Brake / Clutch Line Fitting Guide
Important safety and installation information. Please read this guide fully before fitting – correct installation is essential for safe operation, MOT compliance and long-term reliability.
Thank you for choosing a Pioneer 4x4 braided line kit. The notes below cover both brake and clutch line kits. Clutch line kits use the same braided PTFE construction and fittings as our brake kits and follow the same routing, slack, torque and bleeding principles set out here – bleeding the clutch hydraulic circuit in place of the brakes.
Full system kits
- Replace all OEM brake lines with stainless braided PTFE hoses and stainless steel fittings
- Suitable for retrofit installation on vehicles already in use
- Supplied with copper washers where required, securing clips and detailed installation instructions
- Excellent corrosion and abrasion resistance
- Meet recognised brake hose standards (SAE J1401 equivalent)
- Compatible with DOT 3, DOT 4 and DOT 5.1 brake fluid
Flexible line kits
- Replace only the flexible brake hoses (e.g. caliper or knuckle connections)
- Upgrade the critical flexible points while retaining your OEM hard lines
- Supplied with all necessary fittings, copper washers where required and installation guidance
- Meet recognised brake hose standards (SAE J1401 equivalent)
- Compatible with DOT 3, DOT 4 and DOT 5.1 brake fluid
- Excellent corrosion and abrasion resistance
- Check the hoses are the correct length for your vehicle
- For full system kits, review the entire hose layout before you begin
- For flexible line kits, check which hoses are being replaced and how they connect to the existing lines
- Avoid kinks, twists or torsional stress
- Hoses must not contact suspension, steering or any moving components
- Use all supplied clips and brackets
Get the slack right
Caliper → bracket / locator. These two points move together, so the hose on this side of the bracket can be run tight – there is no movement between them. Leave it slack here and the hose will be pulled tighter than it should be on the side that actually moves.
Bracket → fitting (female / male). This side moves, with each end moving independently, so it needs the maximum free hose length. Too little slack and full lock or suspension travel pulls the hose at the connector, transferring stress to the ferrule – the sharpest point – which over time can wear a hole or cut the hose.
- Tighten in order: caliper / bleeder first, then chassis / fixed fittings
- Tighten the bolts on the vehicle rather than the hose fittings, to avoid putting the hose in torsion
- Re-check hose routing and clearance after tightening
| Stainless steel banjo bolts | ft·lb | Nm |
|---|---|---|
| Minimum | 14 | 19 |
| Maximum | 24 | 32 |
Bleed the system following the vehicle manufacturer's procedure until you have a firm pedal. For a fuller look at master cylinder, servo and caliper matching, see our brake bleeding & master cylinder setup guide.
Experienced owners will tell you bleeding your brakes is easy – it is, but there is plenty of room for error. We've made every effort to be thorough, but if you choose to fit and bleed the kit yourself we cannot take responsibility for what happens next, and we'd recommend having it fitted by a reputable garage or service centre. By purchasing this product you accept our full terms and conditions. Thank you, and drive safely.
How the fitting seals
Each hose is a PTFE inner tube inside a PVC-covered stainless steel braided hose, finished with a precision RLT (Rotational Leak-free Technology) fitting.
- The ferrule has an internally machined peak that compresses into the fitting, so it cannot be pulled out of the assembly once crimped
- Each fitting has three grooves; crimping pushes the PTFE inner into them, over three sealing O-rings
- This lets the RLT fitting rotate after crimping without compromising the hose assembly
- Kits are designed to meet the expectations of MOT inspection when correctly installed
- Responsibility for MOT compliance and roadworthiness rests with the installer and vehicle owner
- Have the vehicle tested after installation to confirm correct operation
- Inspect hoses periodically for wear, leaks or clearance issues
- Make sure all fittings remain tight
- Do not drive if there are leaks or any abnormal pedal feel
Lifetime warranty
Pioneer 4x4 hoses carry a lifetime warranty against corrosion and component failure, except where damage results from:
- Incorrect installation
- Misuse or competitive driving
- Failure to follow the supplied instructions
Pioneer 4x4 accepts no liability for brake failure, vehicle damage, MOT rejection or personal injury resulting from improper installation or use.
If you're unsure, ask
If you're ever unsure about installation or vehicle suitability, please contact us before fitting.
Email pioneer4x4@outlook.com · Tel 01404 643149