How to Install a Brake Hydraulic Hose on a T1N OM647 2003-2006 Sprinter Van

Tools & Materials Needed:

New brake hydraulic hose
Line wrench (to avoid stripping brake line fittings)
Socket set
Brake fluid (DOT 4 or as specified by manufacturer)
Brake bleeder kit or a helper
Jack and jack stands
Wheel chocks
Brake cleaner
Safety glasses and gloves
Drip pan or container
Torque wrench (optional for tightening fittings)

Step-by-Step Instructions:

1. Safety First:

Park the Sprinter van on a flat surface, engage the parking brake, and place wheel chocks behind the rear tires to prevent movement. Ensure the engine is off, and wear safety glasses and gloves to protect yourself from brake fluid, which can be harmful to the skin and eyes.

2. Lift and Support the Vehicle:

Use a jack to lift the van, following proper jacking points (refer to the vehicle’s manual). Once lifted, securely support the van on jack stands to give you safe access to the brake lines. Never rely on the jack alone for support.

3. Remove the Wheel:

Using the appropriate socket, remove the lug nuts and take off the wheel to expose the brake components, including the brake hydraulic hose.

4. Locate the Brake Hydraulic Hose:

The brake hydraulic hose is the flexible rubber hose connecting the hard brake line (metal) from the body of the van to the brake caliper. The hose allows the brake system to flex as the suspension moves.

5. Prepare to Disconnect the Old Hose:

Place a drip pan or container underneath the brake caliper to catch any brake fluid that leaks out when you disconnect the hose.
Spray brake cleaner on the connections to clean off any dirt or grime that could contaminate the brake system during the process.

6. Disconnect the Brake Hose from the Hard Line:

Use a line wrench to loosen and disconnect the brake hose from the hard metal brake line. A line wrench is preferable because it grips the fitting better, preventing it from rounding off.
Once disconnected, you may notice brake fluid starting to drip, so be sure to have the drip pan in place. Plug the hard line temporarily to minimize fluid loss.

7. Disconnect the Hose from the Brake Caliper:

At the caliper end, use the appropriate wrench to remove the banjo bolt (if applicable) or unscrew the fitting that secures the hose to the caliper.
Take note of any washers (such as copper crush washers) used with the banjo bolt. You will likely need to replace them with new ones when installing the new hose.

8. Remove Retaining Clips:

If your van’s brake hose is held in place by retaining clips or brackets, remove those with pliers or a screwdriver to fully release the hose.

9. Install the New Brake Hose:

Attach the hose to the caliper: Install the new brake hose at the brake caliper using the banjo bolt or the appropriate fitting. If your van uses a banjo bolt, make sure to use new copper crush washers on both sides of the fitting to prevent leaks. Tighten the fitting to the manufacturer’s specifications (using a torque wrench if needed).
Attach the hose to the hard line: Connect the other end of the new brake hose to the hard metal brake line and tighten it securely with a line wrench.

10. Secure the Brake Hose with Retaining Clips:

If applicable, reinstall any retaining clips or brackets to secure the new hose in place along its route. Make sure the hose is properly routed and doesn’t rub against any other components or get kinked.

11. Bleed the Brake System:

After installing the new hose, you will need to bleed the brake system to remove any air that may have entered during the hose replacement.
Open the bleeder valve on the caliper and use a brake bleeder kit or have a helper pump the brake pedal. Make sure to top off the master cylinder with fresh brake fluid as needed to prevent it from running dry.
Continue bleeding until no air bubbles are visible and clean brake fluid comes through the bleeder valve. Tighten the bleeder valve once done.

12. Check Brake Fluid Level:

After bleeding the brakes, check the brake fluid reservoir under the hood and add more brake fluid if needed. Be sure to use the correct type of fluid (typically DOT 4) as specified in the owner’s manual.

13. Reinstall the Wheel:

Once the new hose is securely installed and the brake system has been properly bled, reinstall the wheel and hand-tighten the lug nuts. Then, lower the vehicle from the jack stands and fully tighten the lug nuts in a crisscross pattern to ensure even pressure.

14. Test the Brakes:

Before driving the van, pump the brake pedal a few times to build up pressure in the system. The pedal should feel firm and responsive. If it feels spongy or soft, there may still be air in the system, and you may need to bleed the brakes again.

15. Final Inspection:

Check for any leaks around the new brake hose connections. If everything looks secure and there are no leaks, the installation is complete.

By following these steps, you should be able to successfully install a new brake hydraulic hose on your T1N OM647 2003-2006 Sprinter van. If you encounter any issues or are unsure about any part of the process, consider consulting a professional mechanic to ensure the job is done correctly.