Replace the front brake hose that connects the brake line to the caliper, including bleeding the brake system to restore proper braking function.

Warnings

Tools required

Parts

• Front brake hose × 1 — Use OEM specification
• Copper crush washers for banjo bolt × 2 — Typically come with brake hose
• Brake hose retaining clip × 1 — Reuse if not damaged

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 while vehicle is still on ground
4. Raise front of vehicle with floor jack and support on jack stands rated for vehicle weight at manufacturer-specified jacking points
5. Remove front wheel on side being serviced
6. Clean brake hose connection points with wire brush and brake cleaner to prevent contamination
7. Open brake master cylinder reservoir cap to prevent vacuum formation during hose removal
8. Place drain pan under work area to catch brake fluid

Procedure

1. 1

   Disconnect brake hose from brake line
   Locate the brake line-to-hose connection point on the frame or suspension. Using a line wrench on the brake hose fitting and a backup wrench on the brake line fitting, carefully loosen and disconnect the threaded connection. Cap or plug the brake line end immediately to minimize fluid loss and prevent contamination. Allow brake fluid to drain into catch pan.
   ⚠Use a line wrench (flare nut wrench) to prevent rounding off the soft brass fittings. Standard open-end wrenches will likely damage the fittings.
   Torque spec

   Line Fittings23 Nm (17 lb-ft)
2. 2

   Remove brake hose from bracket
   Locate the brake hose bracket that secures the hose to the chassis or suspension component. Remove the retaining clip or bolt that holds the hose in the bracket. Note the routing and orientation of the hose for reinstallation.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
3. 3

   Disconnect brake hose from caliper
   Locate the banjo bolt connecting the brake hose to the brake caliper. Hold the hose end with a wrench to prevent twisting, then remove the banjo bolt. Remove and discard both copper crush washers (one on each side of the hose fitting). Allow remaining fluid to drain. Cap the caliper port to prevent contamination.
   ⚠Do not twist the brake hose during removal as this can damage the internal reinforcement even if you are replacing it, potentially causing fluid to spray.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
4. 4

   Remove old brake hose
   Remove the brake hose completely from the vehicle. Inspect the caliper port and brake line for debris, corrosion, or damage. Clean threads with brake cleaner if necessary.
5. 5

   Prepare new brake hose
   Remove new brake hose from packaging. Verify it matches the old hose in length and fitting types. Install new copper crush washers on the banjo bolt (do not reuse old washers). Ensure no protective caps or plugs remain on the hose fittings.
   ⚠️Verify you have the correct replacement hose for your specific F-150 configuration. Different wheel bases and brake packages use different hose lengths.
6. 6

   Install brake hose to caliper
   Position the new brake hose to the caliper with one new copper crush washer on each side of the banjo fitting. Thread in the banjo bolt by hand to ensure proper alignment. Torque the banjo bolt to specification, ensuring the hose is positioned without twists or kinks.
   ⚠Ensure the brake hose is not twisted. The hose should route naturally without any spiral or torsion along its length.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
7. 7

   Secure brake hose in bracket
   Route the brake hose through the frame or suspension bracket following the same path as the original hose. Install the retaining clip or bolt to secure the hose in the bracket. If using a bolt, torque to specification. Ensure the hose has adequate clearance from suspension components, steering components, and the wheel throughout full steering range and suspension travel.
   ⚠Verify the hose will not contact the wheel, tire, or any moving suspension components through full range of motion before connecting to brake line.
   Torque spec

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

   Connect brake hose to brake line
   Remove the cap or plug from the brake line. Thread the brake hose fitting to the brake line by hand until snug. Using a line wrench and backup wrench, tighten the connection to specification. Wipe away any spilled brake fluid.
   Torque spec

   Line Fittings23 Nm (17 lb-ft)
9. 9

   Bleed the brake system
   Fill the brake master cylinder reservoir to the MAX line with fresh DOT 4 LV brake fluid. Attach bleeder hose to the bleeder screw on the caliper. Open the bleeder screw 1/2 turn. Have an assistant slowly press the brake pedal to the floor and hold. Close the bleeder screw, then release the pedal. Repeat until fluid flows without air bubbles. Check and refill reservoir frequently to prevent it from running dry. Tighten bleeder screw to specification when complete.
   ⚠️Never allow the master cylinder reservoir to run empty during bleeding. This will introduce air into the ABS system requiring special scan tool procedures to bleed.
   ⚠Close the bleeder screw before the assistant releases the brake pedal, or air will be drawn back into the system.
   Torque spec

   Bleeder Screw16 Nm (12 lb-ft)
10. 10

    Reinstall wheel and lower vehicle
    Reinstall the wheel and thread lug nuts by hand. Lower vehicle until tire just contacts ground. Torque lug nuts to specification in a star pattern. Fully lower 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 twists and adequate clearance from all moving components
3. Fill brake master cylinder reservoir to MAX line with DOT 4 LV brake fluid
4. Install reservoir cap securely
5. Clean any brake fluid residue from painted surfaces with water

Verification

• With engine off, pump brake pedal several times. Pedal should become firm and hold pressure. A spongy or soft pedal indicates air in the system requiring additional bleeding
• Inspect all brake connections for fluid leaks while an assistant applies firm pressure to brake pedal
• Turn steering wheel full lock to lock while verifying brake hose does not contact wheel, tire, or suspension components
• Test drive in a safe area at low speed to verify normal brake operation before returning to regular use
• Recheck brake fluid level after test drive and top off if necessary
• Inspect brake hose connections for leaks after test drive

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