Mitsubishi Pick-ups and Montero 1983-1995 Repair Guide

Brake Hoses and Lines



See Figure 1

Metal lines and rubber brake hoses should be checked frequently for leaks and external damage. Metal lines and particularly prone to crushing and kinking under the car. Any such deformation can restrict the proper flow of fluid and therefore impair braking at the wheels. Rubber hoses should be checked for cracking or scraping; such damage can create a weak spot in the hose and it could fail under pressure.

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Fig. Fig. 1: Brake line routing for 1990-95 Pick-ups-although slight differences are present, other models and years are similar

Any time the lines are removed or disconnected, extreme cleanliness must be observed. The slightest bit of dirt in the system can plug a fluid port and render the brakes defective. Clean all joints and connections before disassembly (use a stiff brush and clean brake fluid) and plug the lines and ports as soon as they are opened. New lines and hoses should be blown or flushed clean before installation to remove any contamination with clean brake fluid. To replace a line or hose:

  1. Raise and safely support the vehicle on jackstands.
  3. Remove wheel(s) as necessary for access.
  5. Clean the surrounding area on the joints to be disconnected.
  7. Place a catch pan under the joint to be disconnected. To reduce fluid spillage during the repair, either plug the vent hole in the reservoir cap or substitute a cap with no vent hole.
  9. Using two wrenches-one to hold the joint and one to turn the fitting-disconnect the hose or line to be replaced.
  11. Disconnect the other end of the line or hose, moving the drain pan if necessary. Always use two wrenches if possible.
  13. Disconnect any retaining clips or brackets holding the line and remove the line.
  15. If the system is to remain open for more time than it takes to swap hoses, tape or plug each remaining line and port to keep dirt out and fluid in.
  17. Install the new line or hose, starting the end farthest from the master cylinder first. Connect the other end and confirm that both fittings are correctly threaded and turn smoothly with the fingers. Make sure the new line will not rub against any other part. Brake lines must be at least 1 / 2 in. (13mm) from the steering column and other moving parts. Any protective shielding or insulators must be reinstalled in the original location.

If the new metal line requires bending, do so gently using a pipe bending tool. Do not attempt to bend the tubing by hand; it will kink the pipe and render it useless.

  1. Using two wrenches as before, tighten each fitting to 9-12 ft. lbs. (13-17 Nm).
  3. Install any retaining clips or brackets on the lines.
  5. Refill the brake reservoir and replace the unvented cap if one was substituted.
  7. Bleed the brake system beginning with the wheel closest to the replaced hose.
  9. Install the wheels and lower the vehicle to the ground.