Brake Hose - Rear

Replace the rear brake hose connecting the brake line to the rear caliper, including bleeding the brake system to restore proper braking function.

Warnings

Tools required

Parts

• Rear brake hose assembly × 1 — Use OEM specification
• Copper crush washers for banjo bolt × 2 — Included with brake hose or order separately
• Brake hose retaining clip (if equipped) × 1 — Reuse or replace if damaged

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 1 qt

Preparation

1. Park vehicle on level ground and place transmission in Park (automatic) or gear (manual)
2. Apply parking brake and place wheel chocks at front wheels
3. Verify you have the correct replacement brake hose for your specific F-150 configuration (wheelbase and brake package affect hose length)
4. Open the brake fluid reservoir cap slightly to relieve vacuum (do not remove completely)
5. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground
6. Raise rear of vehicle with floor jack and support securely on jack stands rated for vehicle weight
7. Remove rear wheel completely
8. Spray penetrating oil on brake line fitting and banjo bolt if corrosion is visible; allow 10-15 minutes to penetrate

Procedure

1. 1

   Prepare work area and locate brake hose connections
   Identify the rear brake hose connection points: the banjo bolt at the caliper and the threaded fitting where the hose connects to the hard brake line on the frame or axle. Place a catch pan under the caliper area to collect brake fluid that will drain during disconnection.
2. 2

   Disconnect brake hose from caliper
   Using the appropriate wrench, hold the brake hose fitting stationary and remove the banjo bolt at the caliper. Brake fluid will drain immediately. Remove and discard both copper crush washers from the banjo bolt—these must be replaced with new washers and cannot be reused. Cap or plug the caliper port with a rubber cap or clean shop rag to minimize fluid loss and prevent contamination.
   ⚠Do not allow brake fluid to contact painted surfaces, rubber components, or wiring. Wipe up spills immediately with clean rags.
3. 3

   Disconnect brake hose from hard line
   Using a line wrench (NOT an open-end wrench which can round the fitting), hold the brake hose end stationary with one wrench while loosening the threaded fitting on the hard brake line with another wrench. Unthread completely and separate the hose from the hard line. Additional fluid will drain—ensure catch pan is positioned correctly.
   ⚠Using an open-end wrench instead of a line wrench can round the soft steel fitting, making future service difficult or impossible.
4. 4

   Remove brake hose from bracket
   The brake hose is retained in a mounting bracket with either a clip or bolt. If clip-retained, compress the retaining tabs and slide the hose out of the bracket. If bolt-retained, remove the bracket bolt. Remove the old brake hose assembly completely from the vehicle. Inspect the bracket for damage or corrosion.
5. 5

   Prepare new brake hose assembly
   Remove the new brake hose from packaging. Verify it matches the old hose in terms of fittings, length, and bracket mounting style. Ensure new copper crush washers are available (often included with new hose). Do NOT remove protective caps from fittings until ready to install to prevent contamination.
6. 6

   Install brake hose in mounting bracket
   Route the new brake hose through the mounting bracket in the same orientation as the original. Ensure the hose is not twisted and follows the natural routing path. Install the retaining clip or bracket bolt finger-tight. If using a bolt, torque the brake hose bracket to specification. Verify the hose can move slightly in the bracket to prevent binding during suspension travel.
   ⚠A twisted brake hose will cause internal stress and premature failure. Ensure the hose follows its natural curve without twisting.
   Torque spec

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

   Connect brake hose to hard line
   Remove protective cap from the hard line end of the new brake hose. Thread the hose fitting onto the hard brake line by hand until finger-tight to ensure proper thread engagement. Using a line wrench, tighten the fitting to the specified torque. Hold the brake hose stationary with one wrench while torquing to prevent twisting the hose.
   ⚠Cross-threading will damage the fitting and cause brake fluid leaks. If resistance is felt immediately, back off and restart—fittings should thread smoothly by hand for several turns.
   Torque spec

   Line Fittings23 Nm (17 lb-ft)
8. 8

   Connect brake hose to caliper with new washers
   Remove protective cap from the caliper end of the brake hose. Place one NEW copper crush washer on each side of the banjo fitting (one against the hose, one against the caliper body). Insert the banjo bolt through the assembly and thread into the caliper by hand. Torque the banjo bolt to specification using a torque wrench. Do NOT reuse old copper washers—they will leak.
   ⚠️Reusing old copper crush washers will result in brake fluid leakage and potential brake failure. ALWAYS use new washers supplied with the brake hose.
   Torque spec

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

   Bleed the affected brake circuit
   Refill the brake fluid reservoir to the MAX line with fresh Motorcraft DOT 4 LV brake fluid. Locate the bleeder screw on the rear caliper (typically on the back or top). Attach clear tubing to the bleeder screw and submerge the other end in a container with clean brake fluid. Have an assistant slowly pump the brake pedal 3-4 times and hold pressure. Open the bleeder screw 1/2 to 3/4 turn while pedal is held down—fluid and air will exit. Close the bleeder screw before the pedal reaches the floor. Repeat this process until no air bubbles appear in the clear tubing and only clean fluid flows. Check and refill the reservoir frequently—never let it run dry or air will enter the entire system.
   ⚠️If the brake fluid reservoir runs empty during bleeding, air will enter the ABS module and master cylinder, requiring professional scan tool bleeding procedures.
   ⚠The brake pedal must NOT be released while the bleeder screw is open, or air will be drawn back into the system.
   Torque spec

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

    Inspect all connections for leaks
    With the bleeder screw tightened to specification, carefully inspect both the banjo bolt connection at the caliper and the threaded fitting at the hard line for any signs of brake fluid seepage. Have an assistant press the brake pedal firmly and hold for 30 seconds while you inspect. No fluid should appear at any connection. If leakage is observed, the connection must be loosened, inspected, and reinstalled correctly.
    ⚠️Even minor brake fluid seepage indicates an improper connection that will worsen and cause brake failure. Do not proceed if any leakage is observed.
11. 11

    Reinstall wheel and lower vehicle
    Clean the wheel hub face and wheel mounting surface of any debris or corrosion. Install the wheel and thread all lug nuts by hand until snug. Lower the vehicle until the tire just contacts the ground (still supported partially by jack). Torque the lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands. Perform a final torque check on lug nuts in star pattern.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)
12. 12

    Perform final brake system check
    With the vehicle on the ground, pump the brake pedal several times to ensure it builds firm pressure. The pedal should feel solid within 2-3 pumps and should not sink toward the floor when held under pressure for 30 seconds. Check the brake fluid reservoir level and top off to MAX line if needed. Secure the reservoir cap. Inspect underneath the vehicle one final time for any signs of brake fluid drips or leaks at the new brake hose connections.
    ⚠️A soft, spongy, or sinking brake pedal indicates air remains in the system or a leak exists. Do NOT drive the vehicle until proper brake pedal feel is achieved.

Reassembly

1. Ensure all brake line fittings and banjo bolts are torqued to specification—do not guess or over-tighten
2. Verify brake fluid reservoir is filled to MAX line with correct DOT 4 LV specification fluid
3. Confirm no tools or parts have been left in the wheel well or near brake components
4. Double-check that wheel lug nuts are torqued properly in star pattern

Verification

• Start the engine and pump the brake pedal—it should feel firm and high with minimal travel
• With engine running, apply steady brake pressure for 1 minute and verify pedal does not slowly sink
• Visually inspect under the vehicle at both brake hose connections for any signs of fluid leakage
• Perform a controlled low-speed brake test (10-15 mph) in a safe area to verify proper brake response before returning to normal driving
• After the first 50-100 miles, re-inspect all brake connections for leakage and verify brake pedal feel remains firm
• Check brake fluid level after test drive and add if necessary—level may drop slightly after initial driving as fluid settles into newly serviced components

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