CATALOG / hydraulic-line-replace
Template · hydraulic-line-replace
HYDRAULIC LINE REPLACE
Swap a damaged or weeping hydraulic brake hose, then bleed the line. Branches by fluid type — DOT vs mineral — because mixing destroys seals (battery-shop ER visit). Tier-2 safety-critical throughout.
Intake: answers gate which atoms compose
brake-type
Brake type (this template is hydraulic-only). Vehicle context is captured separately at ticket intake.
hydraulic-disc
fluid-type
Which brake fluid type is in THIS brake? (Read the lever stamp or the OEM spec — DO NOT proceed if uncertain)
dotmineral
Composed steps · 5 atoms in order
atom:intake-consult2 steps
01intake-consult/IC.1
Listen to the customer describe the problem, then ask clarifying questions to confirm the symptom, when it happens, and what changed recently
capture“What did the customer report, in their words?”
capture“What clarifying questions did you ask, and how did they answer?”
NOTENOTE
02intake-consult/IC.2
Set expectations before work begins: the scope of the planned work, what is not included, and the likely outcome
capture“What scope and expectations did you set with the customer?”
NOTE
atom:bay-readiness2 steps
03bay-readiness/BR.1
Clear and stage the work area: bench clear, vehicle secured on the stand, fire-safe location for any battery work
capture“Work area clear and the vehicle secured?”
capture“Photograph the staged work area.”
PASS / FAILPHOTO
04bay-readiness/BR.2
Select and stage the correct tools for the planned job, and put on the PPE the work requires (gloves, eye protection)
capture“Correct tools staged for this job?”
capture“PPE on for the work being done?”
PASS / FAILPASS / FAIL
atom:power-down-and-photo1 step
05power-down-and-photo/1
Power down + photograph cable routing
capture“Vehicle powered down?”
capture“Snap a photo of the cable routing.”
PASS / FAILPHOTO
atom:hydraulic-line-replacewhen brake-type = hydraulic-disc8 steps
06hydraulic-line-replace/HLR.1
Confirm fluid type for THIS brake model and gather the matched hose, olive, and barb insert; mismatched parts won't seal
capture“Fluid type confirmed; correct hose + fittings on bench?”
DECISION · 3
criticalDOT and mineral hoses look identical but have different inner liners — using the wrong hose will swell or chemically rot the liner
Cited sourcessign-off seam
source → sram-level-bleed-procedure✓editorial · Afam · 2026-05-28
source → shimano-mt200-bleed-procedure✓editorial · Afam · 2026-05-28
07hydraulic-line-replace/HLR.2
Drape rags over paint, decals, and any aluminum near the work area — DOT fluid strips paint within minutes, mineral oil stains decals
capture“Rags placed under and around the lever, hose path, and caliper?”
warningPlan the spill before you make it
08hydraulic-line-replace/HLR.3
Loosen the hose fitting at the lever end; catch fluid in a rag; remove lever banjo or fitting
capture“Lever-end fitting loose; fluid caught; lever end disconnected?”
09hydraulic-line-replace/HLR.4
Loosen the caliper-end fitting; catch fluid; remove caliper banjo or fitting; pull the old hose out of the frame routing
capture“Caliper-end disconnected; old hose out of routing?”
10hydraulic-line-replace/HLR.5
Cut the new hose to length (route through frame first to measure); install olive + barb insert per brand spec; thread fittings finger-tight at both ends
capture“New hose cut square to length; olive + insert seated; fittings finger-tight both ends?”
PHOTO
warningCut MUST be square — angled cuts won't compress the olive evenly and will weep
11hydraulic-line-replace/HLR.6
Torque both fittings to brand spec (typically 5–7 N·m for compression fittings — never exceed without a spec source)
capture“Both fittings torqued — what N·m setting?”
VALUE · Nm
Cited sourcessign-off seam
source → park-tool-axle-torque-2024✓editorial · Afam · 2026-05-20
12hydraulic-line-replace/HLR.7
Bleed the brake — branch by fluid type (same procedure as hydraulic-bleed atom)
branch on fluid-type
Post-install bleed — branch by fluid type
DOT FLUIDdotdot-5.1dot5.1
HLR.dot.1Run the DOT-fluid Bleeding Edge bleed procedure (fluid-syringe at caliper pushes fresh DOT 5.1 caliper→lever; catch-syringe at lever captures spent fluid + air) until the catch-syringe captures clear bubble-free fluid; close caliper port first then lever port
capture“DOT bleed complete; fluid clear at both ports?”
capture“Total DOT volume used — how many ml?”
VALUE · mlPASS / FAIL
warningVolume needed is typically 15–20 ml on a fresh hose vs 10–15 ml on a normal bleed — air pockets at the fittings need extra flush
Cited sourcessign-off seam
source → sram-level-bleed-procedure✓editorial · Afam · 2026-05-28
MINERAL OILmineralmineral-oil
HLR.min.1Run the mineral-oil gravity-bleed (catch-cup at caliper, funnel at lever); pump lever 5–10× to clear hose-end bubbles; close caliper, top up reservoir, cover
capture“Mineral bleed complete; lever firm; cover reseated?”
capture“Total mineral-oil volume used — how many ml?”
VALUE · mlPASS / FAIL
warningFresh-hose bleed needs ~15 ml of mineral oil; pump volume to clear all hose-segment air
Cited sourcessign-off seam
source → shimano-mt200-bleed-procedure✓editorial · Afam · 2026-05-28
13hydraulic-line-replace/HLR.8
Pull bleed block / reinstall pads; pump lever 10× and confirm firm bite + no fluid weep at either new fitting
capture“Pads in; lever firm; new fittings dry — any weep?”
PASS / FAILPHOTO
glossary → brakes/hydraulic-hose
atom:findings-handoff3 steps
14findings-handoff/FH.1
Explain the findings and the work done in plain language, without jargon, and confirm the customer understands
capture“How did you explain the findings and work to the customer?”
NOTE
15findings-handoff/FH.2
Communicate any battery findings verbally: state of health, charging guidance, and safety notes, and confirm they were understood
capture“What battery findings did you communicate, and how did the customer respond?”
NOTE
16findings-handoff/FH.3
Communicate any drive-system findings verbally: motor, controller, or sensor behavior observed during service
capture“What drive-system findings did you communicate to the customer?”
NOTE
deviation_rules · 6 declared
ad_hoc_step
a captured step is not in the runbook for the resolved vehicle / fluid-type branches
missed_step
a runbook step for the resolved branches has no capture in the job record
missing_required_evidence
a step's capture.evidence item went unfilled by the tech's narration
branch_candidate
narration matches a finding pattern (spongy lever, fluid weep, dirty fluid) but no branch was taken
contaminated_pad_kept
narration mentions oil or brake fluid on pads but no pad-replace step was added
dot_mineral_crossover
narration mentions both DOT and mineral brake fluid in the same job record
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