Brake Hose - Rear

Replace the rear brake hose on a 2015 Kia Forte 1.8L, including bleeding the brake system and verifying proper brake operation.

Warnings

Tools required

Parts

• Rear brake hose × 1 — Use OEM specification
• Copper crush washers for banjo bolt × 2 — Use OEM specification - 2 per hose
• Brake fluid DOT 4 × 1 — Use OEM specification

Fluids

• DOT 4 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface and place wheel chocks at front wheels
2. Loosen rear wheel lug nuts while vehicle is on ground (do not remove)
3. Raise rear of vehicle with floor jack and support securely on jack stands at manufacturer-designated lift points
4. Remove rear wheel completely
5. Clean brake hose connections with wire brush and apply penetrating oil to fittings if corroded
6. Locate brake fluid reservoir under hood and check fluid level - mark initial level
7. Have brake fluid catch pan and rags ready to contain spills

Procedure

1. 1

   Remove banjo bolt from caliper
   Place drain pan under caliper. Using a flare nut wrench, carefully loosen and remove the banjo bolt connecting the brake hose to the rear caliper. Brake fluid will drain from the connection. Immediately plug the caliper port with a clean rag or rubber cap to minimize fluid loss and prevent contamination. Remove and discard both copper crush washers from the banjo fitting.
   ⚠Brake fluid will spray out under pressure. Position drain pan carefully and protect painted surfaces.
2. 2

   Disconnect hose from brake line bracket
   Locate the brake hose bracket where the flexible hose connects to the hard brake line on the chassis or suspension component. Remove the bracket bolt or clip securing the hose to the bracket. On the Forte, this is typically a bolt securing the hose to a bracket on the rear suspension.
3. 3

   Disconnect hose from hard brake line
   Using a flare nut wrench on the brake line fitting, carefully unthread the brake hose from the hard brake line junction. Turn the hose fitting, NOT the brake line nut, to avoid twisting or damaging the steel brake line. Position drain pan to catch additional fluid. Once disconnected, plug the hard line opening immediately to prevent fluid loss and contamination.
   ⚠Use a flare nut wrench to prevent rounding off the fitting. Never use standard open-end wrenches on brake line fittings.
4. 4

   Remove old brake hose
   Remove the old brake hose completely from the vehicle. Inspect the caliper port and hard brake line threads for damage, corrosion, or debris. Clean threads with a wire brush if necessary. Verify the new brake hose matches the old hose in length, fitting types, and routing configuration.
5. 5

   Install new brake hose to hard line
   Remove plugs from hard brake line. Thread the new brake hose onto the hard brake line fitting by hand, ensuring proper alignment and no cross-threading. The hose should thread smoothly without force. Do not fully tighten yet - leave finger-tight to allow hose positioning adjustment.
6. 6

   Install hose bracket
   Position the brake hose into its mounting bracket on the chassis or suspension. Ensure the hose is not twisted and follows the original routing path. Install the bracket bolt and torque to specification. Verify the hose has proper clearance from suspension components, wheel, and tire through full range of motion.
   ⚠Ensure brake hose is not twisted. The hose must route naturally without tension or contact with moving parts throughout suspension travel.
   Torque spec

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

   Connect banjo bolt to caliper with new washers
   Install one NEW copper crush washer on the banjo fitting, position the fitting onto the caliper port, then install the second NEW copper crush washer. Insert the banjo bolt through the assembly. Hand-thread the banjo bolt initially to verify proper alignment. Torque the banjo bolt to specification while holding the hose to prevent twisting.
   ⚠️CRITICAL: Always use TWO new copper crush washers - one on each side of the banjo fitting. Never reuse old washers.
   Torque spec

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

   Tighten hard line connection
   Return to the hard brake line connection point. Ensure the brake hose is properly positioned without twists, then torque the hose-to-hard-line fitting to finger-tight plus 1/4 to 1/2 turn using a flare nut wrench. Do not over-tighten as this can damage the fitting or cause leaks.
   ⚠Brake line fittings require careful tightening. Over-torque will strip threads or crack fittings.
9. 9

   Bleed rear brake caliper
   Refill the brake fluid reservoir to the MAX line with fresh DOT 4 brake fluid from a sealed container. Attach a clear hose to the bleeder screw on the rear caliper and submerge the other end in a container with clean brake fluid. Have an assistant pump the brake pedal 3-5 times and hold pressure. Open the bleeder screw 1/2 turn - fluid and air will flow out. Close bleeder screw before pedal reaches floor. Repeat until no air bubbles appear in the clear hose and only clean fluid flows. Torque bleeder screw to specification.
   ⚠Monitor reservoir constantly during bleeding. Never let reservoir run empty or air will enter the entire system.
   Torque spec

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

    Check for leaks and inspect connections
    With brake pedal pressure applied by assistant, carefully inspect the banjo bolt connection, hard line connection, and bracket for any signs of brake fluid leakage. Wipe all connections dry, apply firm pedal pressure, and re-inspect. Tighten any weeping connections slightly. Verify all torque specifications are met.
    ⚠️Any brake fluid leak is a critical safety hazard. All connections must be completely dry under pedal pressure.
11. 11

    Reinstall wheel and lower vehicle
    Reinstall the rear wheel, threading lug nuts by hand initially to ensure proper seating. Lower vehicle until tire just contacts 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 Nuts129 Nm (95 lb-ft)

Reassembly

1. Fill brake fluid reservoir to MAX line with fresh DOT 4 brake fluid
2. Pump brake pedal firmly 20-30 times to pressurize system and verify pedal firmness
3. If pedal is soft or spongy, additional bleeding of the affected corner or entire system may be required
4. Clean any brake fluid residue from painted surfaces, caliper, and wheels immediately with water

Verification

• With engine off, pump brake pedal several times - pedal should be firm and maintain height
• Start engine - pedal may drop slightly but should remain firm with normal travel
• Perform visual inspection of all brake hose connections for leaks with pedal applied
• Test drive in safe area at low speed - verify normal brake operation and firm pedal feel
• Perform several moderate brake applications from 25 mph to verify proper braking response
• Re-inspect all connections after test drive for any signs of leakage
• Check brake fluid level and top off to MAX line if needed
• If pedal feels soft, travels too far, or braking performance is compromised, DO NOT drive vehicle - seek professional service immediately

More procedures for this vehicle