Chrysler Full-Size Vans 1967-1988 Repair Guide

Brake Hoses and Lines



See Figures 1 through 5

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Fig. Fig. 1: To remove the flexible brake hose, use a flare nut wrench and loosen the brake line attaching nut ...

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Fig. Fig. 2: ... then position it out of the way. Remove the brake hose bracket retaining bolt

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Fig. Fig. 3: Unbolt the brake hose from the caliper ...

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Fig. Fig. 4: ... and remove the hose assembly

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Fig. Fig. 5: Always use new copper gaskets (arrow) when installing the brake hose

The hydraulic brake lines and brake linings are to be inspected at the recommended intervals in the maintenance schedule. Follow the steel tubing from the master cylinder to the flexible hose fitting at each wheel. If a section of the tubing is found to be damaged, replace the entire section with tubing of the same type (steel, not copper), size, shape, and length. When installing a new section of brake tubing, flush clean brake fluid or denatured alcohol through to remove any dirt or foreign material from the line. Be sure to flare both ends to provide sound, leak-proof connections. When bending the tubing to fit the underbody contours, be careful not to kink or crack the line. Torque all hydraulic connections to 10-15 ft. lbs.

Check the flexible brake hoses that connect the steel tubing to each wheel cylinder. Replace the hose if it shows any signs of softening, cracking, or other damage. When installing a new front brake hose, position the hose to avoid contact with other chassis parts. Place a new copper gasket over the hose fitting and thread the hose assembly into the front wheel cylinder. A new rear brake hose must be positioned clear of the exhaust pipe or shock absorber. Thread the hose into the rear brake tube connector. When installing either a new front or rear brake hose, engage the opposite end of the hose to the bracket on the frame. Install the horseshoe type retaining clip and connect the tube to the hose with the tube fitting nut.

Always bleed the system after hose or line replacement. Before bleeding, make sure that the master cylinder is topped up with high temperature, extra heavy duty fluid of at least SAE 70R3 quality.