Replace the front brake hose on a 2011-2014 Ford F-150 3.5L EcoBoost 4WD, including bleeding the brake system to restore proper braking function.

Warnings

Tools required

Parts

• Front brake hose assembly × 1 — Use OEM Ford specification or equivalent DOT-approved hose
• Brake hose copper crush washers × 2 — New copper washers required for banjo bolt
• Brake hose retaining clip × 1 — May be reusable if undamaged

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground
4. Raise front of vehicle using floor jack at designated jacking points on frame
5. Support vehicle securely on jack stands rated for vehicle weight - never work under a vehicle supported only by a jack
6. Remove front wheel completely
7. Locate brake master cylinder reservoir under hood and check fluid level - mark current level
8. Have assistant available to monitor master cylinder and pump brake pedal during bleeding procedure

Procedure

1. 1

   Clean brake hose connections
   Use wire brush and brake parts cleaner to thoroughly clean the banjo bolt area at the caliper and the threaded fitting where the brake hose connects to the hard line at the frame bracket. Cleaning prevents contamination from entering the brake system during disassembly.
2. 2

   Remove banjo bolt at caliper
   Place a drain pan under the caliper. Using a flare nut wrench, loosen and remove the banjo bolt securing the brake hose to the brake caliper. Allow brake fluid to drain into the pan. Note the position of the copper crush washers (one on each side of the hose fitting) - these MUST be replaced with new washers. Plug the caliper port with a clean shop rag to minimize fluid loss and prevent contamination.
   ⚠️Keep brake fluid away from painted surfaces and immediately wipe up any spills
3. 3

   Remove brake hose from bracket
   Locate the brake hose retaining bracket on the frame or suspension component. Remove the retaining clip or horseshoe clip securing the brake hose to the bracket. Carefully pull the hose through the bracket. If a bolt secures the bracket, use the appropriate wrench to remove it.
4. 4

   Disconnect brake hose from hard line
   Using a flare nut wrench on the brake line fitting (to prevent rounding), unscrew the brake hose from the hard brake line at the frame bracket. Hold the bracket with another wrench if necessary to prevent the hard line from twisting. Allow remaining fluid to drain into catch container. Inspect the hard line fitting threads for damage or corrosion.
5. 5

   Inspect mounting points
   Examine the caliper banjo fitting port, frame bracket, and hard line fitting for corrosion, damage, or stripped threads. Clean all mating surfaces thoroughly with brake parts cleaner. Verify that the new brake hose is the correct length and has the proper fittings before proceeding.
6. 6

   Install new brake hose to hard line
   Thread the new brake hose onto the hard brake line fitting at the frame bracket. Hand-tighten initially, ensuring the hose is not twisted. Use a flare nut wrench to tighten securely, but do not overtighten as this can damage the flare fitting. A typical fitting torque is snug plus 1/6 turn - verify the connection is secure without stripping threads.
7. 7

   Route hose through bracket
   Route the brake hose through the retaining bracket on the frame or suspension. Ensure the hose hangs naturally without kinks, twists, or contact with suspension components through full steering travel. Install the retaining clip or horseshoe clip to secure the hose in the bracket. If bracket uses a bolt, install and torque to specification.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
8. 8

   Install banjo bolt at caliper with new washers
   Place one NEW copper crush washer on the banjo bolt, then position the brake hose banjo fitting onto the caliper port, then place the second NEW copper washer on top. Insert the banjo bolt and hand-tighten. Ensure the hose is properly oriented and not twisted. Torque the banjo bolt to specification using a torque wrench.
   ⚠️Using old copper washers or incorrect torque will cause brake fluid leaks and brake failure
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
9. 9

   Check hose routing and clearance
   Turn the steering wheel full lock left and right while verifying the brake hose does not contact the tire, wheel, suspension components, or frame at any point. The hose should have adequate slack and no sharp bends. Correct routing if necessary before proceeding.
10. 10

    Fill master cylinder reservoir
    Open the brake master cylinder reservoir under the hood and fill to the MAX line with fresh Motorcraft DOT 4 LV brake fluid from a sealed container. Keep the reservoir filled throughout the bleeding process to prevent introducing air into the ABS system.
    ⚠Never let the master cylinder run dry during bleeding - check level frequently
11. 11

    Bleed brake caliper
    Attach a clear brake bleeding hose to the bleeder screw on the caliper and route the other end into a catch container partially filled with clean brake fluid. Have an assistant pump the brake pedal 5-6 times and hold pressure. Open the bleeder screw 1/4 turn and observe fluid flow into the hose - air bubbles should be visible initially. Close the bleeder screw before the assistant releases the pedal. Repeat this process until no air bubbles appear in the fluid stream and flow is solid. Check and refill master cylinder reservoir as needed.
    ⚠Assistant must hold pedal pressure while bleeder is open and NOT release until bleeder is closed, or air will be drawn back into system
    Torque spec

    Bleeder Screw16 Nm (12 lb-ft)
12. 12

    Verify brake pedal feel
    With the engine off, pump the brake pedal several times. The pedal should become firm and maintain pressure. If the pedal feels soft or spongy, repeat the bleeding procedure. Check all connections for leaks while an assistant applies firm brake pedal pressure - no fluid should seep from the banjo bolt or line fittings.
13. 13

    Reinstall wheel
    Clean the wheel hub face and wheel mounting surface. Reinstall the wheel and hand-tighten the lug nuts in a star pattern. Lower the vehicle until the tire just contacts the ground (still supported by jack). Torque the lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Double-check all brake line connections for tightness and proper torque
2. Verify brake hose has no contact with moving parts through full steering range
3. Top off brake master cylinder reservoir to MAX line with DOT 4 LV fluid
4. Wipe down any brake fluid residue from components and wash affected areas with water
5. Dispose of old brake fluid properly according to local regulations

Verification

• With engine running, pump brake pedal firmly several times - pedal must be firm and high, not soft or spongy
• Inspect all brake hose connections for leaks while assistant applies firm brake pressure for 30 seconds
• Test brakes at low speed in a safe area (parking lot) before returning to normal driving - verify firm pedal and straight stopping
• After test drive, recheck all connections for leaks and verify no fluid seepage at banjo bolt or line fittings
• Check brake master cylinder reservoir level and top off if needed
• If pedal remains soft, air may be trapped in ABS system requiring professional scan tool bleeding procedure

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