Complete replacement of all brake lines from the master cylinder to all four wheels, including hard lines and flexible hoses, followed by system bleeding and testing.

Warnings

Tools required

Parts

• Complete brake line kit (front-to-rear hard lines) × 1 — Use OEM specification or equivalent DOT-approved steel lines
• Front flexible brake hose set (left and right) × 2 — Use OEM specification
• Rear flexible brake hose set (left and right) × 2 — Use OEM specification
• Brake line clips and retainers × 1 — Use OEM specification
• Copper crush washers for banjo fittings (if applicable) × 8 — Use OEM specification

Fluids

• Mopar DOT 4 Brake Fluid — 2 qt

Preparation

1. Park vehicle on level, paved surface and apply parking brake firmly
2. Place wheel chocks behind rear wheels
3. Loosen all wheel lug nuts while vehicle is on ground
4. Raise vehicle completely and support on jack stands at frame rails (all four corners)
5. Remove all four wheels
6. Clean the entire brake line routing path from master cylinder to all four wheels with wire brush to identify line paths and fittings
7. Apply penetrating oil to all brake line fittings at master cylinder, ABS module, junction blocks, and calipers/wheel cylinders; allow 15-30 minutes to soak
8. Place large catch pan under vehicle to collect brake fluid
9. Take photographs of line routing, clip locations, and connections for reference during installation

Procedure

1. 1

   Remove master cylinder brake lines
   Working at the master cylinder under the hood, use line wrenches to carefully disconnect the two primary brake lines from the master cylinder. Expect significant brake fluid spillage. Cap or plug the master cylinder ports immediately with clean rubber caps to prevent contamination and further fluid loss. Support lines to prevent damage to fittings.
   ⚠Use line wrenches, not standard open-end wrenches, to prevent rounding off soft brass fittings. Apply steady pressure without jerking.
2. 2

   Disconnect lines at ABS module and junction blocks
   Locate the ABS hydraulic control unit (typically mounted on frame rail near master cylinder) and any junction blocks along the frame. Use line wrenches to disconnect brake lines from these components. Note the specific port locations for each line, as routing varies. Remove any electrical connectors that may interfere with line removal. Cap all open ports.
   ⚠ABS module fittings are aluminum and can strip easily. Use correct size line wrenches and apply anti-seize on threads during reassembly.
3. 3

   Remove front flexible brake hoses
   At each front wheel, disconnect the flexible brake hose from the hard line at the frame-mounted bracket using a line wrench. Then remove the banjo bolt or fitting at the caliper end. Remove the hose retaining clip from the frame bracket. Extract the hose assembly. Note orientation of banjo washers if applicable (replace with new).
   ℹ️Flexible hoses have a specific installed orientation to prevent twisting under suspension travel. Mark or photograph before removal.
4. 4

   Remove rear flexible brake hoses
   At each rear wheel, disconnect the flexible brake hose from the hard line at the axle-mounted bracket. Remove the hose from the caliper or wheel cylinder using appropriate wrench. Remove any retaining clips or brackets. Cap all open connections.
5. 5

   Remove all hard brake lines from frame and body
   Working from front to rear, remove all brake line retaining clips and brackets securing the hard lines to the frame, body, and axle. Carefully extract the old hard lines from their routing paths. Remove lines to rear differential and axle, noting how they route around exhaust, driveshaft, and suspension components. On 4WD models, pay special attention to lines routed near transfer case and front differential.
   ⚠Corroded lines may break during removal. Be prepared for trapped fluid to drain from various points along the lines.
6. 6

   Prepare and route new hard brake lines
   If using pre-bent lines, verify correct fitment by test-fitting before final installation. If fabricating custom lines, carefully measure, cut, flare, and bend new lines to match original routing. Begin installation at master cylinder/ABS module and work toward each wheel. Ensure lines have proper clearance from exhaust, suspension components, driveshaft, and frame edges. Lines must not be kinked, twisted, or under tension.
   ⚠️All brake lines must be properly double-flared and pressure-tested. Single flares or improper flaring will result in catastrophic brake failure.
   ⚠Maintain minimum 1-inch clearance from exhaust components and moving suspension parts through full range of travel.
7. 7

   Install hard lines at master cylinder and ABS module
   Thread new hard lines into master cylinder and ABS module ports by hand first to ensure proper thread engagement. Tighten fittings to manufacturer specifications using line wrenches (typically 12-15 Nm, but verify with service manual as specific torque not provided in database). Work systematically from master cylinder through ABS module to junction blocks. Apply small amount of fresh brake fluid to threads.
   ⚠Cross-threading aluminum ABS module fittings will require expensive component replacement. Thread carefully by hand first.
8. 8

   Secure hard lines with clips and brackets
   Install all new brake line retaining clips and brackets along the frame, body, and axle following original routing. Ensure lines are properly supported every 12-18 inches and cannot vibrate or contact other components. Verify clearance with suspension at full droop and compression, and steering at full lock positions.
   Torque spec

   Bracket Bolts137 Nm (101 lb-ft)
9. 9

   Install front flexible brake hoses
   Install new front flexible brake hoses, ensuring correct orientation (any alignment stripe should face forward). Install frame bracket clips first, then thread hose into hard line fitting at bracket. At caliper end, use new copper crush washers on banjo bolts if applicable. Hand-tighten all connections, then torque banjo bolts to specification (typically 30 Nm, verify with service manual). Ensure hose has adequate slack for full suspension travel and steering motion.
   ⚠Flexible hoses must not twist, stretch, or contact tire or suspension during full range of motion. Test by cycling suspension and turning steering lock-to-lock before bleeding.
10. 10

    Install rear flexible brake hoses
    Install new rear flexible brake hoses at both rear wheels following same procedure as front. Ensure proper orientation and adequate slack for axle articulation. Install retaining clips at axle brackets. Torque all fittings appropriately, using new copper washers where specified.
11. 11

    Inspect entire system before bleeding
    Perform complete visual inspection of all brake line connections from master cylinder to all four wheels. Verify all fittings are tight, all clips and brackets are installed, and no lines contact moving or hot components. Check that all banjo bolts have proper washers and are torqued correctly. Verify no lines are kinked, twisted, or under tension.
    ⚠️Any loose fitting, improper routing, or damaged line can result in complete brake failure. Do not proceed to bleeding until entire system passes inspection.
12. 12

    Fill master cylinder and begin bleeding sequence
    Fill master cylinder reservoir to MAX line with fresh Mopar DOT 4 brake fluid from sealed container. Begin bleeding at wheel furthest from master cylinder (typically right rear for this vehicle), then left rear, right front, left front. At each wheel, attach clear tubing to bleeder screw and submerge other end in container with clean brake fluid. Have assistant pump brake pedal 3-5 times and hold, then open bleeder screw. Close bleeder before pedal reaches floor. Repeat until fluid runs clear without air bubbles. Keep master cylinder topped off throughout process.
    ⚠️Never allow master cylinder to run dry during bleeding or air will enter ABS module, requiring specialized scan tool bleeding procedure.
    ⚠Do not reuse brake fluid collected during bleeding. Always use fresh fluid from sealed container.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
13. 13

    Perform ABS module bleeding if equipped
    For vehicles with ABS (all 2014 Ram 2500 models), a scan tool with ABS bleeding function may be required to purge air from hydraulic control unit. If pedal remains soft after standard bleeding, this indicates air in ABS module. Follow scan tool prompts to cycle ABS valves while bleeding. Alternatively, perform multiple aggressive stops from 25 mph on gravel to activate ABS, then re-bleed all wheels.
    ℹ️Professional scan tool access may be necessary for complete ABS system bleeding. Some auto parts stores offer tool rental.
14. 14

    Install wheels and perform initial brake tests
    Reinstall all four wheels and torque lug nuts to specification in star pattern. Lower vehicle to ground. With engine running, pump brake pedal multiple times and verify firm pedal with no excessive travel. Check for any fluid leaks at all connections. Do not drive vehicle if pedal feels soft or travels more than halfway to floor.
    ⚠️A soft or spongy pedal indicates air remains in system or a leak exists. Do not drive vehicle until firm pedal is achieved.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Perform final torque verification on all brake line fittings, working systematically from master cylinder to each wheel
2. Top off master cylinder to MAX line with fresh DOT 4 brake fluid
3. Verify parking brake operation and adjustment
4. Clean any spilled brake fluid from all surfaces immediately to prevent paint damage
5. Re-torque wheel lug nuts after first 50 miles of driving

Verification

• With engine running, brake pedal should be firm and hold steady pressure without sinking
• Perform leak inspection at all connections with pedal pressure applied; no fluid seepage should be visible
• Test drive in safe area at low speeds (under 15 mph) to verify brakes engage smoothly without pulling
• Perform multiple moderate stops from 25-30 mph to verify proper brake function and seat pads
• Check for leaks again after test drive while system is at operating temperature
• Verify ABS warning light is off and system performs self-check normally
• Perform final aggressive stop test from 45 mph in safe area to verify maximum braking performance
• After 50-100 miles, re-inspect all fittings for any signs of seepage and re-torque if necessary

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