This procedure covers the replacement of a front brake hose on a 2015 Kia Forte 1.8L, including fluid bleeding and system verification.

Warnings

Tools required

Parts

• Front brake hose (left or right as needed) × 1 — Use OEM specification
• Copper crush washers for banjo bolt × 2 — Use OEM specification
• Brake hose retaining clip (if damaged) × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake firmly
2. Loosen wheel lug nuts 1/4 turn while vehicle is on the ground
3. Raise front of vehicle with floor jack and secure on jack stands at manufacturer-recommended lift points
4. Remove the wheel completely from the side requiring brake hose replacement
5. Have fresh DOT 4 brake fluid and new copper crush washers ready before disconnecting any brake lines
6. Place cardboard or absorbent pads under work area to catch brake fluid spills

Procedure

1. 1

   Inspect and document existing brake hose routing
   Before removal, carefully observe how the brake hose is routed from the chassis hard line to the caliper. Note the position of any retaining clips or brackets. Take a photo if possible. Check that the hose you are replacing matches the orientation and length of the new hose.
2. 2

   Remove brake fluid from master cylinder reservoir
   Using a turkey baster or brake fluid syringe, remove approximately half the brake fluid from the master cylinder reservoir. This prevents overflow when disconnecting the brake hose. Dispose of old fluid properly; do not reuse.
   ⚠Brake fluid will damage painted surfaces. Keep fluid away from vehicle body panels and clean any spills immediately.
3. 3

   Disconnect brake hose from caliper at banjo bolt
   Locate the banjo bolt connecting the brake hose to the brake caliper. Using the appropriate box-end wrench or flare nut wrench, loosen and remove the banjo bolt while holding the brake hose fitting to prevent twisting. Be prepared for brake fluid to drain out. Remove and discard both copper crush washers from the banjo fitting. Cap or plug the caliper port if possible to minimize fluid loss.
   ⚠Do not twist the brake hose excessively during removal as this can damage internal construction of the new hose during installation.
4. 4

   Disconnect brake hose from chassis hard line
   Locate where the flexible brake hose connects to the rigid brake line on the chassis or strut assembly. Using a flare nut wrench (typically 10mm or 12mm), carefully loosen the threaded fitting. Use a backup wrench on the hose end fitting to prevent the hose from twisting. Once loose, unthread the connection by hand. Have a catch container ready for draining fluid.
   ⚠Use a flare nut wrench, not a standard open-end wrench, to prevent rounding off the soft brass fittings on the brake line.
5. 5

   Remove brake hose from mounting bracket
   The brake hose is retained to the chassis or strut assembly by a bracket clip or bolt. If a clip-style retainer is used, compress or pry the retaining clip to release the hose grommet. If a bolt secures the bracket, remove the bolt. Carefully extract the brake hose from the bracket, noting its orientation for reinstallation.
6. 6

   Prepare and install new brake hose to bracket
   Clean the mounting bracket area with a wire brush if necessary. Inspect the new brake hose to ensure it matches the old hose exactly in length and fitting types. Insert the new brake hose through the mounting bracket in the same orientation as the original. Install the retaining clip or bracket bolt to secure the hose to the chassis. If a bolt is used, torque to specification.
   Torque spec

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

   Connect brake hose to chassis hard line
   Thread the new brake hose fitting onto the chassis hard line by hand, ensuring threads engage properly without cross-threading. Once hand-tight, use a flare nut wrench to snug the connection. Use a backup wrench on the hose fitting to prevent twisting the hose. Tighten securely but do not over-torque the brass fitting.
   ⚠Cross-threading brake line fittings will ruin the threads and require hard line replacement. Always start threading by hand to ensure proper engagement.
8. 8

   Connect brake hose to caliper with new washers
   Place one NEW copper crush washer on each side of the banjo fitting (one against the caliper, one under the banjo bolt head). Insert the banjo bolt through the hose fitting and thread into the caliper by hand. Ensure the hose is not twisted and has proper clearance from suspension components through full steering range. Torque the banjo bolt to specification using a torque wrench.
   ⚠️Reusing old copper washers will result in brake fluid leaks 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

   Verify brake hose routing and clearance
   Turn the steering wheel full lock in both directions while observing the new brake hose. Verify the hose does not contact the tire, suspension components, or any sharp edges throughout the full range of motion. Check that the hose has a gentle curve without kinks or tight bends. Adjust the hose position in the mounting bracket if necessary.
10. 10

    Refill master cylinder and bleed brake system
    Fill the master cylinder reservoir with fresh DOT 4 brake fluid to the MAX line. Attach clear tubing to the bleeder screw on the caliper and place the other end in a catch container with some clean brake fluid. Have an assistant pump the brake pedal 3-5 times and hold pressure. Open the bleeder screw 1/4 turn to allow fluid and air to escape, then close the screw before the pedal reaches the floor. Repeat until fluid flows without air bubbles. Keep reservoir topped off during bleeding. Tighten bleeder screw to specification.
    ⚠️Never let the master cylinder reservoir run dry during bleeding or air will enter the system requiring more extensive bleeding procedures.
    Torque spec

    Bleeder Screw13 Nm (10 lb-ft)
11. 11

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

    Wheel Lug Nuts129 Nm (95 lb-ft)

Reassembly

1. Double-check all brake line connections for tightness and verify no leaks are present
2. Verify master cylinder reservoir is filled to MAX line with DOT 4 fluid
3. Confirm brake hose has proper clearance through full steering range
4. Ensure wheel lug nuts are properly torqued in star pattern

Verification

• With engine off, pump brake pedal several times. Pedal should become firm and hold pressure. If pedal is soft or spongy, additional bleeding is required
• Start engine and verify brake pedal remains firm with power assist active
• Inspect all brake connections for fluid leaks while assistant applies firm pedal pressure for 30 seconds
• Test drive in a safe area at low speed (under 15 mph) to verify proper brake operation before returning to normal driving
• After test drive, recheck all connections and inspect for leaks
• Check brake fluid level in reservoir and top off if needed
• Road test at normal speeds in a safe area, testing brake response and ensuring no pulling to either side

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