Brake Hose - Rear

Replace the rear brake hose connecting the brake line to the rear brake caliper, including bleeding the brake system to restore proper hydraulic function.

Warnings

Tools required

Parts

• Rear brake hose assembly × 1 — Use OEM Toyota specification
• Brake hose banjo bolt copper washers × 2 — Must be new, use OEM
• Brake line clip or retainer (if damaged) × 1 — Inspect before removal

Fluids

• DOT 3 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake firmly
2. Place wheel chocks in front of the front wheels
3. Loosen rear wheel lug nuts 1/2 turn while vehicle is on ground
4. Raise rear of vehicle with floor jack and support securely on jack stands rated for vehicle weight
5. Remove rear wheel completely
6. Clean the brake hose connection areas with wire brush to remove corrosion
7. Apply penetrating oil to brake line fittings if visible corrosion is present (allow 10 minutes to soak)
8. Open brake fluid reservoir and check level - do not overfill as fluid will be displaced during work
9. Have replacement hose, new copper washers, and all tools ready before disconnecting any brake lines

Procedure

1. 1

   Remove brake hose bracket mounting
   Locate the brake hose bracket where it mounts to the chassis or suspension component. Using a 10mm wrench or socket, remove the bracket bolt that secures the brake hose to the body/frame. Note the orientation and routing of the hose for reinstallation. Do not remove the hose from the caliper yet.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
2. 2

   Disconnect brake line from brake hose
   Using a 10mm flare nut wrench, carefully loosen and disconnect the hard brake line from the rear brake hose at the chassis connection point. Hold the brake hose fitting steady with another wrench if needed to prevent twisting the hose. Allow brake fluid to drain into a container. Cap or plug the hard line immediately to minimize fluid loss and prevent contamination.
   ⚠Use a flare nut wrench (6-point box wrench) to prevent rounding off the soft brake line fitting. A standard open-end wrench may damage the fitting.
3. 3

   Remove banjo bolt from caliper
   Locate the banjo bolt connecting the brake hose to the rear brake caliper. Position a drain pan beneath the caliper. Using a 14mm flare nut wrench or socket, remove the banjo bolt. Brake fluid will drain from both the hose and caliper. Remove and discard both copper crush washers from the banjo fitting. Immediately plug the caliper inlet port with a clean rag or plug to prevent excessive fluid loss.
   ℹ️Note the position of the banjo fitting - it should route the hose without twisting when properly installed.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
4. 4

   Remove old brake hose
   Remove the brake hose completely from the vehicle, including any remaining clips or retainers. Inspect all connection points for damage or excessive corrosion. Clean the banjo fitting mounting surface on the caliper with a clean rag to ensure proper sealing with new washers.
5. 5

   Prepare and route new brake hose
   Unpack the new brake hose and verify it matches the original in length and fitting configuration. Ensure the protective caps are removed from both ends. Route the new hose through the chassis bracket following the same path as the original. Ensure the hose is not twisted and will not contact suspension components through full range of motion. Install any spring clips or retainers onto the hose.
   ⚠Ensure brake hose routing allows full suspension travel and steering motion without stretching, kinking, or contacting moving parts.
6. 6

   Install brake hose to caliper
   Place one NEW copper crush washer on each side of the banjo fitting. Position the banjo bolt through the fitting and thread it into the caliper inlet port by hand. Ensure the hose is oriented correctly without twisting. Torque the banjo bolt to specification using a torque wrench. Verify the hose can move freely and is not kinked.
   ⚠️NEW copper washers are mandatory. Reusing old washers will cause brake fluid leaks and brake system failure.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
7. 7

   Install hose bracket to chassis
   Position the brake hose into the mounting bracket on the chassis or suspension component. Install the bracket bolt and torque to specification. Ensure the hose is properly seated in the bracket and cannot pull free. Double-check that the hose routing allows full suspension articulation.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
8. 8

   Connect hard brake line to hose
   Remove the plug or cap from the hard brake line. Thread the brake line into the brake hose fitting by hand to ensure proper thread engagement. Using the 10mm flare nut wrench, tighten the connection securely. Do not overtighten - the fitting should be snug but not require excessive force. Hold the hose fitting with a backup wrench if it begins to rotate.
   ⚠Cross-threading will destroy the fitting. Ensure the line threads in smoothly by hand before using a wrench.
9. 9

   Fill brake fluid reservoir
   Go to the brake fluid reservoir under the hood. Fill to the MAX line with fresh DOT 3 brake fluid from a sealed container. Keep the reservoir at least half full throughout the bleeding process. Do not allow the reservoir to run dry or air will enter the master cylinder.
   ⚠️If reservoir runs empty during bleeding, the master cylinder will require bleeding and the procedure becomes significantly more complex.
10. 10

    Bleed rear brake caliper
    Locate the bleeder screw on the rear brake caliper (typically on top or rear of caliper). Clean the bleeder screw area thoroughly. Attach clear plastic tubing to the bleeder screw and place the other end in a brake fluid catch container. Have an assistant pump the brake pedal 3-4 times and hold firm pressure. While pressure is held, open the bleeder screw 1/4 to 1/2 turn. Fluid and air will flow into the tube. Close the bleeder screw before the pedal reaches the floor. Repeat this process until only clear, bubble-free fluid flows from the bleeder. Check and refill the reservoir frequently. Torque bleeder screw to specification when complete.
    ⚠Never allow the brake pedal to return to the top while the bleeder is open, as this will draw air into the system.
    ℹ️If working alone, use a vacuum bleeder or one-way check valve bleeder tool as an alternative to the two-person method.
    Torque spec

    Bleeder Screw13 Nm (10 lb-ft)
11. 11

    Reinstall wheel
    Clean the wheel hub surface and wheel mounting surface. Install the wheel and thread lug nuts by hand to prevent cross-threading. Tighten lug nuts in a star pattern with a wrench until snug but not fully torqued. Lower the vehicle until the tire just contacts the ground (still supported by jack). 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)
12. 12

    Final brake system check and pedal test
    With the vehicle on the ground, pump the brake pedal multiple times. The pedal should become firm and hold steady pressure. If the pedal is soft or sinks to the floor, additional bleeding is required - do not drive the vehicle. Check all connection points for brake fluid leaks while assistant applies firm brake pedal pressure. Inspect the banjo bolt, brake line connection, and bleeder screw. Wipe away any residual fluid.
    ⚠️A soft or spongy brake pedal indicates air in the system. Vehicle is unsafe to drive until pedal is firm.

Reassembly

1. Double-check all brake line connections are tight and show no signs of leakage
2. Verify brake hose is properly routed and secured in all brackets without twisting or contact with moving parts
3. Top off brake fluid reservoir to MAX line with fresh DOT 3 fluid
4. Clean any brake fluid spills from painted surfaces, suspension components, and wheels

Verification

• With engine off, pump brake pedal firmly 5-10 times - pedal should be firm and not sink with constant pressure applied
• Start engine and verify brake pedal remains firm (pedal may drop slightly with engine start due to brake booster activation - this is normal)
• Visually inspect all brake connections with brake pedal applied firmly - no fluid should be leaking
• Test drive vehicle in a safe area at low speed (under 15 mph) and verify brakes apply evenly without pulling to one side
• Perform several moderate stops from 25-30 mph in a safe area to verify normal brake function and firm pedal feel
• After test drive, re-inspect all connections for leaks and verify wheel lug nuts remain tight
• Road test at normal speeds only after confirming all systems are functioning properly in controlled low-speed testing

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