This procedure covers the replacement of a front brake hose on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine, including proper bleeding and torque specifications.

Warnings

Tools required

Parts

• Front brake hose assembly × 1 — Use OEM Ford specification for 2015-2020 F-150
• Copper crush washers for banjo bolt × 2 — Two washers per banjo connection
• Brake fluid × 1 — Motorcraft DOT 4 LV

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Loosen front wheel lug nuts while vehicle is on the ground
3. Raise front of vehicle with floor jack and support on jack stands rated for vehicle weight (minimum 3 tons each)
4. Remove front wheel on the side being serviced
5. Clean area around brake hose connections with brake cleaner to prevent contamination
6. Place a drip pan under the work area to catch brake fluid
7. Have new brake hose and fresh copper crush washers ready before disconnecting old hose

Procedure

1. 1

   Prepare brake caliper
   Open the brake fluid reservoir cap in the engine bay to relieve vacuum pressure. This will make disconnection easier and reduce fluid loss. Do not allow reservoir to run dry during this procedure.
   ⚠Keep reservoir cap area clean. Contamination will compromise the entire brake system.
2. 2

   Disconnect hose from caliper
   Using a 14mm flare nut wrench, carefully loosen the banjo bolt connecting the brake hose to the caliper. Hold the hose fitting steady to prevent twisting the hose. Remove the banjo bolt completely and immediately cap or plug the caliper port to minimize fluid loss and air entry. Discard the old copper crush washers.
   ⚠Use a flare nut wrench, not a standard wrench, to prevent rounding off the banjo bolt.
3. 3

   Remove hose from bracket
   Locate the brake hose bracket mounted to the frame or suspension component. Use a 10mm socket to remove the bracket bolt securing the hose to the mounting bracket. Note the orientation and routing of the hose for installation of the new hose.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
4. 4

   Disconnect hose from hard line
   Using the 14mm flare nut wrench, carefully loosen the threaded fitting connecting the brake hose to the metal hard line on the chassis. Support the hose and turn the fitting nut, not the hard line. Once loose, unthread completely and remove the brake hose assembly. Allow residual fluid to drain into catch pan.
   ⚠Do not twist or damage the metal hard line. Hold the line steady while turning only the hose fitting.
5. 5

   Inspect components
   Inspect the caliper banjo port, hard line threads, and bracket mounting point for damage, corrosion, or debris. Clean threads on hard line with wire brush if necessary. Verify new brake hose matches the old hose in length, fitting types, and bracket location.
   ℹ️Any damage to hard line threads or caliper port may require additional component replacement.
6. 6

   Install hose to hard line
   Thread the new brake hose fitting onto the metal hard line by hand. Ensure threads engage smoothly without cross-threading. Once hand-tight, use the 14mm flare nut wrench to snug the connection. Do not fully torque yet; final tightening occurs after hose is properly oriented.
   ⚠Cross-threading will damage the hard line and require expensive replacement. Thread by hand first to verify proper engagement.
7. 7

   Install hose in bracket
   Route the brake hose through the mounting bracket, ensuring it follows the same path as the original hose without twisting. The hose must not contact suspension components, steering components, or the tire during full travel. Install the bracket bolt and torque to specification.
   ⚠A twisted or improperly routed hose can fail prematurely or interfere with suspension movement.
   Torque spec

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

   Connect hose to caliper
   Place one NEW copper crush washer on each side of the banjo fitting (one against the caliper, one under the bolt head). Insert the banjo bolt through the banjo fitting and thread into the caliper. Hand-tighten first, then torque to specification using a torque wrench. Ensure the hose is not twisted and has clearance for caliper movement.
   ⚠️Using old or missing copper washers will cause brake fluid leaks and brake failure. Always use TWO NEW washers.
   Torque spec

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

   Finalize hose orientation and torque
   With all connections made, verify the brake hose has proper clearance and is not twisted along its length. The hose should have a slight natural curve without kinks. Finalize torque on the hard line connection using the flare nut wrench. Ensure hose does not contact any components through full steering and suspension travel.
   ℹ️Turn steering wheel lock-to-lock and compress/extend suspension to verify clearance before bleeding.
10. 10

    Bleed brake system
    Attach clear vinyl tubing to the caliper bleeder screw and submerge the other end in a container with clean brake fluid. Have an assistant pump the brake pedal 3-4 times and hold pressure. Open the bleeder screw 1/2 turn while assistant maintains pedal pressure. Close bleeder before pedal reaches floor. Repeat until fluid flows clear without air bubbles (typically 5-10 cycles). Torque bleeder screw to specification.
    ⚠️Never allow brake pedal to go to the floor with bleeder open. This can damage the master cylinder.
    ⚠Monitor brake fluid reservoir constantly. Never let it run dry or air will enter the ABS module, requiring professional scan tool bleeding.
    Torque spec

    Bleeder Screw16 Nm (12 lb-ft)
11. 11

    Check for leaks
    With all bleeder screws closed and connections torqued, wipe all connections clean and dry. Have assistant apply firm, steady pressure to brake pedal and hold for 30 seconds. Inspect all connections (banjo bolt, hard line fitting, and bleeder screw) for any signs of fluid seepage. Re-torque and re-bleed if any leaks are found.
    ⚠️Any brake fluid leak is unacceptable and must be corrected before driving the vehicle.
12. 12

    Reinstall wheel
    Clean wheel mounting surface on hub. Install wheel and hand-thread all lug nuts. Lower vehicle until tire just contacts ground to prevent wheel rotation. Torque lug nuts in a star pattern to specification. Fully lower vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Fill brake fluid reservoir to MAX line with fresh Motorcraft DOT 4 LV brake fluid
2. Close reservoir cap securely
3. Pump brake pedal 10-15 times to verify firm pedal feel before attempting to drive
4. Dispose of old brake fluid at proper recycling facility; never pour down drain

Verification

• Start engine and verify brake pedal feels firm with normal resistance (should be high and hard, not spongy)
• Check that brake pedal does not slowly sink to floor when held under steady pressure with engine running
• Perform visual inspection of all brake hose connections for any signs of fluid leakage
• Test brakes at low speed (5-10 mph) in a safe area to verify normal braking function before normal driving
• After first test drive, re-inspect all connections for leaks and verify brake fluid level has not dropped
• If pedal feels soft or spongy, or if vehicle pulls to one side during braking, DO NOT DRIVE and repeat bleeding procedure or seek professional service

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