GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2006 🢒 ION 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Front Brake Hose Replacement

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

Removal Procedure

    Object Number: 890980 Size: SH
  1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  3. Clean all dirt and foreign material from the brake hose ends and the brake pipe fitting.
  4. Using a backup wrench on the hose fitting (1), disconnect the brake pipe fitting  (2) from the brake hose. Cap or plug the brake pipe fitting end and the brake hose end to prevent fluid loss and contamination.
  5. Remove the brake hose bracket retaining bolt (3).

    6. Object Number: 890982 Size: SH
  6. Remove the brake hose-to-caliper bolt (1) from the brake caliper.
  7. Remove the brake hose (3) from the brake caliper.
  8. Remove and discard the 2 copper brake hose gaskets (2). These gaskets may be stuck to the brake caliper and/or the brake hose end.
  9. Cap or plug the opening in the brake caliper and the brake hose (3) to prevent fluid loss and contamination.

Installation Procedure

    Object Number: 890982 Size: SH
  1. Remove the caps or plugs from the opening in the brake caliper and the brake hose.

    2. Important: Install NEW copper brake hose gaskets (2).

  2. Assemble the NEW copper brake hose gaskets (2), and the brake hose bolt (1), to the brake hose (3).

    3. Notice: Refer to Fastener Notice in the Preface section.

  3. Install the brake hose-to-brake caliper bolt to the brake caliper.

    4. Tighten
    Tighten the bolt to 48 N·m (35 lb ft).


    Object Number: 890980 Size: SH
  4. Install the front brake hose bracket retaining bolt (3).

    5. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).

  5. Remove the caps or plugs from the brake pipe fitting end and the brake hose end.
  6. Using a backup wrench on the hose fitting (1), connect the brake pipe fitting (2) at the front brake hose.

    7. Tighten
    Tighten the fitting to 19 N·m (14 lb ft).

  7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
  8. Ensure that the hose does not make contact with any part of the suspension. Check the hose in extreme right and extreme 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. Lower the vehicle.