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Submitted By: R!bcracker
Date: October 14, 2008, 08:40:45 PM
Views: 4662

Replacing the Rubber Brake Hoses on a Front Dana 44


This is a simple procedure that can save a ton of headache on the trail or road. It took me little less than a hour to replace both brake hoses on my 1986 Ramcharger.

What you will need:
  • 5/8" open end wrench
  • 3/8" open end and box wrench
  • Screwdriver
  • Hammer
  • Penetrating oil
  • New brake hoses
  • Brake fluid

I got the hoses from Advance Auto Parts, Part #H38421. They were $17 a piece and they had them instock.

Replacement Hose

Removal and Replacement

The brake lines tend to be pretty rusty so use plenty of penetrating oil on the connections and bleeder screws otherwise you will strip the 3/8" connections or, even worse, break the metal lines.

Hose Location

I started by using a screwdriver and hammer to knock loose the retaining clip securing the connection to the axle.

Retaining Clip

Next I removed the 5/8" bolt connecting the hose to the caliper (make sure not to damage this bolt because it is reused). Then I rotated the rubber hose to undo the connection at the hard line (while the connection did come loose, the nut on the steel brake line did not rotate freely-I had to unscrew the hose).

Attach the new brake hose to the hard brake line by inserting it through the bracket connected to the axle and tightening it to the steel brake line. Using the new copper washers on both sides of the block end of the brake hose, connect it to the caliper re-using the 5/8" bolt. Align the connection of the hose and hard line in the bracket and install the retaining clip with gentle hammer taps. Repeat on the other side

New brake hose installed

After the new hoses are installed you need to bleed the brakes. This is easiest with the help of a friend but there are kits to allow a person to do it alone.

During the bleeding process make sure the master cylinder is kept full of brake fluid so air won't get into the brake lines.

Starting at the brake farthest from the master cylinder (passenger's side front), attach a bleeder tube to the bleeder screw (seen in the above picture at the lower left corner). Put the other end in a container of brake fluid. Using a 3/8" box wrench, carefully loosen the bleeder screw which is located at the top of the caliper. Have your friend gently push the brake pedal to the floor and hold it there. Watch for bubbles coming out the end of the tube. Tighten bleeder screw and have your friend release the brake pedal.

Do not release brake pedal when the bleeder screw is loose as air may be introduced into the brake lines.
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