Brake Pipe Replacement

Brake Pipe Replacement

Master Cylinder to BPMV Removal Procedure

Tools Required

J 23738-A Mityvac

Caution: Refer to Safety Glasses Caution (Safety Glasses Warning) .
Caution: Refer to Brake Fluid Caution (Brake Fluid Caution) .
Caution: Refer to Brake Fluid Irritant Caution (Brake Fluid Irritant Caution) .

Notice: Refer to Adding Fluid to the Brake System Notice (Adding Fluid to the Brake System Notice) .


Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (Brake Fluid Effects on Paint and Electrical Components Notice) .

1. Remove the engine. Refer to Engine Replacement (Removal and Replacement) for 3.6L or Engine Replacement (Removal and Replacement) for 6.0L .
2. Remove the sound proofing trim from the bulkhead.
3. Clean the master cylinder, especially around the brake lines and reservoir cap.
4. Place a clean suitable container under the Brake Pressure Modulator Valve (BPMV).
5. Remove the master cylinder reservoir cap.




6. Siphon the brake fluid out of the master cylinder reservoir (1) using a hand vacuum pump (2).




7. Remove the brake pipes (2) from the master cylinder (1).




8. Detach the brake pipes (1) from the retaining clips (2 and 3)





Important: Record the location of all brake pipes to the BPMV assembly for use as an aid during installation.


9. Remove the brake pipes (2) from the BPMV (1).
10. Detach the brake pipes (2) from the retaining clips (3).



Master Cylinder to BPMV Installation Procedure





1. Install the brake pipes (2) to the BPMV (1) using the locations recorded during the removal procedure.

Tighten the brake pipes to 15 Nm (11 lb ft).

2. Attach the brake pipes (2) from the retaining clips (3).




3. Attach the brake pipe (1) to the locating clip (3).
4. Install the locating clip to bulkhead retaining nut (2).




5. Attach the brake pipes (1) to the retaining clips (2 and 3)




6. Install the brake pipes (2) to the master cylinder (1).

Tighten the pipe fittings to 15 Nm (11 lb ft).

7. Install the sound proofing trim to the bulkhead.
8. Install the engine. Refer to Engine Replacement (Removal and Replacement) for 3.6L orEngine Replacement (Removal and Replacement) for 6.0L.
9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (Service and Repair)Hydraulic Brake System Bleeding (Pressure) (Service and Repair) .



Front Brake Pipe Removal Procedure - Right

Caution: Refer to Brake Dust Caution (Brake Dust Caution) .
Caution: Refer to Brake Fluid Caution (Brake Fluid Caution) .
Caution: Refer to Brake Fluid Irritant Caution (Brake Fluid Irritant Caution) .

Notice: Refer to Adding Fluid to the Brake System Notice (Adding Fluid to the Brake System Notice) .


Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (Brake Fluid Effects on Paint and Electrical Components Notice) .

1. Clean the master cylinder, especially around the brake lines and reservoir cap.
2. Place a clean suitable container under the Brake Pressure Modulator Valve (BPMV).
3. Remove the master cylinder reservoir cap.




4. Siphon the brake fluid out of the master cylinder reservoir (1) using a hand vacuum pump (2).




5. Disconnect the brake pipe (1) from the BPMV (2).

Important: Install a rubber cap or plug to the BPMV (2) in order to prevent fluid loss and contamination.


6. Plug the BPMV (2).




7. Detach the brake pipe (1) from the locating clip (2).
Caution: Refer to Safety Glasses Caution (Safety Glasses Warning) .
Caution: Refer to Vehicle Lifting Caution (Service Precautions) .
8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair) .
9. Clean all dirt and foreign material from the brake hose and the brake pipe fittings.





Important: Hold the brake hose (3) with a spanner whilst disconnecting the brake pipe fitting (2) to prevent damage to the brake pipe (1).


10. Disconnect the brake pipe fitting (2) from the brake hose (3).

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


11. Plug the brake hose (3).
12. Remove the brake pipe (1).



Front Brake Pipe Installation Procedure - Right


Notice: Refer to Adding Fluid to the Brake System Notice (Adding Fluid to the Brake System Notice) .


Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (Brake Fluid Effects on Paint and Electrical Components Notice) .





1. Install the brake pipe (1).
2. Remove the rubber cap or plug from the brake hose (3).

Notice: Refer to Fastener Notice (Fastener Notice) .


Important: Hold the brake hose (3) with a spanner whilst connecting the brake pipe fitting (2) to prevent damage to the brake pipe (1).


3. Connect the brake pipe fitting (2) to the brake hose (3).

Tighten the brake pipe fitting to 15 Nm (11 lb ft).

4. Lower the vehicle.




5. Attach the brake pipe (1) to the locating clip (2).




6. Remove the rubber cap or plug from the BPMV (2).
7. Install the brake pipe (1) to the BPMV (2).

Tighten the brake pipe fitting to 15 Nm (11 lb ft).

8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (Service and Repair)Hydraulic Brake System Bleeding (Pressure) (Service and Repair) .



Front Brake Pipe Removal Procedure - Left

Caution: Refer to Brake Dust Caution (Brake Dust Caution) .
Caution: Refer to Brake Fluid Caution (Brake Fluid Caution) .
Caution: Refer to Brake Fluid Irritant Caution (Brake Fluid Irritant Caution) .

Notice: Refer to Adding Fluid to the Brake System Notice (Adding Fluid to the Brake System Notice) .


Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (Brake Fluid Effects on Paint and Electrical Components Notice) .

1. Clean the master cylinder, brake lines and reservoir cap.
2. Place a clean suitable container under the Brake Pressure Modulator Valve (BPMV).
3. Remove the master cylinder reservoir cap.




4. Siphon the brake fluid out of the master cylinder reservoir (1) using a hand vacuum pump (2).




5. Disconnect the brake pipe (1) from the BPMV (2).

Important: Install a rubber cap or plug to the BPMV (2) in order to prevent fluid loss and contamination.


6. Plug the BPMV (2).
Caution: Refer to Safety Glasses Caution (Safety Glasses Warning) .
Caution: Refer to Vehicle Lifting Caution (Service Precautions) .
7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair) .
8. Remove the engine. Refer to Engine Replacement (Removal and Replacement) for 3.6L orEngine Replacement (Removal and Replacement) for 6.0L .
9. Remove the sound proofing trim from the bulkhead.




10. Remove the locating clip to bulkhead retaining nut (2).
11. Detach the brake pipe (1) from the locating clip (3).




12. Detach the brake pipe (1) from the locating clip (2).




13. Detach the brake pipe (2) from the locating clips (1).




14. Detach the brake pipe (1) from the locating clips (2).
15. Clean all dirt and foreign material from the brake hose and the brake pipe fittings.





Important: Hold the brake hose (1) with a spanner whilst disconnecting the brake pipe fitting (3) to prevent damage to the brake pipe (2).


16. Disconnect the brake pipe fitting (3) from the brake hose (1).

Important: Install a rubber cap or plug to the exposed brake hose (1) in order to prevent brake fluid loss and contamination.


17. Plug the brake hose (1).
18. Remove the brake pipe (2).



Front Brake Pipe Installation Procedure - Left


Notice: Refer to Adding Fluid to the Brake System Notice (Adding Fluid to the Brake System Notice) .


Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (Brake Fluid Effects on Paint and Electrical Components Notice) .





1. Install the brake pipe (2).
2. Remove the rubber cap or plug from the brake hose (1).

Notice: Refer to Fastener Notice (Fastener Notice) .


Important: Hold the brake hose (1) with a spanner whilst disconnecting the brake pipe fitting (3) to prevent damage to the brake pipe (2).


3. Connect the brake pipe (2) to the brake hose (1).

Tighten the brake pipe fitting to 15 Nm (11 lb ft).

4. Lower the vehicle.




5. Attach the brake pipe (1) to the locating clip (2).




6. Attach the brake pipe (1) to the locating clip (2).




7. Attach the brake pipe (1) to the locating clip (3).
8. Install the locating clip to bulkhead retaining nut (2).




9. Attach the brake pipe (1) to the locating clips (2).




10. Remove the rubber cap or plug from the BPMV (2).
11. Install the brake pipe (1) to the BPMV (2).

Tighten the brake pipe fitting to 15 Nm (11 lb ft).

12. Install the sound proofing trim to the bulkhead.
13. Install the engine. Refer to Engine Replacement (Removal and Replacement) for 3.6L orEngine Replacement (Removal and Replacement) for 6.0L .
14. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (Service and Repair)Hydraulic Brake System Bleeding (Pressure) (Service and Repair) .



Intermediate Brake Pipe Removal Procedure

Caution: Refer to Brake Dust Caution (Brake Dust Caution) .
Caution: Refer to Brake Fluid Caution (Brake Fluid Caution) .
Caution: Refer to Brake Fluid Irritant Caution (Brake Fluid Irritant Caution) .

Notice: Refer to Adding Fluid to the Brake System Notice (Adding Fluid to the Brake System Notice) .


Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (Brake Fluid Effects on Paint and Electrical Components Notice) .

1. Clean the master cylinder, brake lines and reservoir cap.
2. Place a clean suitable container under the Brake Pressure Modulator Valve (BPMV).
3. Remove the master cylinder reservoir cap.




4. Siphon the brake fluid out of the master cylinder reservoir (2) using a hand vacuum pump (1).




5. Disconnect the brake pipe (1) from the BPMV (2).

Important: Install a rubber cap or plug to the BPMV (2) in order to prevent fluid loss and contamination.


6. Plug the BPMV (2).




7. Detach the brake pipe (1) to the locating clip (2).
Caution: Refer to Safety Glasses Caution (Safety Glasses Warning) .
Caution: Refer to Vehicle Lifting Caution (Service Precautions) .
8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair) .




9. Remove the brake and fuel pipe splash shield to chassis retaining nuts (1).
10. Remove the brake and fuel pipe splash shield (2).
11. Remove the front heat shield. Refer to Exhaust Front Heat Shield Replacement (Exhaust Front Heat Shield Replacement) .
12. Remove the engine. Refer to Engine Replacement (Removal and Replacement) for 3.6L orEngine Replacement (Removal and Replacement) for 6.0L .





Important: The brake and fuel pipe protector shield (4) is retained by rivets (3). These rivets (2) must be drilled out during removal and replaced as per the installation procedure.


13. Remove the brake and fuel pipe protector shield to bulkhead retaining rivets (2).
14. Remove the brake and fuel pipe protector shield to bulkhead retaining bolt (3).
15. Detach the brake and fuel pipe protector shield clips (1).
16. Remove the brake and fuel pipe protector shield (2).
17. Remove the rear subframe. Refer to Rear Frame Replacement (Rear Frame Replacement) .





Important: Hold the brake pipe union (1) with a spanner whilst disconnecting the brake pipe fitting (2) to prevent damage to the intermediate brake pipe (3).


18. Disconnect the intermediate brake pipe (3) from the brake pipe union (1).

Important: Install a rubber cap or plug to the brake pipe union (1) in order to prevent brake fluid loss and/or contamination.


19. Plug the brake pipe union (1).





Important: The brake and fuel pipe retaining brackets (2) are retained by rivets (3). These rivets (3) must be drilled out during removal and replaced as per the installation procedure.


20. Remove the brake and fuel pipe retaining bracket to chassis retaining rivets (3).
21. Remove the brake and fuel pipe retaining brackets (2).
22. Remove the brake pipe (4) from the brake and fuel pipe retaining bracket rubber insulators (1).





Important: Use a small flat blade tool to open the brake and fuel pipe retaining brackets (2) by detaching the brake and fuel pipe retaining bracket (2) clip.


23. Open the brake and fuel pipe retaining brackets (2).
24. Remove the brake pipe (1) from the brake and fuel pipe retaining bracket rubber insulators (3).



Intermediate Brake Pipe Installation Procedure


Notice: Refer to Adding Fluid to the Brake System Notice (Adding Fluid to the Brake System Notice) .


Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (Brake Fluid Effects on Paint and Electrical Components Notice) .





1. Install the brake pipe (1) to the brake and fuel pipe retaining bracket rubber insulators (3).
2. Close the brake and fuel pipe retaining brackets (2).




3. Install the brake pipe (4) to the two brake and fuel pipe retaining bracket rubber insulators (1).
4. Install the two brake and fuel pipe retaining brackets (2).
5. Install the two brake and fuel pipe retaining bracket to chassis retaining rivets (3).
6. Remove the rubber cap or plug from the brake pipe union.





Notice: Refer to Fastener Notice (Fastener Notice) .


Important: Hold the brake pipe union (1) with a spanner whilst connecting the brake pipe fitting (2) to prevent damage to the brake pipe (3).


7. Connect the brake pipe (1) to the brake pipe union (2).

Tighten the brake pipe fitting to 16 N.m (12 lb ft).

8. Install the rear subframe. Refer to Rear Frame Replacement (Rear Frame Replacement) .




9. Install the brake and fuel pipe splash shield (2) to the underbody.
10. Install the brake and fuel pipe splash shield to chassis retaining nuts (1).
11. Install the engine. Refer to Engine Replacement (Removal and Replacement) for 3.6L orEngine Replacement (Removal and Replacement) for 6.0L .
12. Install the front heat shield. Refer to Exhaust Front Heat Shield Replacement (Exhaust Front Heat Shield Replacement) .
13. Lower the vehicle.




14. Install the brake and fuel pipe protector shield (4)
15. Attach the brake and fuel pipe protector shield clips (1).
16. Install NEW brake and fuel pipe protector shield to bulkhead retaining rivets (2).
17. Install the brake and fuel pipe protector shield to bulkhead retaining bolt (3).




18. Attach the brake pipe (1) to the locating clip (2).




19. Remove the rubber cap or plug from the BPMV (2).
20. Install the brake pipe (1) to the BPMV (2).

Tighten the brake pipe fitting to 16 N.m (12 lb ft).

21. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (Service and Repair)Hydraulic Brake System Bleeding (Pressure) (Service and Repair) .



Rear Brake Pipe Removal Procedure - Right

Caution: Refer to Brake Dust Caution (Brake Dust Caution) .
Caution: Refer to Brake Fluid Caution (Brake Fluid Caution) .
Caution: Refer to Brake Fluid Irritant Caution (Brake Fluid Irritant Caution) .

Notice: Refer to Adding Fluid to the Brake System Notice (Adding Fluid to the Brake System Notice) .


Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (Brake Fluid Effects on Paint and Electrical Components Notice) .

1. Clean the master cylinder, brake lines and reservoir cap.
2. Remove the master cylinder reservoir cap.




3. Siphon the brake fluid out of the master cylinder reservoir (1) using a hand vacuum pump (2).




4. Disconnect the brake pipe (1) from the BPMV (2).

Important: Install a rubber cap or plug to the BPMV (2) in order to prevent fluid loss and contamination.


5. Plug the BPMV (2).




6. Detach the brake pipe (1) from the locating clip (2).
Caution: Refer to Safety Glasses Caution (Safety Glasses Warning) .
Caution: Refer to Vehicle Lifting Caution (Service Precautions) .
7. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair) .




8. Remove the brake and fuel pipe splash shield to chassis retaining nuts (1).
9. Remove the brake and fuel pipe splash shield (2).
10. Remove the front heat shield. Refer to Exhaust Front Heat Shield Replacement (Exhaust Front Heat Shield Replacement) t.
11. Remove the engine. Refer to Engine Replacement (Removal and Replacement) for 3.6L orEngine Replacement (Removal and Replacement) for 6.0L .





Important: The brake and fuel pipe protector shield (4) is retained by rivets (3). These rivets (2) must be drilled out during removal and replaced as per the installation procedure.


12. Remove the brake and fuel pipe protector shield to bulkhead retaining rivets (2).
13. Remove the brake and fuel pipe protector shield to bulkhead retaining bolt (3).
14. Detach the brake and fuel pipe protector shield clips (1).
15. Remove the brake and fuel pipe protector shield (2).





Important: Hold the brake hose (3) with a spanner whilst disconnecting the brake pipe fitting (1) to prevent damage to the brake pipe (2).


16. Disconnect the brake pipe fitting (1) from the brake hose (3).

Important: Install a rubber cap or plug to the brake hose (3) in order to prevent brake fluid loss and contamination.


17. Plug the brake hose (3).
18. Remove the brake pipe (2).





Important: The brake and fuel pipe retaining brackets (2) are retained by rivets (3). These rivets (3) must be drilled out during removal and replaced as per the installation procedure.


19. Remove the brake and fuel pipe retaining bracket to chassis retaining rivets (3).
20. Remove the brake and fuel pipe retaining brackets (2).
21. Remove the brake pipe (4) from the brake and fuel pipe retaining bracket rubber insulators (1).





Important: Use a small flat blade tool to open the brake and fuel pipe retaining brackets (1) by detaching the brake and fuel pipe retaining bracket (1) clip.


22. Open the brake and fuel pipe retaining brackets (1).
23. Remove the brake pipes (3) from the brake and fuel pipe retaining bracket rubber insulators (2).



Rear Brake Pipe Installation Procedure - Right





1. Install the brake pipes (3) to the brake and fuel pipe retaining bracket rubber insulators (2).
2. Close the brake and fuel pipe retaining brackets (1).




3. Install the brake pipes (4) to the two brake and fuel pipe retaining bracket rubber insulators (1).
4. Install the two brake and fuel pipe retaining brackets (2).
5. Install the two brake and fuel pipe retaining bracket to chassis retaining rivets (3).




6. Remove the rubber cap or plug from the brake hose (3).

Notice: Refer to Fastener Notice (Fastener Notice) .


Important: Hold the brake hose (3) with a spanner whilst connecting the brake pipe fitting (1) to prevent damage to the brake pipe (2).


7. Connect the brake pipe fitting (1) to the brake hose (3).

Tighten the brake pipe fitting to 15 Nm (11 lb ft).





8. Install the brake and fuel pipe splash shield (2) to the underbody.
9. Install the brake and fuel pipe splash shield to chassis retaining nuts (1).
10. Install the engine. Refer to Engine Replacement (Removal and Replacement) for 3.6L orEngine Replacement (Removal and Replacement) for 6.0L .
11. Install the front heat shield. Refer to Exhaust Front Heat Shield Replacement (Exhaust Front Heat Shield Replacement) .
12. Lower the vehicle.




13. Install the brake and fuel pipe protector shield (4)
14. Attach the brake and fuel pipe protector shield clips (1).
15. Install NEW brake and fuel pipe protector shield to bulkhead retaining rivets (2).
16. Install the brake and fuel pipe protector shield to bulkhead retaining bolt (3).




17. Attach the brake pipe (1) to the locating clip (2).




18. Remove the rubber cap or plug from the BPMV (2).
19. Install the brake pipe (1) to the BPMV (2).

Tighten the brake pipe fitting to 15 Nm (11 lb ft).

20. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (Service and Repair)Hydraulic Brake System Bleeding (Pressure) (Service and Repair) .



Rear Brake Pipe Removal Procedure - Left

Caution: Refer to Brake Dust Caution (Brake Dust Caution) .
Caution: Refer to Brake Fluid Caution (Brake Fluid Caution) .
Caution: Refer to Brake Fluid Irritant Caution (Brake Fluid Irritant Caution) .

Notice: Refer to Adding Fluid to the Brake System Notice (Adding Fluid to the Brake System Notice) .


Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (Brake Fluid Effects on Paint and Electrical Components Notice) .

1. Clean the master cylinder, brake lines and reservoir cap.
2. Remove the master cylinder reservoir cap.




3. Siphon the brake fluid out of the master cylinder reservoir (1) using a hand vacuum pump (2).
4. Remove the rear suspension sub frame assembly. Refer to Rear Frame Replacement (Rear Frame Replacement) .





Important: Hold the brake pipe union (3) with a spanner whilst disconnecting the brake pipe fitting (2) to prevent damage to the brake pipe (1).


5. Disconnect the intermediate brake pipe (1) from the brake pipe union (3).

Important: Install a rubber cap or plug to the brake pipe union (3) in order to prevent brake fluid loss and/or contamination.


6. Plug the brake pipe union (3).





Important: Hold the brake hose (2) with a spanner whilst disconnecting the brake pipe fitting (1) to prevent damage to the brake pipe (3).


7. Disconnect the brake pipe fitting (1) from the brake hose (2).

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


8. Plug the brake hose (2).




9. Remove the brake pipe (1) from the brake pipe retaining clips (2).



Rear Brake Pipe Installation Procedure - Left


Notice: Refer to Adding Fluid to the Brake System Notice (Adding Fluid to the Brake System Notice) .


Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice (Brake Fluid Effects on Paint and Electrical Components Notice) .





1. Install the brake pipe (1) to the brake pipe retaining clips (2).
2. Remove the rubber cap or plug from the brake hose.





Notice: Refer to Fastener Notice (Fastener Notice) .


Important: Hold the brake hose (2) with a spanner whilst connecting the brake pipe fitting (1) to prevent damage to the brake pipe (3) .


3. Connect the brake pipe fitting (1) to the brake hose (3).

Tighten the brake pipe fitting to 15 Nm (11 lb ft).

4. Remove the rubber cap or plug from the brake pipe union.





Notice: Refer to Fastener Notice (Fastener Notice) .


Important: Hold the brake pipe union (2) with a spanner whilst connecting the brake pipe fitting (3) to prevent damage to the brake pipe (2).


5. Connect the brake pipe (1) to the brake pipe union (2).

Tighten the brake pipe fitting to 15 Nm (11 lb ft).

6. Install the rear suspension sub frame assembly. Refer to Rear Frame Replacement (Rear Frame Replacement) .
7. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) (Service and Repair)Hydraulic Brake System Bleeding (Pressure) (Service and Repair) .