Brake Lines - Complete Set

Complete replacement of all brake lines from master cylinder to each wheel, including flexible hoses and hard lines, followed by system bleeding and pressure testing.

Warnings

Tools required

Parts

• Complete brake line kit (OEM or equivalent) × 1 — Use OEM specification
• Front flexible brake hoses (left and right) × 2 — Use OEM specification
• Rear flexible brake hoses (left and right) × 2 — Use OEM specification
• Brake line mounting clips and brackets × 1 — Use OEM specification
• Copper crush washers (various sizes) × 12 — Use OEM specification
• Bleeder screw caps × 4 — Use OEM specification

Fluids

• DOT 4 Racing Brake Fluid — 2.5 qt

Preparation

1. Park vehicle on level surface and verify parking brake is engaged
2. Loosen all wheel lug nuts while vehicle is on ground
3. Lift vehicle and secure on jack stands at all four corners at manufacturer-specified lift points
4. Remove all four wheels and set aside
5. Place large drain pans under work area to catch brake fluid
6. Photograph or diagram the exact routing of all existing brake lines for reference during installation
7. Clean all brake line fittings and surrounding areas with penetrating oil and allow to soak for 15 minutes
8. Verify all replacement lines match original equipment length and thread specifications before beginning removal
9. Have fire extinguisher readily accessible due to brake fluid flammability
10. Ensure adequate ventilation as brake fluid vapors are toxic

Procedure

1. 1

   Drain master cylinder reservoir
   Using a turkey baster or fluid evacuator, remove as much brake fluid as possible from the master cylinder reservoir. This minimizes fluid loss and mess during line removal. Dispose of old brake fluid properly according to local regulations. Never pour down drains or onto ground.
2. 2

   Remove front brake line connections at calipers
   Starting at the front calipers, use a line wrench to carefully loosen the banjo bolt or union fitting connecting the flexible hose to the caliper. Hold the caliper-side fitting stationary while turning the line fitting to prevent twisting. Remove and discard copper crush washers. Immediately plug the caliper port with a rubber cap to prevent fluid loss and contamination. Repeat for both front calipers.
   ⚠Use only line wrenches (flare nut wrenches) to prevent rounding off soft brass fittings. Open-end wrenches will almost certainly damage fittings.
   Torque spec

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

   Disconnect front flexible hoses from hard lines
   Locate where the front flexible hoses connect to the hard lines at the chassis or suspension mounting points. Use two line wrenches—one to hold the chassis-side fitting and one to loosen the hose-side fitting. Remove any mounting brackets or clips securing the flexible hose. Remove both front flexible hoses completely.
   ⚠Do not allow flexible hoses or hard lines to twist during removal. Twisting can damage internal hose reinforcement or crack hard line flares.
   Torque spec

   Line Fittings22 Nm (16 lb-ft)
4. 4

   Remove rear brake line connections at calipers
   Move to the rear calipers and repeat the disconnection process. Use line wrench to remove the flexible hose connection at each rear caliper. Remove and discard copper crush washers. Cap all open ports immediately. Note the routing of the rear lines as they often pass through more complex paths around the rear differential and suspension components.
   Torque spec

   Line Fittings22 Nm (16 lb-ft)
5. 5

   Disconnect rear flexible hoses from hard lines
   Locate the rear flexible-to-hard line connections, typically near the rear differential or frame rails. Use two line wrenches to separate the connections. Remove any mounting clips securing the flexible hoses to the chassis or suspension. Remove both rear flexible hoses completely.
   Torque spec

   Line Fittings22 Nm (16 lb-ft)
6. 6

   Remove hard brake lines from chassis
   Starting from the master cylinder and working toward each wheel, systematically remove all hard brake lines. Disconnect lines at the master cylinder, proportioning valve (if equipped), and ABS hydraulic control unit using line wrenches. Remove all mounting clips, brackets, and retainers securing lines to the chassis, frame rails, and underbody. For the Levante, pay special attention to lines routed along the transmission tunnel and rear subframe. Note exact clip positions for reinstallation.
   ⚠The ABS hydraulic control unit is sensitive electronic equipment. Do not strike, drop tools on, or allow brake fluid to contact electrical connectors.
   Torque spec

   Line Fittings22 Nm (16 lb-ft)

   Mounting Bolts28 Nm (21 lb-ft)
7. 7

   Inspect and prepare mounting points
   With all old lines removed, thoroughly inspect all mounting points, brackets, and fittings for corrosion, damage, or wear. Clean all threaded fittings with a wire brush. Replace any damaged mounting clips or brackets. Verify all ports on the master cylinder, ABS unit, and calipers are clean and free of debris. This is the only opportunity to access these areas easily.
8. 8

   Install hard brake lines to chassis
   Beginning at the master cylinder, route new hard brake lines exactly as photographed during removal. Ensure proper clearance from exhaust components (minimum 25mm), driveshaft, suspension travel paths, and sharp edges. Install all mounting clips and brackets but leave slightly loose to allow final positioning adjustment. Do not fully tighten any fittings until all lines are routed and positioned correctly. Hand-start all fittings first to verify proper thread engagement.
   ⚠️Maintain minimum 25mm clearance from exhaust components. Heat from exhaust can boil brake fluid inside lines, causing vapor lock and complete brake failure.
   ⚠Verify lines do not contact suspension components through full range of travel. Cycle suspension by hand to check clearance before finalizing installation.
   Torque spec

   Mounting Bolts28 Nm (21 lb-ft)
9. 9

   Connect hard lines to master cylinder and ABS unit
   Connect all hard lines to the master cylinder and ABS hydraulic control unit. Use new copper crush washers where applicable. Hand-tighten all fittings first to ensure proper thread engagement and alignment. Once verified, use line wrench and torque wrench to tighten all fittings to specification. Double-check that no lines are twisted or under tension.
   Torque spec

   Line Fittings22 Nm (16 lb-ft)
10. 10

    Install front flexible brake hoses
    Install new front flexible brake hoses, connecting first to the chassis-side hard line connection. Install new copper crush washers at banjo fittings. Ensure hoses are not twisted—alignment marks on hose ends must be properly oriented. Install mounting brackets at suspension attachment points. Route hoses to allow full suspension travel and steering lock-to-lock without stress or contact. Torque all line fittings to specification using line wrench.
    ⚠Turn steering wheel full lock in both directions and cycle suspension to verify flexible hoses do not contact any components or become stretched. Hose failure during operation will cause complete loss of braking on that wheel.
    Torque spec

    Line Fittings22 Nm (16 lb-ft)
11. 11

    Install rear flexible brake hoses
    Install new rear flexible brake hoses using the same process as front hoses. Pay particular attention to routing around the rear differential, driveshaft (on RWD configuration), and rear suspension components. Install new copper crush washers. Verify proper orientation using alignment marks. Torque all fittings to specification.
    Torque spec

    Line Fittings22 Nm (16 lb-ft)
12. 12

    Connect flexible hoses to calipers
    Connect all four flexible hoses to their respective calipers using new copper crush washers on all banjo fittings. Apply small amount of fresh brake fluid to threads for lubrication. Hand-start all fittings, verify proper thread engagement, then torque to specification using line wrench. Ensure no hoses are twisted during final tightening.
    Torque spec

    Line Fittings22 Nm (16 lb-ft)
13. 13

    Finalize all mounting clips and brackets
    Working from the master cylinder to each wheel, verify all hard brake lines are properly secured in mounting clips and brackets. Ensure lines sit naturally in clips without tension or deformation. Tighten all bracket mounting bolts to specification. Perform final clearance check of all lines against exhaust, suspension, driveshaft, and chassis through full range of motion.
    Torque spec

    Mounting Bolts28 Nm (21 lb-ft)

    Bracket Bolts107 Nm (79 lb-ft)
14. 14

    Fill master cylinder and pressure bleed system
    Fill master cylinder reservoir with fresh DOT 4 Racing Brake Fluid to MAX line. Connect pressure bleeder to reservoir (typically 15-20 PSI). Beginning with the wheel farthest from master cylinder (right rear for RWD), attach clear tubing to bleeder screw and submerge end in container of fresh brake fluid. Open bleeder screw and allow fluid to flow until completely clear and bubble-free. Close bleeder screw to specification. Repeat for left rear, right front, then left front. Monitor reservoir level constantly and never allow to run dry.
    ⚠️Never allow master cylinder reservoir to run empty during bleeding. Air entering the master cylinder or ABS unit may require dealer-level scan tool to purge.
    ⚠Bleeder screws are brass and easily stripped. Use proper size six-point socket or wrench and do not exceed torque specification.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
15. 15

    Perform ABS system bleeding procedure
    For the Levante with ABS/ESC, after manual bleeding, the ABS hydraulic control unit internal valves must be cycled to purge trapped air. This requires a Maserati-specific scan tool or compatible professional scan tool with Levante ABS bleeding function. Connect scan tool and follow manufacturer's procedure to activate ABS pump and cycle internal valves while bleeding. If scan tool is not available, this vehicle must be taken to a Maserati dealer or qualified shop for final ABS bleeding.
    ⚠️Without proper ABS bleeding, air can remain trapped in the hydraulic control unit, causing unpredictable brake behavior and potential loss of ABS function during emergency braking.
16. 16

    Reinstall wheels and perform initial brake tests
    Reinstall all four wheels and torque lug nuts to specification in star pattern. Lower vehicle to ground. Press brake pedal firmly multiple times to verify solid, high pedal feel. Pedal should be firm within 3-4 pumps and maintain pressure. Check master cylinder fluid level and top off to MAX line. Inspect all line connections for leaks while assistant applies firm pedal pressure.
    ⚠️A low, soft, or spongy pedal indicates air in the system or a leak. Do not drive the vehicle until pedal feel is firm and no leaks are present.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Torque wheel lug nuts to 140 Nm (103 lb-ft) in star pattern after vehicle is lowered
2. Top off brake fluid reservoir to MAX line with fresh DOT 4 Racing Brake Fluid
3. Install reservoir cap securely to prevent moisture contamination
4. Clean any brake fluid residue from chassis, suspension, and painted surfaces immediately with water
5. Apply thread locker to caliper bolts if calipers were removed during service

Verification

• Perform comprehensive visual inspection of all brake line connections, fittings, and mounting points for proper installation and no contact with other components
• With engine running (for brake booster assist), press brake pedal firmly and hold for 60 seconds. Pedal must remain firm and high—any sinking indicates a leak or air in system
• Start engine and verify no warning lights (ABS, brake, ESC) illuminate on instrument cluster
• Inspect all line connections for leaks while assistant applies maximum pedal pressure for 30 seconds
• Test drive in safe, low-traffic area starting at very low speeds (5-10 mph) to verify proper brake function and pedal feel before normal operation
• Perform several moderate brake applications from 30 mph to verify straight-line braking with no pull to either side
• Test ABS function in safe area at 20-25 mph with hard brake application on low-traction surface to verify ABS pulses and functions correctly
• After initial 50-mile break-in period, re-inspect all brake line connections for leaks and verify no warning lights have illuminated
• Check brake fluid level after initial drive—level drop may indicate trapped air bleeding out during operation
• Document date of brake line replacement and fluid type used for future service records

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