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.
REMOVAL & INSTALLATION
See Figure 1
- Raise and safely support the vehicle.
- Remove the necessary components to gain access to the brake line.
- Disconnect the brake line fittings at each end of the line. Use 2 flare or open ended wrenches.
- Disconnect the line from any retaining clips and remove the line from the vehicle.
- Try to obtain a replacement line that is the same length as the line that was removed. If the line is longer, you will have to cut it and flare the end.
Use only brake line tubing approved for automotive use.
- Use a suitable tubing bender to make the necessary bends in the line. Work slowly and carefully; try to make the bends look as close as possible to those on the line being replaced.
When bending the brake line, be careful not to kink or crack the line. If the brake line becomes kinked or cracked, it must be replaced.
- Before installing the brake line, flush it with brake cleaner to remove any dirt or foreign material.
- Install the line into the vehicle. Be sure to attach the line to the retaining clips, as necessary. Make sure the replacement brake line does not contact any components that could rub the line and cause a leak.
- Connect the brake line fittings and tighten to 10-2 ft. lbs. (13-24 Nm).
- Bleed the brake system.
- Install any removed components and lower the vehicle.
BRAKE LINE FLARING
See Figures 2 and 3
Use only brake line tubing approved for automotive use; never use copper tubing. Whenever possible, try to work with brake lines that are already cut to the length needed. These lines are available at most auto parts stores and have machine made flares, the quality of which is hard to duplicate with most of the available inexpensive flaring kits.
When the brakes are applied, there is a great amount of pressure developed in the hydraulic system. An improperly formed flare can leak with resultant loss of stopping power. If you have never formed a double-flare, take time to familiarize yourself with the flaring kit; practice forming double-flares on scrap tubing until you are satisfied with the results.
The following procedure applies to most commercially available double-flaring kits. If these instructions differ in any way from those in your kit, follow the instructions in the kit.
- Cut the brake line to the necessary length using a tubing cutter.
- Square the end of the tube with a file and chamfer the edges.
- Insert the tube into the proper size hole in the bar until the end of the tube sticks out the thickness of the single flare adapter. Tighten the bar wing nuts tightly so the tube cannot move.
- Place the single flare adapter into the tube and slide the bar into the yoke.
- Position the yoke screw over the single flare adapter and tighten it until the bar is locked in the yoke. Continue tightening the yoke screw until the adapter bottoms on the bar. This should form the single flare.
Make sure the tube is not forced out of the hole in the bar during the single flare operation. If it is, the single flare will not be formed properly and the procedure must be repeated from Step 1.
- Loosen the yoke screw and remove the single flare adapter.
- Position the yoke screw over the tube and tighten until the taper contacts the single flare and the bar is locked in the yoke. Continue tightening to form the double flare.
Make sure the tube is not forced out of the hole in the bar during the double flare operation. If it is, the double flare will not be formed properly and the procedure must be repeated from Step 1.
- Loosen the screw and remove the bar from the yoke. Remove the tube from the bar.
- Check the flare for cracks or uneven flaring. If the flare is not perfect, cut it off and begin again at Step 1.