Replace the front brake hose on a 2014 Ram 2500 with 6.7L Cummins diesel engine, including proper bleeding and torque specifications to ensure safe braking performance.

Warnings

Tools required

Parts

• Front brake hose assembly × 1 — Use OEM specification
• Copper crush washers for banjo bolt × 2 — Replace both washers
• Brake fluid × 1 — Mopar DOT 4

Fluids

• Mopar DOT 4 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level surface and set parking brake firmly
2. Chock rear wheels securely
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle using floor jack on frame rail and support with jack stands rated for vehicle weight
5. Remove front wheel(s) on side being serviced
6. Have assistant available for brake bleeding procedure
7. Open new container of Mopar DOT 4 brake fluid
8. Inspect brake hose for damage location - look for cracks, bulging, chafing, or leaks at fittings

Procedure

1. 1

   Remove brake hose from caliper
   Locate the banjo bolt connecting the brake hose to the caliper. Clean the area around the banjo bolt with a wire brush. Using a line wrench, loosen and remove the banjo bolt. Note the position of the copper crush washers on each side of the banjo fitting. Allow brake fluid to drain into a drain pan. Immediately cap or plug the caliper inlet port with a clean rubber cap or tape to minimize fluid loss and prevent contamination.
   ⚠Brake fluid will begin draining immediately when banjo bolt is removed. Position drain pan accordingly.
2. 2

   Release hose from mounting bracket
   Locate the brake hose mounting bracket on the frame or suspension component. If equipped with a clip-type bracket, compress or pry the retaining clip and slide the hose out of the bracket. If equipped with a bolted bracket, remove the bracket bolt and set aside for reuse. Note the routing and orientation of the hose for proper installation of the new hose.
   ℹ️Some brackets use spring clips while others use bolts. Take a photo of the hose routing before removal.
3. 3

   Disconnect hose from brake line
   Locate the hard brake line connection at the frame rail or strut tower. Using a line wrench on the brake hose fitting and a backup wrench on the hard line fitting, carefully loosen and disconnect the hose from the brake line. If fittings are corroded, apply penetrating oil and allow to soak for several minutes. Remove the old brake hose completely from the vehicle.
   ⚠Use a line wrench (flare nut wrench) to prevent rounding off the brass fittings. Use a backup wrench to prevent twisting the hard brake line.
4. 4

   Inspect and prepare new brake hose
   Verify the new brake hose matches the original in length, fitting type, and bracket configuration. Check that new copper crush washers are included or obtained separately. Do not remove protective caps from hose ends until ready to install. Inspect all fittings and threads on the new hose for damage or debris.
5. 5

   Install new hose to brake line
   Remove the protective cap from the brake line end of the new hose. Thread the new hose fitting onto the hard brake line by hand, ensuring it starts straight and threads smoothly. Once hand-tight, use a line wrench to snug the fitting. Do not fully torque at this time - allow the hose to rotate freely for proper alignment at the caliper end.
6. 6

   Install hose into mounting bracket
   Route the new brake hose through the frame or suspension mounting bracket, ensuring the hose follows the same path as the original. Verify the hose is not twisted and will not contact suspension components, steering linkage, or the tire through full steering and suspension travel. If using a clip-type bracket, press the hose firmly into the bracket until it clicks. If using a bolted bracket, install the bracket bolt and torque to specification.
   ⚠Hose must not be twisted. Verify alignment before tightening any connections. A twisted hose can fail prematurely.
   Torque spec

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

   Connect hose to caliper with new washers
   Remove the protective cap from the caliper end of the brake hose and the plug from the caliper inlet port. Place one NEW copper crush washer on the banjo bolt, insert the bolt through the banjo fitting, place the second NEW copper crush washer on the bolt, then thread into the caliper inlet port. Hand-tighten the banjo bolt while ensuring the hose is properly oriented and not twisted. Torque the banjo bolt to specification.
   ⚠️CRITICAL: New copper washers MUST be used on both sides of the banjo fitting. Reusing old washers will cause brake fluid leaks.
   Torque spec

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

   Final torque brake line connection
   With the hose now secured at both the caliper and mounting bracket, verify the hose is not twisted along its entire length. Use a line wrench with a backup wrench to torque the brake line connection to proper specification. Ensure the hose does not rotate during final tightening.
   ℹ️The brake line connection uses the Mounting Bolts torque specification of 37 Nm (27 lb-ft).
   Torque spec

   Mounting Bolts37 Nm (27 lb-ft)
9. 9

   Verify hose clearance and routing
   Turn the steering wheel full lock to lock while observing the brake hose. Verify the hose does not contact the tire, suspension components, or steering linkage at any point. Have an assistant bounce the suspension while checking for interference. Correct any routing issues before proceeding.
   ⚠Brake hose contact with moving components will cause premature failure and potential brake system loss.
10. 10

    Bleed brake system
    Locate the bleeder screw on the brake caliper. Clean the bleeder screw and surrounding area. Attach a clear hose to the bleeder screw and submerge the other end in a container with clean brake fluid. Have an assistant top off the master cylinder reservoir with Mopar DOT 4 brake fluid. With the assistant maintaining steady pressure on the brake pedal, open the bleeder screw 1/2 to 3/4 turn. Allow fluid and air to escape until fluid runs clear without bubbles, then close the bleeder screw before the assistant releases the pedal. Repeat this process until no air bubbles are visible and the brake pedal feels firm. Torque the bleeder screw to specification.
    ⚠️Never allow the master cylinder reservoir to run dry during bleeding or air will be introduced into the ABS system, requiring special scan tool procedures.
    ⚠Close bleeder screw BEFORE assistant releases brake pedal, or air will be drawn back into the system.
    Torque spec

    Bleeder Screw18 Nm (14 lb-ft)
11. 11

    Reinstall wheel and lower vehicle
    Clean the wheel hub surface and wheel mounting surface with a wire brush. Install the wheel and hand-thread all lug nuts. Torque lug nuts in a star pattern to specification. Lower the vehicle to the ground and perform a final torque check on the lug nuts.
    Torque spec

    Wheel Lug Nuts183 Nm (135 lb-ft)

Reassembly

1. Top off master cylinder reservoir to MAX line with Mopar DOT 4 brake fluid
2. Inspect all brake hose connections for leaks while assistant applies firm brake pedal pressure
3. Clean any spilled brake fluid from components, chassis, and wheels with water
4. Properly dispose of old brake hose and used brake fluid according to local regulations

Verification

• With engine off, pump brake pedal several times - pedal should build firm pressure and not sink to the floor
• Start engine and verify brake pedal remains firm with no excessive travel
• Inspect all brake hose connections for fluid leaks with brake pedal applied
• Turn steering wheel lock-to-lock and verify brake hose does not contact any components
• Perform a low-speed brake test in a safe area (parking lot) before returning to normal driving
• Test brakes at progressively higher speeds in a safe area, ensuring straight-line stopping without pulling
• After first 50 miles, recheck all connections for leaks and verify brake pedal feel remains firm
• Check master cylinder fluid level after test drive and top off if needed

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