GM Chevy Mid-Size Cars 1964-1988 Repair Guide

Brake Hoses and Pipes

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HYDRAULIC BRAKE LINE CHECK



The hydraulic brake lines and brake linings are to be inspected at the recommended intervals in the maintenance schedule. Follow the steel tubing (pipe) 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 the system 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. (14-20 Nm).

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 or use the banjo bolt to secure it to the caliper, as applicable. 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.

REMOVAL & INSTALLATION



Brake Hose
  1. Raise the end of the vehicle which contains the hose to be repaired, then support the vehicle safely using jackstands.
  2.  
  3. If necessary, remove the wheel for easier access to the hose.
  4.  
  5. Note the hose routing to assure correct installation.
  6.  
  7. Disconnect the hose from the wheel cylinder or caliper and plug the opening to avoid system contamination or excessive fluid loss.
  8.  
  9. Disconnect the hose from the brake line and plug the openings to avoid excessive fluid loss or contamination.
  10.  

To install:
  1. Install the brake hose to the brake line, then make sure that the line is routed properly as noted during removal.
  2.  
  3. Tighten all hydraulic connections to 10-15 ft. lbs. (14-20 Nm).
  4.  
  5. Properly bleed the brake system, then check the connections for leaks.
  6.  
  7. Remove the supports and carefully lower the vehicle.
  8.  

Brake Line

There are 2 options available when replacing a brake line. The first, and probably most preferable, is to replace the entire line using a line of similar length which is already equipped with machined flared ends. Such lines are usually available from auto parts stores and usually require only a minimum of bending in order to properly fit then to the vehicle. The second option is to bend and flare the entire replacement line (or a repair section of line) using the appropriate tools.

Buying a line with machined flares is preferable because of the time and effort saved, not to mention the cost of special tools if they are not readily available. Also, machined flares are of a higher quality than those produced by hand flaring tools or kits.

  1. Raise the end of the vehicle which contains the hose to be repaired, then support the vehicl