Replace the front brake hose assembly, including disconnection from the brake caliper and chassis bracket, followed by brake system bleeding.

Warnings

Tools required

Parts

• Front brake hose assembly × 1 — Use OEM specification for 2016-2024 Tucson AWD
• Copper crush washers (banjo bolt) × 2 — Typically included with brake hose

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen front 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 jacking points
4. Remove front wheel completely on side being serviced
5. Open hood and locate brake fluid reservoir. Check fluid level and do not allow it to drop below MIN during procedure
6. Clean area around brake hose connections with wire brush to prevent contamination during disassembly
7. Place drain container under brake caliper area to catch fluid spillage

Procedure

1. 1

   Remove brake hose retaining clip from chassis bracket
   Locate the brake hose bracket where the hose attaches to the chassis strut mount area. Using a flat blade screwdriver or pliers, carefully remove the retaining clip that secures the brake hose to the bracket. Note the orientation of the clip for reinstallation.
2. 2

   Disconnect brake hose from caliper banjo fitting
   Using a 12mm wrench to hold the brake hose end fitting stationary, use a 14mm wrench to loosen and remove the banjo bolt connecting the brake hose to the brake caliper. Be prepared for brake fluid spillage. Once bolt is removed, pull the brake hose away from the caliper and immediately plug or cap the caliper port to minimize fluid loss and contamination. Discard the old copper crush washers - do not reuse.
   ⚠Brake fluid will drain from both the hose and caliper. Have rags and drain container positioned to catch fluid.
3. 3

   Disconnect brake hose from brake line at chassis bracket
   Locate where the flexible brake hose connects to the rigid brake line at the chassis bracket. Using a 14mm flare nut wrench on the brake hose fitting and a 12mm wrench on the brake line fitting, carefully loosen the connection. Flare nut wrenches prevent rounding of soft brake fittings. Once loose, unthread the hose completely and remove it from the vehicle. More brake fluid will drain - catch it in your container.
   ⚠Use a flare nut wrench to prevent rounding the soft brake line fittings. Standard open-end wrenches can damage fittings.
4. 4

   Inspect brake line and caliper ports
   Examine the rigid brake line threads and caliper banjo port for damage, corrosion, or cross-threading. Clean threads with a wire brush if necessary. Check that the banjo bolt threads in the caliper are clean and undamaged. If any components show damage, they must be replaced before proceeding.
5. 5

   Install new brake hose to chassis bracket
   Route the new brake hose along the same path as the original, ensuring it does not contact suspension components or the tire during full steering lock in both directions. Thread the brake hose fitting into the rigid brake line at the chassis bracket by hand first to ensure proper thread engagement. Once hand-tight, use wrenches to snug the connection - do not fully torque yet. Insert the hose into the chassis bracket and install the retaining clip in the same orientation as removed.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
6. 6

   Connect brake hose to caliper with new copper washers
   Install one NEW copper crush washer on each side of the banjo fitting (one against the caliper, one against the banjo bolt head). Position the banjo fitting onto the caliper port, ensuring proper alignment. Thread the banjo bolt by hand to verify correct thread engagement. Once hand-tight, torque the banjo bolt to specification. Verify the brake hose routing allows full suspension travel and steering motion without binding or stretching.
   ⚠️Both copper washers MUST be new. Reusing washers will cause brake fluid leaks and potential brake failure.
   Torque spec

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

   Torque brake line connection at chassis bracket
   Return to the chassis bracket connection between the brake hose and rigid brake line. Using a 14mm wrench on the hose fitting and a 12mm backup wrench on the brake line, torque the connection to 10.0 Nm (7.0 lb-ft) per the brake hose bracket specification. Do not overtighten as this can damage the soft brake fittings.
   Torque spec

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

   Verify brake hose routing and clearance
   Turn the steering wheel to full lock in both directions while observing the brake hose. Verify the hose does not contact the tire, wheel, suspension components, or chassis at any point. Bounce the suspension to verify adequate clearance during compression and extension. The hose should have a gentle curve with no kinks or tight bends. Adjust routing if necessary.
9. 9

   Refill brake fluid reservoir
   Check the brake fluid level in the master cylinder reservoir under the hood. Add fresh DOT 4 brake fluid from a sealed container until the level reaches the MAX line. Keep the reservoir filled above the MIN line throughout the bleeding process to prevent air from entering the system.
10. 10

    Bleed the affected brake caliper
    Locate the bleeder screw on the rear of the brake caliper. Attach clear tubing to the bleeder screw and submerge the other end in a container with clean brake fluid. Have an assistant pump the brake pedal 3-4 times and hold pressure. Using a 10mm wrench, open the bleeder screw 1/4 turn. Fluid and air will flow through the tubing. Close the bleeder screw before the pedal reaches the floor. Repeat this process until no air bubbles appear in the tubing 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 professional scan tool bleeding.
    Torque spec

    Bleeder Screw14 Nm (10 lb-ft)
11. 11

    Reinstall wheel and lower vehicle
    Clean the wheel mounting surface on the hub. Install the wheel and thread lug nuts by hand to prevent cross-threading. Snug lug nuts in a star pattern with a wrench. Lower the vehicle until the tire just contacts the ground (to prevent wheel rotation). Torque lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Double-check all brake connections for tightness and proper torque
2. Verify brake hose routing has adequate clearance at full steering lock and suspension travel
3. Top off brake fluid reservoir to MAX line with fresh DOT 4 fluid
4. Wipe down all brake components to remove spilled brake fluid

Verification

• With engine off, pump brake pedal several times. Pedal should become firm and hold pressure without sinking
• Start engine and verify brake pedal remains firm with approximately 1/3 pedal travel
• Check all brake hose connections for leaks while assistant applies steady brake pressure
• Perform a low-speed test drive in a safe area. Apply brakes gently at first, then progressively harder to verify normal brake operation
• After test drive, recheck all connections for leaks and verify brake fluid level is at MAX line
• Check brake pedal feel is firm and consistent. If pedal feels spongy, additional bleeding is required
• Inspect brake hose routing one final time to confirm no contact with suspension or steering components

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