Replace a Brake Line assembly


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Corrosion on brake lines can lead to an MoT failure : credit: © Dave Barker
All vehicles need a regular check of their brake lines. Dave Barker explains replacement of a more complex Range Rover Sport arrangement

Need to know

Time: 1 hour 
Cost: See below
Difficulty: 1 out of 5
Models: Range Rover Sport from 2014, Range Rover from 2013, Discovery 5 from 2017.
Tools needed: General workshop tools, including 10, 11, 12 and 14mm spanners and sockets.
Parts & costs: Brake hose rear right-hand (LR096526 ), prices from £31 to £91 depending on aftermarket or genuine; brake hose rear left-hand (LR096525), prices from £30 to £94.
Work safely:  
• Wear protective gloves or barrier cream to protect the skin from brake fluid, oils and sharp edges of components.
• When lifting a vehicle off the ground check the jack, axle stands or vehicle lift are rated to support the weight of the vehicle, and are in safe working order.

Thanks to: Maddison 4x4, Water House Farm, Station Road, Topcliffe (near Thirsk), YO7 3SG. Tel: 01845 587407,


This 2015 Range Rover Sport with just 55,000 miles on the clock failed an MoT because of corrosion of the steel pipe in the centre of the rear brake hose assembly on one side of the car (the hose on the opposite side passed okay). These twin hose/steel pipe assemblies run from the vehicle’s main rear brake line, under the body and past the rear upper suspension arms to the rear brake calipers. They have a section of flexible hose at each end (where the assembly joins the main brake line and the brake caliper), with a section of exposed steel pipe in the centre between the flexible hoses. It’s the central steel section, located at the back of the suspension arm, that commonly suffers corrosion. On new replacement hoses, both genuine and aftermarket, this bare steel section is replaced with a plastic-coated pipe which is less likely to corrode.

With the hose assembly replaced, the Range Rover Sport passed its MoT test and, hopefully, this new hose with its plastic-coated pipe will last longer than the original factory-fitted part. One wonders why Land Rover never used a plastic-coated pipe such as this originally, maybe cost?

New assembly: The replacement hose assembly includes the bracket (top left) at the feed end bolted under the inner wheelarch liner, a P-clip in the centre bolted into the wheelarch, a fixing block bolted behind the disc, plus the banjo union which is bolted to the brake caliper.

The problem: Here’s the corroded pipe after removal. Brake pipe corrosion can be difficult to see on the vehicle, though reaching in and feeling the pipes gives a fair indication.


Removing the damaged brake line

Lift and remove: With the vehicle safely supported, and the right-hand rear wheel removed, this corroded section of brake pipe was visible alongside the rear suspension arm.

Pull back then undo: The inner wheelarch liner was pulled back and the brake pipe union was undone, releasing the main brake line from the flexible hose

Plugged up: A threaded plug was now screwed onto the end of the main brake pipe in order to prevent any further loss of brake fluid while the system was being worked on.

Unbolted: The bolt that secures the brake hose mounting bracket to the Range Rover Sport’s body was unbolted, thus releasing the hose from the inner wing.

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Released: The P-clip which holds this section of flexible brake hose to the body was released using a ratchet spanner because of the tight access.

Undo: The brake disc end of the flexi brake hose is secured in position at the back of the disc by a single bolt; withdrawing that releases the hose.

Disconnect: The steel pipe end of the flexi hose is held to the brake caliper by a banjo bolt which is now removed – catch the fluid drips.


Fitting the new assembly

Substitution: The flexi hose with steel end section has been removed from the vehicle and, here, the new brake hose assembly is threaded into position.

Secure in position: Before the fluid connections, the assembly is secured to vehicle, starting with the P-clip bracket, then the mounting bracket at caliper end was bolted back.

Reconnect: After cleaning all faces of the mating components, the hose is now re-secured to the caliper with the new banjo bolt and washer supplied.

Refit: Here, the new end bracket is bolted to the inner wing before connecting the brake line, again ensuring the mating fluid components are absolutely clean.

Check, bleed, check: Bolts and connections are re-checked for tightness before bleeding the brake lines. Then checked for fluid leaks, foot brake applied, then a further leak check.


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