Brake Line - Single

Replace a single damaged or leaking brake line on a 2017 Maserati Levante 3.0L V6 Twin Turbo, including proper flaring, routing, and complete system bleeding.

Warnings

Tools required

Parts

• Brake line (pre-fabricated or bulk line material) × 1 — Use OEM specification or SAE J1047 compliant steel line
• Brake line fittings (if fabricating) × 2 — Match OEM thread size and type
• Brake line clips/retainers × 2 — Use OEM specification

Fluids

• DOT 4 Racing Brake Fluid — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind wheels that will remain on ground.
2. Locate the damaged brake line section and determine which wheel(s) will need to be removed for access.
3. Open the brake fluid reservoir cap to relieve system pressure and allow easier fluid evacuation.
4. Lift and support the vehicle using jack stands at appropriate lift points. Never work under a vehicle supported only by a jack.
5. Remove the wheel(s) necessary to access the damaged brake line section.
6. Clean the area around all brake line fittings with wire brush and penetrating oil if corroded. Allow penetrant to soak for 10-15 minutes.
7. Place drain pan below work area to catch brake fluid.
8. If fabricating line: measure the damaged line precisely, including all bends and routing. Use the old line as a template if possible.

Procedure

1. 1

   Disconnect brake line at upstream fitting
   Using a line wrench (not standard wrench), carefully loosen the upstream brake line fitting where it connects to the next component (master cylinder, junction block, or another line). Hold the component-side fitting stationary with a second wrench to prevent twisting. Once loose, unthread by hand and immediately plug the open port with a rubber cap or bolt to minimize fluid loss and contamination.
   ⚠️Use only a proper line wrench (flare nut wrench) to prevent rounding the soft brass or steel fittings. Rounded fittings may require cutting the line and are extremely difficult to remove.
   Torque spec

   Line Fittings22 Nm (16 lb-ft)
2. 2

   Disconnect brake line at downstream fitting
   Using the same technique, loosen and remove the downstream brake line fitting (connecting to caliper, wheel cylinder, or another line section). Hold the stationary fitting with a backup wrench. Remove the line and plug the open port immediately. Allow brake fluid to drain into the catch pan.
   Torque spec

   Line Fittings22 Nm (16 lb-ft)
3. 3

   Remove brake line from mounting clips
   Trace the entire length of the damaged line and release it from all mounting clips and brackets along the chassis or suspension components. Note the exact routing path, proximity to heat sources, and relationship to other components. Take photos for reference during installation. Inspect clips for damage and replace if broken or deformed.
4. 4

   Fabricate or prepare replacement brake line
   If using pre-fabricated line: verify it matches the original in length, fitting type, and bend configuration. If fabricating: cut new brake line tubing to length using a tubing cutter (not a hacksaw if possible, as this can leave burrs). Create double-flare ends using the flaring tool according to tool instructions. Ensure flares are perfectly formed without cracks or splits. Bend the line to match the original routing using a tubing bender to prevent kinking. Never create sharp bends that restrict flow.
   ⚠️Improperly formed flares or kinked lines will fail under pressure and cause brake failure. If flares are cracked, split, or uneven, remake them. Do not compromise on this critical step.
   ⚠Brake line must be routed away from heat sources (exhaust), sharp edges, and moving suspension components. Verify adequate clearance through full suspension travel before final installation.
5. 5

   Route and install new brake line
   Route the new brake line following the exact path of the original, ensuring it does not contact exhaust components, suspension parts through their full travel, or sharp edges. Secure the line in all original mounting clip locations. Verify there is no tension on the line and that it has slight slack to accommodate suspension movement. The line should not be pulled tight between connection points.
6. 6

   Connect upstream fitting
   Remove the plug from the upstream port. Thread the new brake line fitting into the upstream connection by hand, ensuring it starts smoothly without cross-threading. Once hand-tight, use a line wrench to tighten to specification while holding the component-side fitting with a backup wrench. Do not overtighten as this can damage the flare seat.
   ⚠️Cross-threading brake line fittings will cause leaks and brake failure. If fitting does not thread smoothly by hand, stop and investigate. Never force fittings.
   Torque spec

   Line Fittings22 Nm (16 lb-ft)
7. 7

   Connect downstream fitting
   Remove the plug from the downstream port. Thread the downstream brake line fitting by hand into its connection point, verifying smooth threading. Torque to specification using a line wrench while holding the stationary fitting with a backup wrench.
   Torque spec

   Line Fittings22 Nm (16 lb-ft)
8. 8

   Verify line routing and clearances
   With both fittings connected, manually cycle the suspension through its full range of travel (if line is near suspension components) and turn the steering wheel lock-to-lock (if line is near steering components). Verify the brake line has adequate clearance from all moving parts, exhaust components, and sharp edges. Adjust routing or clips if any interference is detected.
9. 9

   Fill brake fluid reservoir
   Top off the brake fluid reservoir to the MAX line with fresh DOT 4 Racing brake fluid. Do not reuse old fluid. Keep the reservoir filled above the MIN line throughout the bleeding process to prevent introducing air into the ABS system.
   ⚠️Never allow the reservoir to run dry during bleeding. If air enters the ABS hydraulic unit, specialized scan tool bleeding procedures will be required.
10. 10

    Bleed the brake system
    Bleed the brake system starting with the wheel furthest from the master cylinder (typically right rear), then left rear, right front, and left front. At each wheel: attach clear tubing to the bleeder screw with the other end submerged in clean brake fluid in a container. Have an assistant pump the brake pedal 3-4 times and hold pressure. Open the bleeder screw 1/4 turn using a properly sized wrench. Allow fluid and air to escape until flow stops, then close the bleeder screw before releasing the pedal. Repeat until no air bubbles appear in the tubing. Check and refill the reservoir frequently. Tighten each bleeder screw to specification after bleeding.
    ⚠Monitor the brake fluid reservoir constantly during bleeding. Check level after every 2-3 pumps and refill as needed.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
11. 11

    Inspect all connections for leaks
    With the system bled, have an assistant apply firm and steady brake pedal pressure (do not pump) while you inspect all brake line connections, fittings, and the new line for any signs of fluid seepage or leaks. Pay special attention to the new fittings. If any leaks are detected, relieve pressure, tighten the fitting slightly (in small increments), and retest. Do not exceed specified torque.
    ⚠️Any brake fluid leak is unacceptable. If leaks persist after proper torquing, the flare or fitting may be damaged and must be replaced.
12. 12

    Reinstall wheel and perform pedal test
    Reinstall the wheel(s) and torque lug nuts to specification in a star pattern. Lower the vehicle to the ground. With the engine off, pump the brake pedal several times. The pedal should become firm and not sink to the floor. The pedal travel should feel normal compared to before the repair.
    ⚠️If the brake pedal feels soft, spongy, or sinks to the floor, air remains in the system or a leak exists. Do not drive the vehicle. Repeat bleeding procedure or inspect for leaks.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all mounting clips are secure and the brake line is properly supported along its entire length.
2. Verify brake fluid reservoir is filled to the MAX line with fresh DOT 4 Racing brake fluid.
3. Close the brake fluid reservoir cap securely.
4. Double-check torque on all brake line fittings and wheel lug nuts.

Verification

• Start the engine and pump the brake pedal. The pedal should be firm and not sink. The brake warning light should not be illuminated.
• Perform a low-speed test drive in a safe area. Test brakes at 5-10 mph to verify proper operation before proceeding to normal speeds.
• Verify straight-line braking with no pulling to either side.
• After test drive, re-inspect all brake line fittings and connections for any signs of leakage.
• Check brake fluid level again after test drive and top off if necessary.
• Verify pedal feel remains firm and consistent with no sponginess.
• If vehicle is equipped with electronic brake systems (ABS, stability control), verify no warning lights are illuminated on the dashboard.
• Schedule a follow-up inspection after 50-100 miles to re-check all fittings for leaks and verify proper brake operation.

Related trouble codes on this vehicle

Codes that commonly send this job to the bay — tap one for symptoms, causes, and diagnostic steps.

Chasing one of these codes and not sure which part is guilty? Ask a master mechanic about YOUR car →

More procedures for this vehicle