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

Warnings

Tools required

Parts

• Front brake hose assembly (left or right) × 1 — Use OEM specification
• Brake hose-to-hard line copper washers × 2 — Use OEM specification
• Brake hose-to-caliper copper washers × 2 — Use OEM specification

Fluids

• Mopar DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface and set 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 frame rails
4. Remove front wheel completely
5. Place drip pan under work area to catch brake fluid
6. Clean brake hose fittings, mounting bracket, and hard line connection with wire brush and penetrating oil if corroded
7. Have fresh DOT 4 brake fluid and bleeding equipment ready
8. Identify which side you are working on (driver or passenger) and obtain correct replacement hose

Procedure

1. 1

   Remove brake hose from hard line
   Locate where the rubber brake hose connects to the metal hard line at the frame bracket. Using a line wrench (not a standard wrench), carefully loosen the brake line fitting nut. Hold the hose fitting with another wrench if needed to prevent twisting the hose. Once loose, unthread the fitting by hand and allow brake fluid to drain into pan. Remove and discard the old copper washers from both sides of the fitting.
2. 2

   Remove brake hose from mounting bracket
   The brake hose passes through a mounting bracket on the frame or suspension component. Locate the retaining clip or bracket bolt that secures the hose in place. Remove the clip by prying it out with a flathead screwdriver, or remove the bracket bolt using a 13mm wrench. Slide the hose out of the bracket.
3. 3

   Disconnect brake hose from caliper
   At the brake caliper, locate the banjo bolt connecting the brake hose to the caliper inlet. Using a 13mm wrench, loosen and remove the banjo bolt. Hold a rag or container underneath to catch draining fluid. Once removed, separate the hose from the caliper and discard the old copper crush washers on both sides of the banjo fitting. Do not reuse these washers.
4. 4

   Install new brake hose to caliper
   Position the new brake hose to the caliper inlet with the hose routing away from any suspension components or steering arms. Install NEW copper crush washers on both sides of the banjo fitting (one between hose and caliper, one between banjo bolt head and hose). Insert the banjo bolt and hand-tighten. Ensure the hose is not twisted or kinked. Torque the banjo bolt to specification.
   ⚠️Verify hose routing allows full suspension travel and steering lock-to-lock without stretching, kinking, or contacting moving parts.
   Torque spec

   Line Fittings23 Nm (17 lb-ft)
5. 5

   Secure hose in mounting bracket
   Route the brake hose through the frame or suspension mounting bracket. Ensure the hose is positioned correctly without twisting. Install the retaining clip by pressing it firmly into place, or install and torque the mounting bracket bolt to specification. Verify the hose can move slightly but is securely retained.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
6. 6

   Connect brake hose to hard line
   Install NEW copper washers on the hard line fitting (one on each side of the connection point). Thread the brake hose fitting onto the hard line by hand to ensure proper thread engagement. Once hand-tight, use a line wrench to carefully torque the fitting to specification. Do not over-tighten as this can damage the fitting or cause leaks.
   ⚠Use a line wrench (flare nut wrench) on brake fittings to prevent rounding off the soft metal nuts. Standard wrenches will likely damage fittings.
   Torque spec

   Line Fittings23 Nm (17 lb-ft)
7. 7

   Verify hose installation and routing
   Before bleeding, perform a complete visual inspection. Check that the brake hose does not contact any suspension components, steering linkage, or tire at full steering lock in both directions. Verify the hose has adequate slack for full suspension droop and compression. Ensure all fittings are tight and properly seated. Check that new copper washers are installed at all connections.
8. 8

   Bleed brake system at affected wheel
   Locate the brake caliper bleeder screw on the back of the caliper. Clean the bleeder screw area. Attach a clear hose to the bleeder screw and place the other end in a container partially filled with clean brake fluid. Have an assistant pump the brake pedal 3-4 times and hold pressure. Open the bleeder screw 1/4 turn while assistant maintains pedal pressure. Close bleeder before pedal reaches floor. Repeat until fluid flows without air bubbles. Top off master cylinder reservoir frequently during bleeding to prevent introducing more air.
   ⚠Never allow the brake fluid reservoir to run dry during bleeding or you will introduce air into the entire system requiring complete system bleeding.
   Torque spec

   Bleeder Screw16 Nm (12 lb-ft)
9. 9

   Check for leaks and verify connections
   With the bleeder screw closed and torqued, have an assistant apply firm, steady pressure to the brake pedal (do not pump). Inspect all three connection points: caliper banjo fitting, mounting bracket, and hard line fitting. Look for any signs of brake fluid seepage or dripping. If any leaks are detected, release pedal pressure, address the leak by re-torquing or replacing washers, and re-bleed. Wipe all connections dry with a clean rag for final inspection.
   ⚠️Even minor brake fluid seepage indicates a potential failure point. Any leak must be corrected before operating the vehicle.
10. 10

    Reinstall wheel and perform final checks
    Reinstall the wheel onto the hub, threading lug nuts by hand first to ensure proper seating. Lower vehicle until tire just contacts ground (keeping jack stands in place). Torque lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands. Pump brake pedal several times to verify firm pedal feel. Check brake fluid reservoir level and top off to MAX line with fresh DOT 4 fluid. Start engine and test brake operation at low speed before returning to service.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Torque all connections to specification using proper tools (line wrenches for fittings, torque wrench for all fasteners)
2. Ensure all copper washers are new and properly positioned at banjo bolt and line fittings
3. Verify brake hose routing allows full suspension and steering travel without interference
4. Top off brake fluid reservoir to MAX line with fresh Mopar DOT 4 brake fluid from sealed container

Verification

• With engine running, brake pedal should feel firm and not sink when steady pressure is applied for 30 seconds
• Inspect all three brake hose connection points (caliper, bracket, hard line) for any signs of fluid leakage with pedal under pressure
• Turn steering wheel lock-to-lock and cycle suspension through full travel to verify hose does not contact any components or become stretched
• Test drive in safe area at low speed (under 15 mph) to verify normal brake operation before returning to regular service
• After test drive, recheck all fittings for leaks and verify brake pedal remains firm
• If brake pedal feels spongy or travels too far, additional bleeding is required - DO NOT drive until corrected

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