Russell Brakes for the Ford Excursion: Which Parts Fit

By Core Brake Parts Tech Team — Circleville, OH warehouse

The Russell part that fits the Ford Excursion is the 696490 stainless braided brake line kit, and it is built for one specific truck: a 4WD Excursion running a 4 to 5.5 inch suspension lift. If your Excursion is stock height or 2WD, that kit is the wrong part, and what you want instead are pads and rotors matched to your drivetrain and year. This guide covers what the Russell kit does, who should buy it, and which pads and rotors we carry that fit the Excursion.

What the Russell 696490 Kit Is and Who It Fits

The Russell 696490 stainless braided brake line kit for the lifted Excursion 4WD is a pre-assembled set of five hoses. Parts catalog data lists it for the 2000-2005 Ford Excursion 4WD and the 1999-2004 F-250 and F-350 Super Duty 4WD, all with a 4 to 5.5 inch lift. The Excursion shares its chassis and front suspension layout with the Super Duty pickups of that era, which is why one hose kit covers both.

Construction details from the catalog listing:

• Five lines per kit, covering both front and rear flexible hose positions.
• Stainless steel braided hose with zinc-plated fittings in the OEM fitting style, so they thread into the stock hard lines and calipers.
• Pre-assembled from the factory, so there is no crimping or cutting at home.
• Listed as meeting DOT requirements and legal in all 50 states.

That DOT point matters more than it sounds. Brake hose on a road vehicle is covered by Federal Motor Vehicle Safety Standard 106, which sets labeling and performance rules for brake hose, hose assemblies and end fittings. The stated purpose of the standard is to reduce deaths and injuries from brake failure caused by a hose rupture. A DOT-compliant hose carries the DOT symbol printed along its length, so you can confirm what you are installing.

Why a Lifted Excursion Needs Longer Brake Hoses

The flexible hoses at each wheel have to reach from the fixed hard line on the frame to a caliper that moves up and down with the axle. Ford sized the factory hoses for factory ride height. Add a 4 to 5.5 inch lift and the axles sit farther from the frame, so at full droop, like when a tire drops into a hole off-road or the truck is on a lift, a stock-length hose can be pulled tight. A hose stretched at its fittings can chafe, kink or pull loose, and a failed hose means lost pressure in that circuit.

Extended-length lines put the slack back so the hose can follow the full suspension travel. The braided stainless cover also resists abrasion better than bare rubber on a truck that sees brush and rocks.

Signs your current hoses need attention

• Hoses pulled straight or tight when the axle is at full droop.
• Cracks, bulges or a wet, oily film on the rubber near the fittings.
• A pedal that feels softer than it used to, or one that sinks, after the lift went in.
• The BRAKE warning light on with the parking brake released. Ford's owner guide says that condition means the brake system needs service immediately.

Before You Order: Fitment Checks

Braided line kits are cut to the geometry of a specific lift range, so a few checks save a return:

1. Drivetrain. The 696490 kit is listed for 4WD Excursions only.
2. Lift height. It is designed for 4 to 5.5 inches. A leveling kit is too little, and a much taller lift may need longer hoses still.
3. Rear hose layout. Compare the rear caliper position and hose routing on your truck with the kit's fitment notes before you install.
4. Fitting condition. Old steel hard-line flare nuts on a 20-year-old truck are often rusted. Have a flare-nut wrench and penetrating oil ready so you do not round them off.

Pads and Rotors That Fit the Excursion

Brake lines alone do not add stopping power; they keep the hydraulic system firm and intact. The friction side is pads and rotors, and on the Excursion those change by drivetrain and model year, so match the listing exactly. Here is what we carry for it:

Notice the split: the front rotors listed here are 4WD fitments, while the pads and rear rotors are 2WD fitments for 2000-2002. Do not assume a 2WD pad fits a 4WD truck or the reverse. If your exact year and drivetrain is not in the table, browse our brake pads and brake rotors collections by vehicle.

Extra Duty or Yellowstuff?

EBC builds its Extra Duty pads for light trucks and SUVs dealing with towing, heavy loads, and lifted suspension on oversized tires. EBC explains that a bigger tire's larger rolling radius gives the brakes more leverage to overcome, which shows up as a spongy-feeling pedal in hard stops, and it pitches the higher-friction Extra Duty compound as the answer. EBC describes its truck Yellowstuff as an ultra high friction sport compound for towing and heavy loads, with a brake-in surface coating that helps the pads seat quickly after installation. For a heavy Excursion that tows, either is a sensible step up from a basic pad; Extra Duty leans toward low dust and rotor life, Yellowstuff toward maximum bite.

Which slotted rotor?

EBC's GD rotors use wide slots meant to keep pad wear even, run cooler, and clear dirt, mud and water from the pad face, and EBC describes them as suited to 4x4s. The USR series uses a narrower slot pattern aimed at quieter running, and the BSD uses a blade-style slot. On a truck that sees trails and towing, GD is the natural pick; if road noise bothers you, look at USR.

What to Replace at the Same Time

• Brake fluid. Opening every hose lets air in, so the whole system gets bled anyway. Ford specifies Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid for the Excursion, filled to the line on the reservoir. Use fresh fluid from a sealed container.
• Sealing washers. Caliper banjo fittings seal on crush washers. Never reuse the old ones.
• Pads and rotors, if worn. If the calipers are coming off for the hose swap, it is the cheapest time to do the friction parts too. Hardware is in our brake hardware kits collection.

How Hard Is the Job?

A hose swap on an Excursion is a moderate driveway job for someone who has bled brakes before. The steps are: support the truck safely on stands, break loose the hard-line flare nut at each hose, remove the hose clips and the caliper end, install the new hose with new washers, then bleed the system starting at the wheel farthest from the master cylinder. Tighten every fitting to the value in the factory service manual. Budget extra time for seized flare nuts on an older truck.

When you finish, check the pedal before the truck moves. Ford's owner guide warns that if the BRAKE lamp stays lit with the parking brake released, the system needs service before driving. Then cycle the suspension, or at least turn the wheels lock to lock, and confirm no hose touches the tire, frame or steering parts.

If you tow, keep Ford's towing guidance in mind: the Excursion's brakes are rated for operation at GVWR, not GCWR, and Ford says never to connect a trailer's hydraulic brake system directly to the truck's brakes. Use a proper trailer brake setup, and downshift on long grades so the brakes do not overheat.

Frequently Asked Questions

Does the Russell 696490 kit fit a stock-height Excursion?

It is designed for 4WD Excursions with a 4 to 5.5 inch lift. On a stock-height truck the extra length is not needed and can leave slack hose that rubs, so stay with factory-length hoses.

Are braided stainless brake lines street legal?

They can be, if they meet FMVSS 106. The 696490 kit is listed as meeting DOT requirements and legal in all 50 states. Look for the DOT marking printed on the hose.

What brake fluid does the Ford Excursion use?

Ford's owner guide specifies Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, filled to the line on the reservoir.

Will braided lines make my Excursion stop shorter?

Not on their own. Stopping power comes from pads, rotors and tires. Braided lines help the pedal stay firm and consistent, and on a lifted truck the correct length keeps the hoses from being stretched.

Do 2WD and 4WD Excursions use the same brake pads?

Do not assume so. The pads and rear rotors we carry are listed for 2000-2002 2WD trucks, while the front rotors are listed for 2000-2005 4WD. Buy by the exact year and drivetrain on the listing.

Sources

1. Russell 696490 Brake Hydraulic Hose Kit catalog listing - five lines, stainless braided, zinc-plated fittings, DOT, 4-5.5 inch lift, Excursion and Super Duty 4WD fitment
2. Ford 2005 Excursion Owner Guide - DOT 3 brake fluid, BRAKE warning lamp guidance, towing and trailer brake warnings
3. 49 CFR 571.106, FMVSS 106 Brake Hoses - purpose, scope and DOT labeling of brake hose
4. EBC Extra Duty Light Truck, Jeep and SUV Brake Pads - intended use, larger tires and pedal feel
5. EBC Yellowstuff Truck Sport Brake Pads - high friction compound for towing, brake-in coating
6. EBC GD Sport Rotors - wide slot purpose and 4x4 suitability