Complete replacement of all brake lines from the master cylinder to all four wheels, including hard lines and flexible hoses, ensuring a fully restored brake hydraulic system.

Warnings

Tools required

Parts

• Complete brake line kit for 2015-2020 F-150 RWD × 1 — Pre-formed OEM or aftermarket kit
• Front flexible brake hoses (left and right) × 2 — Use OEM specification
• Rear flexible brake hoses (left and right) × 2 — Use OEM specification
• Brake line clips and retainers × 1 — Assorted set
• Copper crush washers for banjo fittings × 8 — Various sizes as needed
• Thread sealant for brake fittings × 1 — Permatex or equivalent

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 2 qt

Preparation

1. Park vehicle on level surface and chock rear wheels securely
2. Disconnect negative battery terminal to disable ABS pump during work
3. Remove all four wheels and tires
4. Spray all brake line fittings with penetrating oil and allow to soak for 15-30 minutes
5. Place drip pans under work areas to catch brake fluid
6. Have plastic caps or plugs ready to seal open lines immediately to prevent contamination
7. Review complete brake line routing before removal; take photos of routing and clip locations for reference
8. Verify replacement lines match original routing and have correct fittings

Procedure

1. 1

   Remove brake fluid from master cylinder
   Use a turkey baster or fluid transfer pump to remove as much brake fluid as possible from the master cylinder reservoir. This minimizes spillage during line removal. Dispose of old fluid properly; do not reuse.
   ⚠Brake fluid will damage paint. Protect fenders with towels or plastic sheeting.
2. 2

   Disconnect front flexible brake hoses at calipers
   Starting with the front wheels, use a flare nut wrench to disconnect the flexible brake hose from the caliper. If using banjo bolt connections, remove the bolt and discard the copper crush washers. Immediately cap the caliper inlet and hose end to prevent contamination. Note the routing of the hose through any brackets or clips.
   ⚠Use flare nut wrenches to prevent rounding off brake line fittings. Standard open-end wrenches will damage fittings.
3. 3

   Disconnect front flexible hoses from hard lines
   Trace each front flexible hose to where it connects to the hard line at the frame or suspension mounting point. Use flare nut wrench to disconnect the fitting. Remove any retaining clips holding the hose to the frame or control arm. Cap all open line ends immediately.
4. 4

   Remove front hard brake lines
   Working from the wheel end toward the master cylinder, disconnect all hard line fittings using flare nut wrenches. Note the location of all mounting clips along the frame rail and suspension. Remove clips as needed. At junction blocks or proportioning valves, disconnect all lines and cap openings. Label lines if routing is complex.
   ℹ️Take detailed photos of line routing and clip positions before removal. Factory routing prevents contact with moving parts and heat sources.
5. 5

   Disconnect rear flexible brake hoses
   At each rear wheel, disconnect the flexible brake hose from the wheel cylinder or caliper using a flare nut wrench. Remove the hose from its mounting bracket on the axle or frame. Disconnect the hose from the hard line at the frame. Cap all openings immediately.
6. 6

   Remove rear hard brake lines
   Disconnect rear hard lines at all junction points, following lines from wheels to master cylinder. Remove lines from clips along the frame rail. On RWD models, carefully route lines away from the driveshaft and exhaust components. Note the path across the rear axle or suspension.
   ⚠Rear brake lines may be corroded or brittle. Handle carefully to avoid breaking fittings that need to be reused (such as at master cylinder).
7. 7

   Disconnect lines at master cylinder and ABS module
   At the master cylinder and ABS hydraulic control unit, carefully disconnect all brake line fittings using flare nut wrenches. Note which port each line connects to; take photos for reference. Clean the area around fittings before removal to prevent contamination. Cap all master cylinder and ABS module ports immediately.
   ⚠️Do not allow dirt or debris to enter master cylinder or ABS module. Contamination will require expensive component replacement.
8. 8

   Clean all mounting points and fittings
   Use a wire brush to clean all brake line mounting clips, brackets, and fittings that will be reused. Clean the threads on master cylinder, ABS module, and caliper/wheel cylinder ports. Inspect for damage. Replace any damaged clips or brackets.
9. 9

   Install new hard brake lines to master cylinder and ABS module
   Begin installation at the master cylinder and ABS module. Route new hard lines following the original path documented in photos. Hand-tighten fittings first to ensure proper thread engagement. Once all lines are positioned correctly, tighten fittings with flare nut wrench. Do not overtighten; typical spec is 12-15 lb-ft for 3/16" lines. Apply light coat of thread sealant if specified by line kit manufacturer.
   ⚠Cross-threading brake line fittings will ruin components. Ensure fittings thread smoothly by hand before using wrenches.
10. 10

    Route and secure hard lines along frame
    Follow the documented original routing path. Install new or reuse original mounting clips at all locations. Ensure lines do not contact the driveshaft, exhaust, suspension components, or any moving parts. Leave slight slack at bends to prevent stress on fittings. Verify clearance through full suspension travel before securing all clips.
    ⚠️Brake lines must not contact the driveshaft, exhaust, or any moving components. Contact will cause line failure and complete brake system loss.
11. 11

    Install new flexible brake hoses at front
    Route new front flexible hoses from hard line connection points to calipers following original path. Install hoses in frame or suspension brackets first, ensuring correct orientation (hoses should not twist). Connect to hard lines hand-tight, then torque to specification. At calipers, install new copper crush washers on both sides of banjo bolt fitting if applicable, then hand-tighten.
    ℹ️Flexible hoses have specific orientation marks. Install with markings visible and hose untwisted to prevent internal damage.
12. 12

    Install new flexible brake hoses at rear
    Route new rear flexible hoses from hard line connection points to wheel cylinders or calipers. Install in axle or frame mounting brackets ensuring proper orientation. Connect to hard lines and wheel end components using same procedure as front. Install new copper crush washers where applicable.
13. 13

    Inspect complete installation
    Perform thorough visual inspection of entire brake line system. Verify all fittings are tight, all clips are installed, proper clearances exist around all moving parts, exhaust, and driveshaft. Check that flexible hoses are not twisted or kinked. Ensure no lines are stretched or stressed. Have a second person verify critical clearances.
    ⚠️A missed clip or improper routing can cause brake line failure. Double-check all clearances and mounting points.
14. 14

    Fill and bleed brake system
    Fill master cylinder with fresh Motorcraft DOT 4 LV brake fluid to MAX line. Bleed brakes in this sequence: right rear, left rear, right front, left front. Use vacuum bleeder or two-person method. At each wheel, attach clear tubing to bleeder screw, open bleeder, and pump fluid until completely free of air bubbles. Close bleeder before releasing brake pedal. Maintain master cylinder fluid level above MIN throughout bleeding process. Continue until firm pedal is achieved.
    ⚠️Air in brake lines will cause brake failure. Continue bleeding until absolutely no air bubbles appear and pedal is firm.
    ⚠Never let master cylinder run dry during bleeding or air will enter ABS module, requiring specialized scan tool to bleed.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
15. 15

    Perform ABS module bleed if equipped
    If vehicle has ABS (standard on F-150), the ABS module may require bleeding using a scan tool to cycle the ABS valves. If brake pedal remains soft after manual bleeding, professional ABS bleeding with a scan tool capable of bi-directional controls is required. This activates the ABS pump and valves to purge trapped air.
    ℹ️Many brake jobs on ABS-equipped vehicles require a professional scan tool for complete bleeding. If pedal is not firm after manual bleeding, seek professional assistance.

Reassembly

1. Reinstall all four wheels and torque lug nuts to specification in star pattern
2. Reconnect negative battery terminal
3. Top off master cylinder reservoir to MAX line with fresh Motorcraft DOT 4 LV brake fluid
4. Clean any brake fluid residue from vehicle body and components with water

Verification

• With engine off, pump brake pedal 10-15 times. Pedal should be firm and hold steady pressure. A soft or sinking pedal indicates air in the system requiring additional bleeding
• Start engine and verify brake pedal does not sink with steady pressure applied. Pedal should remain firm
• Check for leaks at all brake line connections while assistant applies firm brake pressure. Inspect master cylinder, ABS module, all hard line fittings, flexible hoses, and calipers/wheel cylinders
• Perform low-speed test in safe area. Brake pedal should feel normal and vehicle should stop straight without pulling to either side
• Test ABS function in safe area on low-traction surface. ABS should activate normally without warning lights
• Road test at progressively higher speeds in safe area, verifying proper brake operation and pedal feel before returning to normal service
• Recheck all brake line connections and fittings for leaks after test drive. Also verify fluid level in master cylinder
• Monitor brake pedal feel over the next several days. Any change in pedal firmness requires immediate re-inspection and possible re-bleeding

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