Brake hoses and lines — inspection and replacement
Inspection
1. About every six months, with the vehicle raised and supported securely on jack stands, the rubber hoses which connect the steel brake lines with the front and rear brake assemblies should be inspected for cracks, chafing of the outer cover, leaks, blisters and other damage. These are important and vulnerable parts of the brake system and inspection should be complete. A light and mirror will be helpful for a thorough check. If a hose exhibits any of the above conditions, replace it with a new one.
Replacement
Disc brake hose (front or rear)
2. Loosen the wheel lug nuts, raise the vehicle and support it securely on jack stands. Remove the wheel.
3. At the frame bracket, unscrew the brake line fitting from the hose (see illustration). Use a flare-nut wrench to prevent rounding off the corners. If the bracket begins to bend, hold the hose fitting with an open-end wrench.
i. 3 Unscrew the brake line threaded fitting with a flare-nut wrench to protect the fitting corners from being rounded off
4. Remove the U-clip from the female fitting at the bracket with a pair of pliers (see illustration), then pass the hose through the bracket.
i. 4 Pull off the U-clip with a pair of pliers
5. At the caliper end of the hose, remove the banjo fitting bolt, then separate the hose from the caliper. Note that there are two copper sealing washers on either side of the fitting — they should be replaced with new ones during installation.
6. Unbolt the hose from the bracket on the strut, where applicable.
7. Installation is the reverse of removal. Make sure the hose isn’t twisted. Tighten the banjo bolt to the torque listed in this Chapter’s Specifications, and tighten the brake hose-to- brake line fitting securely.
8. Bleed the caliper (see Brake hydraulic system — bleeding).
9. Install the wheel and lug nuts, lower the vehicle and tighten the lug nuts to the torque listed in the Tune-up and routine maintenance Specifications.
Metal brake lines
10. When replacing brake lines, be sure to use the correct parts. Don’t use copper tubing for any brake system components. Purchase steel brake lines from a dealer or auto parts store.
11. Prefabricated brake line, with the tube ends already flared and fittings installed, is available at auto parts stores and dealer parts departments. These lines can be bent to the proper shape with a tubing bender.
12. When installing the new line, make sure it’s securely supported in the brackets and has plenty of clearance between moving or hot components.
13. After installation, check the master cylinder fluid level and add fluid as necessary. Bleed the brake system (see Brake hydraulic system — bleeding) and test the brakes carefully before driving the vehicle in traffic.