Brake Hose - Front

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

Warnings

Tools required

Parts

• Front brake hose × 1 — 01469-TVC-A01 or equivalent OEM
• Copper crush washers for banjo bolt × 2 — Use OEM specification
• Brake hose retaining clip (if damaged) × 1 — Use OEM specification

Fluids

• DOT 3 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Loosen wheel lug nuts 1/4 turn while vehicle is on ground
3. Raise front of vehicle with floor jack and support securely on jack stands at manufacturer-specified lift points
4. Remove front wheel completely
5. Place drain pan under work area to catch brake fluid
6. Have fresh DOT 3 brake fluid ready and keep container sealed until use
7. Clean the brake hose fittings and surrounding area with brake cleaner to prevent contamination

Procedure

1. 1

   Remove brake hose from caliper
   Locate the banjo bolt connecting the brake hose to the caliper on the backside of the caliper body. Using a 12mm wrench, hold the brake hose stationary while loosening the banjo bolt with another wrench. Remove the banjo bolt completely and immediately cap or plug the caliper port to minimize fluid loss. Note the position of the copper crush washers (one on each side of the banjo fitting) and discard them.
   ⚠Brake fluid will drain immediately when bolt is removed. Position drain pan directly underneath.
2. 2

   Disconnect brake hose from bracket
   Locate the brake hose bracket on the strut or frame rail. Remove the retaining clip that secures the brake hose to the bracket by carefully prying it out with a small screwdriver or pick. Note the orientation of the clip for reinstallation. Pull the brake hose through the bracket to free it.
3. 3

   Disconnect brake hose from hard line
   Locate where the flexible brake hose connects to the metal brake line (typically near the strut or frame). Using a flare nut wrench on the brake line fitting, hold the brake hose hex fitting stationary with a box wrench while loosening the flare nut. Completely unthread the connection and allow fluid to drain into the pan. Remove the old brake hose from the vehicle.
   ⚠Use a flare nut wrench (6-point) to prevent rounding off the brake line fitting. A regular open-end wrench may damage the fitting.
4. 4

   Inspect and prepare components
   Inspect the brake line threads and caliper banjo port for damage or corrosion. Clean threads with a wire brush if needed. Check that the new brake hose matches the old one in length, fittings, and routing. Verify you have two NEW copper crush washers for the banjo bolt. Do not reuse old washers.
5. 5

   Install new brake hose to hard line
   Thread the new brake hose onto the metal brake line by hand, ensuring proper alignment and no cross-threading. The hose should route naturally without twisting or kinking. Tighten the connection using a flare nut wrench on the line fitting and box wrench on the hose hex. Torque to specification if applicable, or tighten firmly (typically 11-13 lb-ft for brake line fittings).
6. 6

   Install brake hose through bracket
   Route the brake hose through the frame or strut bracket, ensuring the hose is not twisted and will have adequate clearance during steering and suspension travel. Install the retaining clip to secure the hose in the bracket. Ensure the clip is fully seated and the hose is held firmly but can still rotate slightly in the bracket.
   Torque spec

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

   Connect brake hose to caliper
   Position a NEW copper crush washer on each side of the brake hose banjo fitting (one against the fitting, one against the caliper). Align the banjo fitting with the caliper port and insert the banjo bolt through the assembly by hand. Ensure the hose is positioned so it will not contact suspension components or the wheel during operation. Thread the banjo bolt in by hand several turns to ensure proper threading.
   ⚠️New copper washers are mandatory. Reused washers will leak and cause brake failure.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
8. 8

   Torque banjo bolt to specification
   Using a torque wrench, tighten the banjo bolt to exactly 25.0 Nm (18.0 lb-ft). Hold the brake hose to prevent it from twisting during tightening. Verify the hose routing one final time - it should have no kinks, twists, or contact points with moving components through full steering and suspension range.
   ⚠Over-torquing can damage the caliper port threads. Under-torquing will cause leaks. Use a calibrated torque wrench.
   Torque spec

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

   Bleed brake system at affected wheel
   Clean the bleeder screw on the caliper. Attach a clear hose to the bleeder screw and submerge the other end in a container partially filled with fresh brake fluid. Have an assistant pump the brake pedal 3-4 times and hold pressure. Open the bleeder screw 1/4 turn and observe fluid and air bubbles flowing through the clear hose. Close bleeder screw before pedal reaches floor. Repeat this process until fluid flows with no air bubbles (typically 5-10 repetitions). Keep master cylinder reservoir filled during bleeding process.
   ⚠️Never let the master cylinder reservoir run dry during bleeding or you will introduce air into the entire system.
   Torque spec

   Bleeder Screw13 Nm (10 lb-ft)
10. 10

    Reinstall wheel and lower vehicle
    Install the wheel and thread lug nuts by hand until snug. Lower vehicle until tire just contacts ground but weight is still on jack stands. Torque lug nuts to 129.0 Nm (95.0 lb-ft) in a star pattern. Fully lower vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts129 Nm (95 lb-ft)
11. 11

    Final brake system check and test
    Check brake fluid level in master cylinder reservoir and top off to MAX line with fresh DOT 3 fluid if needed. Pump brake pedal repeatedly (15-20 times) and verify firm pedal feel. Pedal should not feel spongy or sink slowly to floor. Inspect all connections for leaks while an assistant applies firm pressure to brake pedal. Wipe connections dry, apply pedal pressure, and look for fresh fluid seepage.
    ⚠️A soft or sinking brake pedal indicates air in the system or a leak. Do not drive vehicle until problem is corrected.

Reassembly

1. Ensure all brake line connections are tight and leak-free
2. Verify brake hose has proper clearance from suspension components, steering components, and wheel through full range of motion
3. Check that retaining clips are fully seated in brackets
4. Confirm brake fluid reservoir is filled to MAX line
5. Dispose of old brake fluid and washers properly

Verification

• With engine running, pump brakes several times and verify firm, high pedal feel with no sponginess
• Perform a visual inspection of all connections for brake fluid leaks while assistant holds firm pedal pressure
• Test drive in safe area at low speed (under 10 mph) to verify proper brake function before normal driving
• Perform several moderate brake applications from 25-30 mph in a safe area and verify straight stopping with no pulling
• After test drive, re-inspect all connections for leaks and re-check fluid level
• If pedal feel is abnormal or any leaks are present, do not drive vehicle and repeat bleeding procedure or seek professional assistance

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