Brake Hose Replacement - Intermediate

Brake Hose Replacement - Intermediate
Removal Procedure

1. Raise and suitably support the vehicle.

Important: The intermediate brake hose assembly is serviced as an assembly.

2. Remove the right rear tire and wheel assembly.
3. Clean all dirt and foreign material from the brake hose and the brake pipe fittings.





4. Disconnect the crossover brake pipe fitting (1) from the intermediate brake hose assembly (3) and cap or plug the brake pipe fitting end.

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

5. Lift the retaining clip (2) over the end of the brake hose.
6. Using a flat-bladed tool, remove the brake hose retainer (2) from the rear frame assembly.
7. Disconnect the (2) Brake Pressure Modulator Valve (BMPV) brake pipe fittings from the intermediate brake hose assembly and cap or plug the brake pipe fitting ends.





8. Disconnect the brake hose to caliper bolt (4) from the brake caliper (1).
9. Disconnect the brake hose from the brake caliper.
10. Place a shop towel on a hard surface.
11. Tap the threaded end of the brake hose to caliper bolt (4) on the shop towel to remove the gasket (3) from the bolt (4).
12. Remove and discard the two copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper (1) and/or the brake hose end (2).





13. Remove the intermediate brake hose assembly mounting nuts (1) from the studs.
14. Remove the intermediate brake hose assembly (2) from the vehicle.

Installation Procedure





1. Install the intermediate brake hose assembly (2) to the mounting studs.

Notice: Make sure the brake hose is not twisted or kinked after installation. Damage to the hose could result.


2. Install the intermediate brake hose assembly mounting nuts (1) to the mounting studs.
Tighten the intermediate brake hose assembly mounting nuts to 14 Nm (10 ft. lbs.).

Notice: Refer to Fastener Notice in Service Precautions.

3. Remove the caps and/or plugs from the (2) (BPMV) to intermediate brake pipe fittings.
4. Connect the (2) (BMPV) brake pipe fittings to the intermediate brake hose assembly.
5. Remove the rubber plug from the brake hose to caliper bolt hole of the brake caliper.





6. Assemble the brake hose (2), the NEW copper brake hose gaskets (3), and the brake hose bolt (4) to the brake hose (2).

Important: Install NEW copper brake hose gaskets.

7. Install the brake hose (2) to caliper bolt (4) to the brake caliper (1).
Tighten the brake hose to caliper bolt to 50 Nm (37 ft. lbs.).





8. Remove the rubber cap and/or plug from the crossover brake pipe end.
9. Using a flat-bladed tool, install the brake hose retainer (2) to the rear frame assembly.
10. Connect the crossover brake pipe fitting (1) to the intermediate brake hose assembly (3).
Tighten the brake pipe fittings to 18 Nm (13 ft. lbs.).
11. Bleed the hydraulic brake system.
12. Install the tire and wheel assembly.
13. Lower the vehicle.