Front Brake Hose Replacement Single Piston Caliper

1. Raise and suitably support vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the front tires and wheels assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
3. Clean all dirt and foreign material from the brake hoses and brake pipe fitting.

Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination.

4. Place a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose, then cap or plug the brake pipe fitting end.
5. Disconnect the brake pipe fitting from the flexible brake hose at the frame.
6. Remove the front brake hose retainer at the frame bracket.



7. Remove the brake hose to caliper bolt from the brake caliper.
8. Remove the brake hose from the brake caliper.
9. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.

Important: Install NEW copper brake hose gaskets

1. Assemble the NEW copper brake hose gaskets, and the brake hose bolt to the brake hose.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the front flex hose to the brake caliper.

Tighten
Tighten the bolt to 54 N·m (40 lb ft).

Important: The hose must not be twisted. Make sure the hose is not in contact with any suspension component.

3. With the weight of the vehicle on the suspension, install the brake hose into the bracket.



4. Install the brake pipe retainer.
5. Remove the rubber cap or plug from the exposed brake pipe fitting end.
6. Connect the brake pipe fitting nut to the brake hose.

•	Use a backup wrench on the hose fitting.

•	Do not bend the bracket or the pipe.

Tighten
Tighten the brake pipe fitting to 17 N·m (13 lb ft).

7. Ensure that the hose does not make contact with any part of the suspension. Check the hose in extreme right and left turn conditions. If the hose makes contact, remove the hose and correct the condition.
8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .
9. Install the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
10. Remove the safety stands and lower the vehicle.

Front Brake Hose Replacement Dual Piston Caliper

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
3. Clean all dirt and foreign material from the brake hoses and brake pipe fitting.

Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination.

4. Place a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose, then cap or plug the brake pipe fitting end.
5. Disconnect the brake pipe fitting from the flexible brake hose at the frame.
6. Remove the front brake hose retainer at the frame bracket.



7. Disconnect the brake pipe fitting at the frame.
8. Remove the brake pipe retainer.
9. Remove the front flex hose support bracket nut and bolt.



10. Remove the front brake hose bolt and gaskets from the caliper.
11. Remove the front brake hose.
12. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper and/or the brake hose end.

Important: Install NEW copper brake hose gaskets

1. Assemble the NEW copper brake hose gaskets, and the brake hose bolt to the brake hose.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the front brake hose to the brake caliper.

Tighten
Tighten the front brake hose bolt to 54 N·m (40 lb ft).

Important: The hose must not be twisted. Make sure the hose is not in contact with any suspension component.

3. With the weight of the vehicle on the suspension, install the brake hose into the bracket.
4. Install the front brake hose support bracket bolt and nut.

Tighten
Tighten the front brake hose nut to 22 N·m (16 lb ft).




5. Remove the rubber cap or plug from the exposed brake pipe fitting end.
6. Install the front brake pipe retainer.
7. Connect the brake pipe fitting nut to the brake hose.

•	Use a backup wrench on the hose fitting.

•	Do not bend the bracket or the pipe.

Tighten
Tighten the brake pipe fitting to 17 N·m (13 lb ft).

8. Ensure that the hose does not make contact with any part of the suspension. Check the hose in extreme right and left turn conditions. If the hose makes contact, remove the hose and correct the condition.
9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .
10. Install the front tires and wheels assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
11. Remove the safety stands and lower the vehicle.