Replace the front brake hose connecting the hard brake line to the caliper, including bleeding the brake system to remove air.

Warnings

Tools required

Parts

• Front brake hose × 1 — Use OEM Ford part or equivalent DOT-approved hose
• Copper crush washers for banjo bolt × 2 — Two washers per banjo connection
• Brake hose retaining clip (if equipped) × 1 — Inspect existing clip for damage

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level ground, place transmission in Park, and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground
4. Lift front of vehicle with floor jack at designated front jacking point and secure with jack stands under frame rails
5. Remove front wheel completely on side being serviced
6. Clean brake hose connections, banjo bolt, and line fitting with wire brush to prevent debris contamination
7. Open hood and check brake fluid reservoir level, have assistant available to monitor fluid level during bleeding
8. Place drain pan under brake caliper area to catch fluid spillage

Procedure

1. 1

   Remove banjo bolt from caliper
   Locate the banjo bolt connecting the brake hose to the rear of the brake caliper. Using a 13mm wrench, loosen and remove the banjo bolt. Be prepared for brake fluid to drain out. Remove and discard both copper crush washers (one on each side of the banjo fitting). Cap or plug the caliper port with a clean rag to minimize fluid loss.
2. 2

   Disconnect hose from brake line
   Locate where the flexible brake hose connects to the hard brake line on the frame or suspension mount. Using the appropriate size flare nut wrench (typically 11mm or 12mm), carefully loosen the threaded fitting. Turn counterclockwise while holding the hose-end fitting steady with another wrench to prevent twisting the hose. Remove the fitting completely and allow remaining fluid to drain into the catch pan.
   ⚠Use a flare nut wrench (line wrench) to prevent rounding off the soft brass fitting. A standard open-end wrench will likely damage the fitting.
3. 3

   Remove hose bracket mounting
   The brake hose is secured to a bracket on the frame or suspension component with a retaining clip or bolt. If using a clip, use pliers to compress and remove it. If bolted, use a 10mm socket or wrench to remove the bracket bolt. Carefully note the routing and orientation of the hose for proper installation of the new hose.
   ℹ️Take a photo of the hose routing before removal to ensure correct installation path and prevent hose kinking or rubbing.
4. 4

   Remove old brake hose
   With all connections freed, remove the old brake hose assembly completely. Inspect the hard brake line threads and caliper port for damage, corrosion, or debris. Clean threads with a wire brush if necessary. Inspect the new brake hose to ensure it matches the old hose length and fitting types exactly.
5. 5

   Install new brake hose to frame bracket
   Begin installation by routing the new brake hose through the same path as the original, ensuring no twists or kinks. Install the hose into the frame bracket first, securing it with the retaining clip or bracket bolt. If using a bolt, hand-tighten only at this stage to allow for hose alignment adjustment.
6. 6

   Connect hose to hard brake line
   Thread the brake hose fitting into the hard brake line by hand first to ensure proper thread engagement. Once hand-tight, use the flare nut wrench to tighten the fitting. Hold the hose-end steady to prevent twisting the flexible hose. Torque to specification using a torque wrench.
   ⚠Do not over-tighten brake line fittings. Excessive torque can strip the soft brass threads or crack the fitting.
   Torque spec

   Line Fittings26 Nm (19 lb-ft)
7. 7

   Install hose bracket bolt to specification
   If the hose bracket uses a bolt (rather than clip), torque the bracket bolt to specification now. Ensure the hose is properly positioned in the bracket without twisting and that it has adequate clearance from suspension components, wheels, and steering components through full range of motion.
   Torque spec

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

   Connect banjo bolt to caliper
   Install a NEW copper crush washer onto the banjo bolt, then insert the banjo fitting into the caliper port followed by the second NEW copper crush washer. Thread the banjo bolt by hand to ensure proper alignment. The banjo fitting should rotate freely on the bolt. Torque the banjo bolt to specification. Verify the hose is not twisted and has proper clearance during steering and suspension travel.
   ⚠️Always use NEW copper crush washers. Reusing old washers will result in brake fluid leaks and potential brake failure.
   Torque spec

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

   Check hose clearances
   With all connections secure, turn the steering wheel lock-to-lock while observing the brake hose for interference with wheels, suspension components, or steering parts. Have an assistant bounce the suspension or manually compress it to check clearance through full travel. The hose must not contact any components or show kinking at any point.
10. 10

    Bleed the brake system
    Fill the brake fluid reservoir to the MAX line with fresh Motorcraft DOT 4 LV brake fluid. Attach bleeder hose to the caliper bleeder screw (usually located on top rear of caliper). Submerge the other end in a clear bottle partially filled with clean brake fluid. Have an assistant pump the brake pedal 3-5 times and hold pressure. Open the bleeder screw 1/4 turn with an 8mm wrench. Fluid and air bubbles will flow out. Close bleeder screw before assistant releases pedal. Repeat until no air bubbles appear and only clear fluid flows. Check reservoir level frequently and refill as needed.
    ⚠️Never let the brake fluid reservoir run empty during bleeding or air will enter the ABS hydraulic unit, requiring special scan tool bleeding procedures.
    Torque spec

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

    Check for leaks
    With the bleeder screw closed, have assistant apply firm pedal pressure and hold for 30 seconds. Inspect the banjo bolt connection, line fitting, and bleeder screw for any signs of brake fluid leakage. Wipe all connections clean and recheck. If any leaks are found, depressurize system, correct the issue (check torque, verify new washers installed), and rebleed.
12. 12

    Reinstall wheel
    Reinstall the wheel onto the hub, threading lug nuts by hand first. Using the star pattern, snug all lug nuts with the socket and breaker bar, but do not torque fully while vehicle is on jack stands.
13. 13

    Lower vehicle and torque wheels
    Carefully lower the vehicle from jack stands using the floor jack until wheels contact the ground but vehicle weight is still partially supported. Torque the lug nuts to specification using a star pattern. Lower vehicle completely and remove jack. Recheck lug nut torque with vehicle on ground in star pattern.
    Torque spec

    Wheel Lug Nuts169 Nm (125 lb-ft)

Reassembly

1. Top off brake fluid reservoir to MAX line with fresh Motorcraft DOT 4 LV brake fluid
2. Dispose of old brake fluid properly at recycling center or auto parts store
3. Clean any brake fluid spills from frame, suspension, and body panels with water immediately
4. Verify brake pedal is firm with no sponginess before attempting to drive

Verification

• With engine running, pump brakes several times and verify firm pedal with no excessive travel
• Check for pedal fade: press and hold brake pedal firmly for 60 seconds - pedal should not sink
• Inspect all brake hose connections for leaks with pedal applied
• Perform low-speed brake test in safe area (parking lot) at 5-10 mph to verify proper brake function and firm pedal feel
• Test brakes at progressively higher speeds up to 25 mph before driving normally
• After 50-100 miles, recheck all connection points for leaks and verify lug nut torque
• Monitor brake pedal feel over first few days of driving for any changes that might indicate air in system

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