Complete replacement of all brake lines from master cylinder to all four wheels, including hard lines and flexible hoses, followed by system bleeding and verification.

Warnings

Tools required

Parts

• Complete brake line kit for 2015-2020 F-150 (front to rear hard lines) × 1 — Use OEM specification or quality aftermarket
• Front brake hose (flexible) - driver side × 1 — Use OEM specification
• Front brake hose (flexible) - passenger side × 1 — Use OEM specification
• Rear brake hose (flexible) - driver side × 1 — Use OEM specification
• Rear brake hose (flexible) - passenger side × 1 — Use OEM specification
• Brake line clips and retainers × 1 — Assorted sizes for frame routing
• Copper crush washers for banjo fittings (if applicable) × 8 — Replace all sealing washers
• Thread sealant for brake fittings × 1 — Brake-specific thread sealant

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 2 qt

Preparation

1. Park vehicle on level ground with transmission in Park and parking brake released (you will be replacing rear brake lines)
2. Place wheel chocks at all four wheels before lifting
3. Lift front and rear of vehicle and support on jack stands at frame contact points rated for vehicle weight
4. Remove all four wheels
5. Photograph or diagram existing brake line routing, noting all clips, brackets, and frame attachment points
6. Apply penetrating oil to all brake line fittings at master cylinder, ABS module, junction blocks, and wheel connections
7. Prepare clean workspace for new brake lines and ensure all components are present before beginning removal
8. Have brake fluid collection containers ready; expect significant fluid loss during line removal

Procedure

1. 1

   Drain and remove master cylinder reservoir cap
   Remove master cylinder reservoir cap. Use a turkey baster or fluid evacuator to remove as much brake fluid as possible from the reservoir to minimize spillage during line removal. Dispose of old fluid properly. Keep reservoir cap off to prevent vacuum formation during line removal.
2. 2

   Disconnect brake lines from master cylinder
   Working at the master cylinder (located on driver side firewall), use a line wrench to carefully loosen the two brake line fittings. The master cylinder feeds primary and secondary circuits. Have rags ready to catch fluid. Once loose, carefully unthread lines by hand and immediately plug open ports with clean rubber caps or plugs to prevent contamination.
   ⚠Use only line wrenches (flare nut wrenches) on brake fittings to prevent rounding. Do not use open-end wrenches.
3. 3

   Disconnect lines from ABS hydraulic control unit
   Locate the ABS hydraulic control unit (typically mounted on driver side frame rail near master cylinder). Using line wrenches, disconnect all four brake lines (one to each wheel) from the ABS module. Label each line location if not using pre-bent kit with obvious routing. Cap all open ports immediately.
   ⚠The ABS module contains sensitive valves. Do not allow dirt or debris to enter any ports. Keep all ports capped when lines are disconnected.
4. 4

   Remove front brake flexible hoses
   At each front wheel, locate where the flexible brake hose connects to the rigid line (typically on the frame rail or upper control arm bracket). Use line wrench on the hard line side and appropriate wrench on the hose fitting. Remove the hose-to-caliper connection at the caliper (may be banjo bolt or threaded fitting). Remove any retaining clips holding the hose to the chassis or suspension components. Remove both front flexible hoses.
   ℹ️If using banjo bolts, note the orientation of copper crush washers. New washers must be installed on both sides of the banjo fitting.
5. 5

   Remove rear brake flexible hoses
   At each rear wheel, disconnect the flexible brake hose from the hard line junction point (typically on the frame rail or rear axle). Disconnect the hose from the rear caliper or wheel cylinder. Remove retaining clips. On RWD F-150, the rear hoses typically connect to a junction block on the rear axle housing. Remove both rear flexible hoses.
6. 6

   Remove hard brake lines from frame
   Working from front to rear, remove all clips, brackets, and retainers securing the hard brake lines to the frame rails and underbody. The lines run along both driver and passenger frame rails from the ABS module to the rear axle. Use line wrenches to disconnect any intermediate junction blocks or distribution blocks. Remove all old hard lines from the vehicle. Inspect frame mounting points and clean any corrosion from bracket bolt holes.
   ℹ️Take photos during removal to ensure correct routing of new lines. Lines must not contact exhaust, driveshaft, or moving suspension components.
7. 7

   Prepare and route new hard brake lines
   If using pre-bent line kit, verify each line matches the routing of the original. Start with the lines from master cylinder to ABS module. Route new lines along frame rails, ensuring proper clearance from all moving parts, exhaust system, and sharp edges. Install all mounting clips and brackets loosely at first. For the 5.0L V8, verify clearance around the exhaust manifolds and catalytic converters. Lines should follow the same path as original equipment.
   ⚠Maintain minimum 1 inch clearance from exhaust components. Heat can cause brake fluid to boil, resulting in brake failure.
8. 8

   Install and torque hard line connections
   Beginning at the master cylinder, thread new brake line fittings by hand to ensure proper engagement. Once hand-tight, use a line wrench to torque all hard line fittings to specification. Install lines to ABS module, junction blocks, and rear axle distribution points. Ensure all fittings are clean and free of debris before connection. Apply brake-specific thread sealant only if specified by line manufacturer (most double-flare fittings seal without sealant).
   ⚠Do not over-torque brake line fittings. Excessive torque can damage flares and cause leaks. Use a torque wrench set to 26 Nm (19 lb-ft).
   Torque spec

   Line Fittings26 Nm (19 lb-ft)
9. 9

   Install new flexible brake hoses - front
   Install new front flexible brake hoses. Connect the hard line end first (at frame rail or control arm bracket), then connect to the caliper. If using banjo bolts, install new copper crush washers on both sides of the banjo fitting. Ensure hoses are not twisted and have adequate slack for full suspension travel. Install all retaining clips to chassis brackets.
   ⚠Cycle the steering full left and right while checking for hose interference. Hoses must not contact tires, suspension components, or reach their limit of flex.
   Torque spec

   Line Fittings26 Nm (19 lb-ft)
10. 10

    Install new flexible brake hoses - rear
    Install new rear flexible brake hoses. Connect the hard line junction point first (typically at rear axle housing or frame rail), then connect to the rear caliper. Install new copper crush washers if using banjo fittings. Ensure adequate slack for full suspension articulation. Secure all retaining clips.
    ⚠With vehicle on jack stands, manually cycle rear suspension through full travel to verify hose clearance and adequate length.
    Torque spec

    Line Fittings26 Nm (19 lb-ft)
11. 11

    Secure all line mounting hardware
    Working from front to rear, tighten all brake line mounting clips, brackets, and retainers. Verify that lines are properly seated in all clips and cannot vibrate or contact any components. Double-check clearances around exhaust, driveshaft, and suspension travel limits. Torque any bracket bolts that secure line support brackets to the frame.
    ℹ️Loose or improperly secured brake lines can chafe and fail over time. Ensure all clips are properly engaged.
    Torque spec

    Bracket Bolts127 Nm (94 lb-ft)
12. 12

    Fill master cylinder reservoir
    Fill the master cylinder reservoir with fresh Motorcraft DOT 4 LV brake fluid to the MAX line. Use fluid from a sealed container only. Keep the reservoir at least half-full throughout the bleeding process.
13. 13

    Bleed brake system - initial procedure
    Begin bleeding process using either traditional two-person method or pressure bleeder. For 2015-2020 F-150 with 5.0L V8, the recommended bleeding sequence is: 1) Right rear, 2) Left rear, 3) Right front, 4) Left front. At each wheel, attach clear tubing to the bleeder screw and submerge the other end in a container with clean brake fluid. Open bleeder screw, apply brake pedal (or pressure), close bleeder before pedal/pressure is released. Repeat until fluid runs clear with no air bubbles. Torque bleeder screws when complete.
    ⚠️Never allow the master cylinder reservoir to run dry during bleeding. This will introduce air into the ABS module requiring special bleeding procedures.
    ⚠With a complete brake line replacement, expect significant air in the system. Budget at least 30-45 minutes for thorough bleeding.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
14. 14

    Perform ABS module bleeding (if required)
    If the brake pedal remains soft after initial bleeding, the ABS hydraulic control unit may require bleeding. This typically requires a scan tool capable of activating the ABS pump and cycling the ABS valves. Follow the scan tool's ABS bleeding procedure for Ford F-150. Alternatively, perform additional manual bleeding cycles at all four wheels while having an assistant rapidly pump the brake pedal to help purge air from the ABS module.
    ℹ️Some air may remain trapped in the ABS module without scan tool bleeding. If pedal feel is not firm after extensive manual bleeding, professional ABS bleeding with scan tool is recommended.
15. 15

    Final inspection and leak check
    With vehicle still on jack stands, inspect every brake line connection for leaks. Have an assistant apply firm, steady pressure to the brake pedal (do not pump) and hold for 2-3 minutes while you inspect all fittings, especially at the master cylinder, ABS module, junction blocks, and caliper connections. Wipe all connections dry first to make fresh leaks visible. Check that all mounting clips are secure and lines have proper clearance. Verify brake fluid level in reservoir is at MAX line.
    ⚠️Any brake fluid leak, no matter how small, is a safety-critical failure. Do not drive the vehicle if any leaks are present.

Reassembly

1. Reinstall all four wheels and torque lug nuts to specification in a star pattern
2. Lower vehicle to ground and perform final lug nut torque verification
3. Top off master cylinder reservoir to MAX line with fresh DOT 4 LV fluid
4. Pump brake pedal multiple times with engine off to verify firm pedal feel
5. Start engine and verify brake pedal remains firm with engine running (power assist active)

Verification

• With engine running, verify brake pedal is firm and does not slowly sink to the floor when held under steady pressure for 30 seconds
• Perform visual inspection of all brake line connections with pedal applied - verify no leaks present
• Test drive in a safe, traffic-free area at low speed (under 15 mph) and verify brakes engage properly with no pedal pulsation or pulling to one side
• Perform multiple moderate brake applications from 30 mph to verify consistent pedal feel and stopping power
• Perform one hard stop from 45 mph in a safe area to verify full braking capability and ABS function (if conditions permit)
• Re-inspect all brake line connections after test drive for any signs of leakage or weeping
• After 50-100 miles of normal driving, re-inspect all connections and verify master cylinder fluid level has not dropped (indicating a slow leak)
• Monitor brake pedal feel for the first several days of driving - any change in pedal firmness may indicate air in the system or a developing leak

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