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

Warnings

Tools required

Parts

• Rear brake hose assembly × 1 — Use OEM Toyota specification
• Copper crush washers for banjo bolt × 2 — Two washers per banjo bolt - DO NOT reuse old washers

Fluids

• DOT 3 Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Place wheel chocks in front of front wheels
3. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground
4. Raise rear of vehicle with floor jack and support securely on jack stands at manufacturer-approved jacking points
5. Remove rear wheel on side being serviced
6. Have assistant available for brake bleeding procedure, or use one-person bleeder kit
7. Ensure brake fluid reservoir is accessible from engine bay

Procedure

1. 1

   Prepare work area and clean connections
   Spray brake hose connections (banjo bolt at caliper and flare nut at chassis) with penetrating oil if corrosion is present. Use wire brush to clean threads and connection points. Wipe area clean with brake parts cleaner. Position drain pan under caliper to catch brake fluid.
2. 2

   Remove banjo bolt at caliper
   Using a 14mm wrench, loosen and remove the banjo bolt securing the brake hose to the rear caliper. Brake fluid will drain from the hose and caliper. Allow fluid to drain into pan. Remove and discard the two copper crush washers (one on each side of the banjo fitting). Plug the caliper port with a clean lint-free rag to minimize fluid loss and prevent contamination.
   ⚠Do not allow brake fluid to contact painted surfaces or remain on rubber components. Clean immediately if contact occurs.
3. 3

   Disconnect brake hose from chassis line
   Locate the brake hose-to-chassis brake line connection (typically a flare nut fitting). Using a 10mm flare nut wrench, carefully loosen and remove the flare nut connecting the flexible brake hose to the hard brake line. Support the brake hose while loosening to prevent twisting the hard line. Additional fluid will drain; catch in pan.
   ⚠Use a flare nut wrench (6-point box wrench with slot) to prevent rounding off the soft brass or steel fitting. Do not use open-end wrench or adjustable wrench.
4. 4

   Remove brake hose bracket fastener
   Locate the bracket that secures the brake hose to the chassis or suspension component. Using an 8mm wrench or socket, remove the bracket bolt or clip. Note the routing and orientation of the brake hose for installation of the new hose.
   ℹ️Take a photo of the brake hose routing before removal to ensure correct installation of replacement hose.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
5. 5

   Remove old brake hose
   Remove the old brake hose assembly from the vehicle. Inspect the hard brake line connection point and caliper port for damage, corrosion, or debris. Clean threads on hard brake line and caliper port with wire brush if needed. Ensure no debris enters the brake system.
6. 6

   Install new brake hose to chassis line
   Verify the new brake hose matches the old hose length and fitting types. Route the new brake hose following the same path as the original. Thread the flare nut onto the chassis hard brake line by hand, ensuring it threads smoothly without cross-threading. Do NOT fully tighten yet - leave finger tight to allow hose positioning.
   ⚠Ensure brake hose is not twisted. The hose should route naturally without any kinks or sharp bends.
7. 7

   Secure brake hose bracket
   Position the brake hose in the chassis bracket ensuring proper orientation and routing. Install the bracket fastener and tighten to specification using torque wrench. Verify the hose can move slightly but is properly supported.
   Torque spec

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

   Connect brake hose to caliper with new washers
   Install one NEW copper crush washer onto the banjo bolt, then insert the banjo fitting into the caliper port. Install the second NEW copper crush washer, then thread the banjo bolt by hand. Ensure the banjo fitting is properly seated and the hose routing is correct with no twists. Tighten the banjo bolt to specification using torque wrench.
   ⚠CRITICAL: Banjo bolt requires NEW copper crush washers on both sides of the fitting. Reusing old washers will cause brake fluid leaks.
   Torque spec

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

   Tighten chassis line connection
   Verify the brake hose is properly routed without twists along its entire length. Using the 10mm flare nut wrench, tighten the flare nut connection at the chassis hard brake line. Tighten firmly but do not overtorque - flare fittings seal by metal-to-metal contact and excessive torque can damage the flare.
   ⚠Flare fittings require careful tightening. Stop immediately if excessive resistance is felt - this may indicate cross-threading or damage.
10. 10

    Bleed rear brake caliper
    Locate the bleeder screw on the rear caliper (typically on top or rear of caliper). Clean area around bleeder screw. Attach clear hose to bleeder screw and route into catch bottle partially filled with clean brake fluid. Have assistant slowly depress brake pedal to floor and hold. Open bleeder screw 1/4 to 1/2 turn with 8mm wrench. Allow fluid and air to discharge. Close bleeder screw before pedal reaches floor. Release brake pedal. Repeat process until fluid flows with no air bubbles (typically 5-10 cycles). Check and maintain brake fluid reservoir level throughout bleeding process - never let reservoir run dry.
    ⚠️Never allow brake fluid reservoir to empty during bleeding. Air entering the master cylinder requires extensive bleeding of entire system.
    ⚠Bleeder screw must be closed BEFORE brake pedal is released, or air will be drawn back into the system.
    Torque spec

    Bleeder Screw14 Nm (10 lb-ft)
11. 11

    Check for leaks and verify connections
    With brake pedal depressed and held, inspect all connections (banjo bolt and flare nut) for brake fluid leaks. Wipe connections dry and re-check. If any leaks are found, release pedal pressure and re-tighten connections as needed. Verify bleeder screw is tight to specification.
    ⚠️Any brake fluid leak is a critical safety issue. Do not proceed until all leaks are eliminated.
    Torque spec

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

    Reinstall wheel and lower vehicle
    Reinstall the rear wheel, threading lug nuts by hand to prevent cross-threading. Tighten lug nuts in star pattern with hand wrench. Lower vehicle until tire just contacts ground but weight is still on jack stands. Torque lug nuts to specification in star pattern. Fully lower vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
13. 13

    Final brake system check and top off fluid
    Check brake fluid reservoir level in engine bay. Add fresh DOT 3 brake fluid to bring level to MAX line. Ensure reservoir cap is installed securely. With engine off, pump brake pedal 15-20 times to verify firm pedal. Pedal should become firm and hold pressure - if pedal is soft or sinks, additional bleeding is required.
    ⚠️Soft or spongy brake pedal indicates air in the system. DO NOT drive vehicle until proper pedal feel is achieved.

Reassembly

1. If replacing both rear brake hoses, repeat entire procedure for opposite side
2. Clean any brake fluid spills from wheels, calipers, and chassis components using water
3. Properly dispose of old brake fluid according to local environmental regulations - do not pour down drain

Verification

• With engine off, pump brake pedal multiple times - pedal should be firm and maintain pressure without sinking
• Visually inspect all brake hose connections for fluid leaks while assistant applies firm pedal pressure
• Check brake fluid reservoir level - should be at MAX line
• Perform low-speed test drive in safe area (parking lot) to verify normal brake operation before returning to regular driving
• After test drive, re-check all connections for leaks and verify pedal firmness
• Re-torque wheel lug nuts after first 50-100 miles of driving

More procedures for this vehicle