Replace the rear brake hose connecting the chassis brake line to the rear axle assembly, including bleeding the brake system.

Warnings

Tools required

Parts

• Rear brake hose × 1 — Use OEM specification
• Brake hose copper washers/seals × 4 — Included with brake hose kit

Fluids

• Mopar DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface and apply parking brake
2. Place wheel chocks in front of front wheels
3. Loosen rear wheel lug nuts while vehicle is on ground
4. Raise rear of vehicle and secure on jack stands at frame rails
5. Remove rear wheels
6. Clean brake line fittings and hose mounting areas with wire brush and brake cleaner
7. Apply penetrating oil to all brake line fittings and allow to soak for 10-15 minutes
8. Open brake fluid reservoir and verify fluid level is at MAX line
9. Place cardboard or catch pan under work area to protect from brake fluid spills

Procedure

1. 1

   Disconnect chassis brake line from hose
   Locate the rear brake hose-to-chassis line junction near the frame rail. Using a flare nut wrench on the brake line fitting and a line wrench to hold the hose end, loosen the fitting. Complete removal by hand. Immediately cap or cover the open chassis line end to prevent contamination and fluid loss.
   Torque spec

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

   Remove hose frame bracket mounting
   Locate the brake hose bracket bolt securing the hose to the frame rail. Using the appropriate wrench, remove the mounting bolt and extract the brake hose from the frame bracket. Note the orientation of any clips or retainers for reinstallation.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
3. 3

   Disconnect hose from axle junction block
   At the rear axle, locate where the brake hose connects to the axle-mounted junction block or distribution block. Using a flare nut wrench, carefully loosen and remove the hose fitting. Note the position of any copper washers or sealing washers on both sides of the connection. Allow brake fluid to drain into catch pan.
   ⚠The axle-mounted junction block fittings are brass and can strip easily. Use proper flare nut wrenches and avoid excessive force.
   Torque spec

   Line Fittings23 Nm (17 lb-ft)
4. 4

   Remove old brake hose
   Remove the old brake hose completely from the vehicle. Inspect the hose for signs of failure (bulging, cracking, chafing) to confirm replacement was necessary. Dispose of old hose properly.
5. 5

   Prepare new brake hose
   Remove new brake hose from packaging and verify it matches the old hose configuration. Ensure all new copper washers/seals are included. Do not remove protective caps from hose ends until ready to install. Verify hose routing will not result in contact with suspension components, exhaust, or sharp edges through full suspension travel.
6. 6

   Install hose to axle junction block
   Remove protective cap from hose axle end. Install new copper washers on both sides of the banjo bolt fitting (if equipped) or ensure proper sealing washers are positioned. Thread fitting into axle junction block by hand until snug, ensuring hose is not twisted. Using a line wrench, tighten to specification.
   ⚠Do not twist or kink the brake hose during installation. The hose must hang naturally without stress or torsion.
   Torque spec

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

   Secure hose to frame bracket
   Route the brake hose through the frame bracket in the same orientation as the original. Ensure hose will not contact any moving parts or sharp edges. Install the mounting bolt and tighten to specification. Verify hose can move slightly within bracket to accommodate suspension travel.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
8. 8

   Connect hose to chassis brake line
   Remove protective cap from chassis end of new hose. Align hose fitting with chassis brake line. Thread fitting by hand to ensure proper thread engagement. Once hand-tight, use line wrench to hold hose end and flare nut wrench on chassis line fitting. Tighten to specification. Do not over-tighten as this can damage the flare seat.
   Torque spec

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

   Verify hose routing and clearance
   Manually cycle the rear suspension through full compression and extension (have assistant push down on rear bumper). Verify brake hose does not contact any components, has adequate slack, and does not become stretched at full droop. Correct routing if necessary.
10. 10

    Refill brake fluid reservoir
    Check brake fluid reservoir level and top off to MAX line with fresh Mopar DOT 4 brake fluid. Keep reservoir above MIN line throughout bleeding process to prevent air entry into ABS system.
    ⚠️Use only Mopar DOT 4 brake fluid. Wrong fluid type can cause complete brake system failure.
11. 11

    Bleed rear brake circuit
    Attach bleeder hose to rear bleeder screw on the caliper. Submerge other end in container with clean brake fluid. Have assistant slowly depress brake pedal fully and hold. Open bleeder screw 1/2 turn until fluid flows, then close before pedal reaches floor. Repeat until no air bubbles appear in discharged fluid (typically 5-10 cycles). Check and refill reservoir frequently.
    ⚠Never allow brake pedal to go to floor with bleeder open, and never release pedal while bleeder is open, as this can draw air into the system.
    Torque spec

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

    Install wheel and lower vehicle
    Reinstall rear wheel, threading lug nuts by hand. Lower vehicle until tire just contacts ground. Torque lug nuts in star pattern to specification. Fully lower vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Final brake fluid reservoir level should be at MAX line
2. All brake line fittings must be tightened to exact specification with proper line wrenches
3. Brake hose must have proper clearance from all suspension and drivetrain components
4. No brake fluid leaks should be present at any connection point

Verification

• With engine off, pump brake pedal several times until firm. Pedal should become firm and hold pressure without sinking
• Start engine and verify brake pedal does not sink with sustained pressure (30 seconds minimum)
• Inspect all connections for brake fluid leaks while assistant applies firm brake pressure
• Test drive in safe area at low speed to verify normal brake operation before returning to service
• Perform multiple moderate brake applications from 20-30 mph to verify even braking and proper pedal feel
• Re-check all connections and fluid level after test drive. Top off reservoir if needed
• Schedule re-torque inspection of all connections after 50-100 miles of driving

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