall the wheel, threading lug nuts by hand to ensure proper seating. Using a torque wrench in a star pattern, torque lug nuts to specification. Carefully raise the vehicle slightly with the floor jack to unload the jack stands, remove jack stands, and lower the vehicle completely to the ground. With vehicle on ground, perform a final torque check of lug nuts in a star pattern.
    Torque spec

    Wheel Lug Nuts142.4 Nm (105 lb-ft)

Reassembly

1. Ensure all torque specifications have been met for banjo bolt, bracket hardware, and wheel lug nuts
2. Verify brake hose routing provides adequate clearance from all suspension and steering components through full range of motion
3. Confirm master cylinder reservoir is filled to MAX line with DOT 4 brake fluid
4. Double-check all connections for leaks before road testing

Verification

• Start engine and pump brake pedal - pedal should be firm and hold steady pressure with no sinking
• Perform a low-speed brake test in a safe area (5-10 mph) to verify braking function before normal driving
• Check for leaks at all connection points after initial brake application
• After initial test drive, recheck all connection points for leaks and verify no fluid loss from master cylinder reservoir
• Monitor brake pedal feel over the next several days - any softening indicates air in system or a leak requiring immediate attention
• Turn steering wheel to full lock in both directions while stationary and verify brake hose has adequate clearance and no contact with suspension or wheel
• The Viper is a high-performance vehicle - verify full braking performance at low speed before attempting highway speeds or aggressive driving

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