Replace the front brake hose connecting the chassis brake line to the caliper, including bleeding the brake system to remove air.

Warnings

Tools required

Parts

• Front brake hose × 1 — Use OEM Toyota part number for specific side
• Copper crush washers (banjo bolt) × 2 — Two washers per banjo bolt connection
• Brake hose retaining clip (if damaged) × 1 — Inspect during removal

Fluids

• DOT 3 Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, stable surface and engage parking brake
2. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground
3. Raise front of vehicle with floor jack and support securely on jack stands at chassis jacking points
4. Remove front wheel on side being serviced
5. Open hood and check brake fluid level in master cylinder reservoir; siphon out fluid to prevent overflow during work
6. Have helper available for brake bleeding process or use pressure/vacuum bleeder

Procedure

1. 1

   Locate and inspect brake hose routing
   Identify the front brake hose running from the chassis bracket near the strut to the caliper banjo connection. Inspect the routing and note any additional clips or brackets securing the hose. Clean the banjo bolt connection area with wire brush if corroded.
2. 2

   Disconnect brake hose from caliper
   Position catch pan under caliper. Using a 14mm box wrench, hold the brake hose fitting stationary while loosening the banjo bolt with another wrench. Remove banjo bolt completely and immediately cap or plug the caliper port to minimize fluid loss. Remove and discard both copper crush washers from banjo bolt. Allow brake fluid to drain into catch pan.
   ⚠Brake fluid will spill during this step. Keep catch pan positioned and have rags ready.
3. 3

   Remove brake hose from chassis bracket
   Locate the brake hose bracket bolt securing the hose to the chassis or strut mounting bracket. Using appropriate wrench size, remove the bracket bolt. If hose has a retaining clip in the bracket, carefully release the clip and withdraw the hose from the bracket. On some configurations, the hose may be held by a formed clip that slides out.
4. 4

   Disconnect brake hose from hard line
   Using a 10mm flare nut wrench on the brake hard line fitting, carefully loosen the connection. Hold the brake hose end stationary while turning the flare nut to prevent twisting the hose. If connection is corroded, apply penetrating oil and wait 10-15 minutes before attempting removal. Once loose, unthread completely and cap the hard line to prevent contamination.
   ⚠Flare nut fittings are easily rounded. Use a proper six-point flare nut wrench, not an open-end wrench.
5. 5

   Remove old brake hose
   Remove the brake hose completely from the vehicle. Inspect the caliper banjo port and hard line seat for damage, corrosion, or debris. Clean threads on hard line and caliper with brake cleaner if needed. Verify new brake hose matches old hose in length, fitting types, and routing configuration.
6. 6

   Install new brake hose to hard line
   Begin threading the new brake hose onto the chassis hard line by hand. Ensure threads engage smoothly without cross-threading. Once hand-tight, use flare nut wrench to snug the connection. Do not final tighten yet—hose must be free to rotate for proper alignment at caliper end. Ensure hose routing matches original configuration without kinks or contact with suspension components.
7. 7

   Install brake hose to chassis bracket
   Route the brake hose through the chassis bracket ensuring proper orientation. Install the retaining clip or bracket bolt to secure the hose in position. If using bracket bolt, torque to specification. Verify hose can move slightly for final positioning without binding in bracket.
   ℹ️Verify exact bracket installation sequence with factory service manual as configuration may vary by production date.
   Torque spec

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

   Connect brake hose to caliper
   Place one NEW copper crush washer on each side of the brake hose banjo fitting. Position the banjo fitting onto the caliper inlet port, ensuring proper alignment. Insert the banjo bolt through the fitting and thread into caliper by hand. Hold the hose stationary and torque the banjo bolt to specification. Verify copper washers are properly seated on both sides of the banjo fitting.
   ⚠️Copper washers MUST be new. Reused washers will leak and cause brake failure.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
9. 9

   Verify brake hose routing and final tighten
   Check that brake hose has no twists, kinks, or tight bends. Hose must have adequate slack for full suspension travel. Turn steering wheel lock-to-lock and cycle suspension (push down on front of vehicle) to verify hose does not contact any components through full range of motion. Once routing is verified, final tighten the hard line connection at the chassis.
   ⚠Hose contact with suspension or steering components will cause premature failure and potential brake loss.
10. 10

    Bleed brake system - fill reservoir
    Top off the brake fluid reservoir with fresh DOT 3 brake fluid to the MAX line. Keep reservoir topped off throughout bleeding process. Locate the bleeder screw on the brake caliper (typically on the back side, top of caliper body). Clean bleeder screw area and remove dust cap if present.
11. 11

    Bleed brake caliper
    Attach clear tubing to bleeder screw and submerge other end in container with small amount of clean brake fluid. Have helper pump brake pedal 3-4 times and hold pressure. Open bleeder screw 1/2 turn while helper maintains pedal pressure. Fluid and air will flow into tubing. Close bleeder screw before pedal reaches floor, then have helper release pedal. Repeat process until fluid flows with no air bubbles. Check and refill reservoir frequently. Torque bleeder screw to specification when complete.
    ⚠️Never let brake pedal go to floor while bleeder is open. Never allow reservoir to empty or air will enter ABS unit.
    Torque spec

    Bleeder Screw14 Nm (10 lb-ft)
12. 12

    Verify brake hose connections for leaks
    With bleeder closed, have helper apply firm brake pedal pressure and hold for 30 seconds. While pressure is held, carefully inspect the banjo bolt connection at caliper and flare nut connection at hard line for any signs of brake fluid seepage. Wipe connections dry and repeat check. Any leakage requires immediate correction before proceeding.
    ⚠️Even minor leaks will worsen and cause brake failure. All connections must be completely dry under pressure.
13. 13

    Reinstall wheel and lower vehicle
    Reinstall wheel onto hub, threading lug nuts by hand to prevent cross-threading. Tighten lug nuts in star pattern until snug. Lower vehicle to ground and remove jack stands. With vehicle on ground, torque lug nuts to specification in star pattern.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)

Reassembly

1. Top off brake fluid reservoir to MAX line with fresh DOT 3 fluid
2. Dispose of old brake fluid according to local regulations—never pour down drain
3. Install master cylinder reservoir cap securely
4. Clean any brake fluid spills from painted surfaces immediately with water

Verification

• Start engine and pump brake pedal—pedal must feel firm and not sink to floor with constant pressure
• Check brake fluid level—should be at MAX line with no visible air bubbles in reservoir
• Inspect all brake hose connections for leaks with pedal applied—all connections must be completely dry
• Test vehicle in safe area at low speed (5-10 mph)—brakes must apply evenly without pulling to either side
• Perform several moderate stops from 25-30 mph in safe area to verify normal brake function before returning to service
• Recheck brake fluid level after test drive and top off if needed
• If brake pedal feels soft, spongy, or sinks slowly, repeat bleeding process—do not drive vehicle

More procedures for this vehicle