GM Lumina/Grand Prix/Cutlass Supreme/Regal 1988-1996

Brake Hoses and Pipes

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REMOVAL & INSTALLATION



Front Hose
  1. Disconnect the negative battery cable.
  2.  
  3. Raise the vehicle and support with jackstands.
  4.  
  5. Remove the front wheel assembly.
  6.  
  7. Clean all dirt and foreign material from the brake hose and fitting.
  8.  
  9. Remove brake pipe from the brake hose at the bracket. Use flare nut and back-up wrenches to avoid fitting damage.
  10.  
  11. Remove the brake hose retainer at the mounting bracket.
  12.  
  13. Disconnect the hose from the bracket.
  14.  
  15. Remove the inlet fitting at the caliper, bolt and two copper washers.
  16.  

To install:
  1. Install a new inlet fitting bolt, hose and new copper washers, install the inlet to the caliper. Tighten the bolt to 30 ft. lbs. (40 Nm).
  2.  
  3. With the vehicle weight on the suspension, install the brake hose to the bracket and install the hose retainer. Make sure there are NO kinks in the hose.
  4.  
  5. Attach the brake pipe to the hose and tighten the fitting to 11-15 ft. lbs. (15-20 Nm).
  6.  


WARNING
Make sure the hose is NOT kinked or touching any part of the frame or suspension after installation. These conditions may cause the hose to fail prematurely.

  1. Check the hose after turning the steering wheel extreme right and then extreme left. If the hose is tight or touching anything, make the proper adjustments.
  2.  
  3. Install the wheel and tire assembly.
  4.  
  5. Carefully lower the vehicle and bleed the brake system as outlined in this section.
  6.  
  7. Connect the negative battery cable and pump the brake pedal before moving the vehicle.
  8.  

Rear
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle with jackstands.
  4.  
  5. Remove the rear wheel and tire assembly.
  6.  
  7. Clean all dirt and foreign material from the brake hose and fitting.
  8.  
  9. Remove brake pipe from the brake hose at the bracket. Use flare nut and back-up wrenches to avoid fitting damage.
  10.  
  11. Remove the brake hose retainer at the mounting bracket.
  12.  
  13. Remove the hose from the bracket.
  14.  
  15. Remove the inlet fitting at the caliper, bolt and two copper washers.
  16.  

To install:
  1. Using new copper washers, install the inlet fitting to the caliper. Tighten the bolt to 30 ft. lbs. (40 Nm).
  2.  
  3. With the vehicle weight on the suspension, install the brake hose to the bracket and install the hose retainer. Make sure there is NO kinks in the hose.
  4.  
  5. Install the brake pipe to the hose and tighten the fitting to 15 ft. lbs. (20 Nm).
  6.  


WARNING
Make sure the hose is NOT kinked or touching any part of the frame or suspension after installation. These conditions may cause the hose to fail prematurely.

  1. Check the hose after turning the steering wheel extreme right and then extreme left. If the hose is tight or touching anything, make the proper adjustments.
  2.  
  3. Install the wheel and tire assembly.
  4.  
  5. Carefully lower the vehicle and bleed the system as outlined in this section.
  6.  
  7. Connect the negative battery cable and pump the brake pedal before moving the vehicle.
  8.  

BRAKE PIPE FLARING



See Figures 1, 2 and 3

Click image to see an enlarged view

Fig. Fig. 1: Insert and hold the forming mandrel in the flaring tool body



Click image to see an enlarged view

Fig. Fig. 2: Slide the clamping nut over the brake pipe before attaching the collet



Click image to see an enlarged view

Fig. Fig. 3: View of an ISO flare formed with tool J 29803-A

When replacing the steel brake pipes, always use double walled steer piping which is designed to withstand high pressure and resist corrosion. Also, it is important to make sure that the pipe is of the same size to assure both a proper fit and proper brake operation.


WARNING
Never use copper tubing. It is subject to fatigue, cracking and/or corrosion, which can result in brake line failure.

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 brake are applied, there is a great deal of pressure developed in the hydraulic system. An improperly formed flare can leak with a 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.

Precautions:


Always use double walled steel brake pipe.
 
Carefully route and retain replacement pipes.
 
Always use the correct fasteners and mount in the original location.
 
Use only double lap flaring tools. The use of single lap flaring tools produces a flare which may not withstand system pressure.
 

Flaring Procedures
  1. Obtain the recommended pipe and steel fitting nut of the correct size. Use the outside diameter of the pipe to specify size.
  2.  
  3. Cut the pipe to the appropriate length with a pipe cutter. Do not force the cutter. Correct length of the pipe is determined by measuring the old pipe using a string and adding approximately 1 / 8 in. (3mm) for each flare.
  4.  
  5. Make sure the fittings are installed before starting the flare.
  6.  
  7. Chamfer the inside and outside diameter of the pipe with the de-burring tool.
  8.  
  9. Remove all traces of lubricant from the brake pipe and flaring tool.
  10.  
  11. Clamp the flaring tool body in a vise.
  12.  
  13. Select the correct size collet and forming mandrel for the pipe size used.
  14.  
  15. Insert the proper forming mandrel into the tool body. While holding the forming mandrel in place with your finger, thread in the forcing screw until it makes contact and begins to move the forming mandrel. When contact is made, turn the forcing screw back 1 complete turn.
  16.  
  17. Slide the clamping nut over the brake pipe and insert the prepared brake pipe into the correct collet. Leave approximately 0.750 in. (19mm) of tubing extending out of the collet. Insert the assembly into the tool body. The brake pipe end must contact the face of the forming mandrel.
  18.  
  19. Tighten the clamping nut into the tool body very tight or the pipe may push out.
  20.  
  21. Wrench tighten the forcing screw in until it bottoms. Do not overtighten the forcing screw or the flare may become oversized.
  22.  
  23. Back the clamping nut out of the tool body and disassemble the clamping the clamping nut and collet assembly. The flare is now ready for use.
  24.  
  25. Bend the pipe assembly to match the old pipe. Clearance of 0.750 in. (19mm) must be maintained to all moving or vibrating parts.
  26.  

 
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