!Guide! Replacing Flexi Brake Hoses - MK7 2011

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-Ford Fiesta Zetec JA8  08-13

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-Tightly place clingfilm over the fluid reservoir and reattach the cap to create a vacuum

Front calliper brake hoses
-Brush off rust & apply penetrating oil to the brake hose retaining clip
-Brush off rust & apply penetrating oil to the main brake line union where it fastens to the brake hose ferrule 
-Brush off rust & apply penetrating oil to the bolt that secures the brake hose to the strut assembly
-Brush off rust & apply penetrating oil to the brake hose banjo bolt that secures the hose to the calliper
-Apply some heat to all of these areas if they are very rusty. Wire brush & spray them again.

-Crack off the banjo bolt with a 12mm SOCKET & then lightly nip it back up (It can round off with a spanner)
-Remove the brake hose bolt that secures the hose to the strut assembly & pull the hose free (10mm SOCKET) (It can round off with a spanner)
-Slightly crack off the brake line union with MOLE GRIPS (It can round off with a spanner)

-Unbolt the hose from the calliper & seal it with an ear plug (12mm SOCKET)
-Unfasten the main brake line union (11mm spanner)
-Attach mole grips to the lip of the retaining clip that is securing the brake hose ferrule & pull the clip off
-Fully unmount the brake line from the brake hose ferrule & position the line over to one side
-Tap the top of the brake hose ferrule until it releases from its mounting point

-Position the new brake hose into the mount & secure it with the retaining clip
-Plug the brake line into the brake hose ferrule and fasten the union until it is reasonably tight (11mm spanner)
-Fasten the bolt that secures the hose to the strut assembly until it is reasonably tight (10mm SOCKET) (Ideally replace the bolt)
-Fasten the new brake hose to the calliper (Ideally replace the copper washer and banjo bolt) (12mm SOCKET)

-Bleed the brake lines that have been opened

-Apply a conservative amount of aluminium anti seize to the hat of the rotors (Don't get any on the studs)
-Put the front wheels back on (19mm)
-Lower the car back down
-Torque the 19mm wheel nuts to 110Nm

Rear drum brake hoses
-Brush off rust & apply penetrating oil to the 2 brake hose retaining clips
-Brush off rust & apply penetrating oil to the main brake line union where it fastens to the brake hose ferrule 
-Brush off rust & apply penetrating oil to the small drum brake line union where it fastens to the brake hose ferrule 
-Apply some heat to all of these areas if they are very rusty. Wire brush & spray them again.

-Slightly crack off both brake line unions with MOLE GRIPS (They can round off with a spanner)
-Attach mole grips to the lip of the 2 retaining clips that are securing the brake hose ferrules in position & pull the clips off
-Unfasten the main brake line union (11mm spanner)
-Unfasten the small drum brake line union (11mm spanner)
-Fully unmount the brake lines from the brake hose ferrules & position the lines over to one side
-Tap the top of the brake hose ferrules until they release from their mounting points

-Position the new brake hose into the 2 mounting points & secure them with retaining clips
-Plug the brake lines into the hose ferrules and fasten the unions until they are reasonably tight (11mm spanner)

-Bleed the brake lines that have been opened

-Apply a conservative amount of aluminium anti seize to the brake drum mating surface (Don't get any on the studs)
-Put the rear wheels back on
-Lower the car back down
-Torque the 19mm wheel nuts to 110Nm

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Useful sources:

Replacing Ford Fiesta corroded brake hose ferrules

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