Service Procedure
Tools RequiredJ 45405 ISO Metric Bubble Flaring and 45 Degree Inverted Flaring Kit (contact your regional headquarters to obtain a tool on loan).
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
2. Remove the right front tire and wheel. Refer to Tire and Wheel Removal and Installation in SI.
3. Remove the right-hand side wheelhouse panel. Refer to Wheelhouse Panel Replacement in SI.
4. Remove the front air deflector. Refer to Front Air Deflector Replacement in SI.
5. Remove the four fuel and brake line bundle clips along the right frame rail. The first fuel and brake line bundle clip (1) is located to the rear of the cradle near the catalytic converter. The last fuel and brake line bundle clip (4) is located near the exhaust insulator, hanger and bracket location. Refer to the illustration.
6. Remove the fuel and brake line bundle clip and bracket (1) located forward of the cradle and underneath the rear portion of the wheelhouse panel. The fuel and brake line bundle is between the catalytic converter (2) and protective heat wrap (3).
7. Cut the two brake lines. The brake lines should be cut within 25 mm (1 in) rearward of second fuel and brake line bundle clip. Mark the left and right rear brake lines with a marker or tape.
8. The right rear brake line is wrapped with red tape (1). Before removing the brake line, mark the port and nut location with a red marker. The left rear brake line is wrapped with green tape.
9. Remove the brake tube nuts (1) from the ABS module.
10. Remove the brake line bundle clips (1) near the alternator (3).
Notice:
Do not push the brake lines forward toward the ABS module to avoid damaging the steering assembly.
Important:
Use two technicians to perform steps 11-14. One technician will guide the brake line rearward of the catalytic converter. The second technician will route the brake lines from the ABS module location
11. Remove the two brake lines from the vehicle. Pull the brake lines away from the ABS module along the frame rail.
12. Route the right rear brake line (line wrapped with red tape) along the frame rail to the ABS module.
13. Connect right rear brake line to the ABS module. Tighten the nuts (1).
Tighten
Tighten the nuts (1) to 20 Nm (15 lb-ft).
14. Route the left rear brake line (line is wrapped with green tape) along the frame rail to the ABS module.
15. Connect the right rear brake line to the ABS module. Tighten the nuts (1).
Tighten
Tighten the nuts (1) to 20 Nm (15 lb-ft).
IMPORTANT:
The right rear brake line must be inserted into the red (1) area of the brake bundle clip. The left rear brake line must be inserted into the green (2) area of the brake bundle clip.
16. Install the two brake line bundle clips (1) located near the alternator (3).
17. Flare the existing brake lines using J-45405, ISO Metric Bubble Flaring and 45 Degree Inverted Flaring Kit. Use 3/16-inch detail included with J-45405 tool.
18. Attach protective heat wrap (1) around the brake lines. Push the protective heat wrap (1) up and forward to the catalytic converter (3) and cradle location.
19. Connect the new brake lines with the existing brake lines with a union (1). The union for these brake lines is between the second and third fuel and brake line bundle clip. Adjust the cut of the existing brake line to the union location.
20. Install the fuel and brake line bundle clip (1) and bracket (2) forward of the cradle and underneath the rear portion of the wheelhouse panel.
21. Install the three fuel and brake line bundle clips (locations 2, 3 and 4). Refer to the illustration.
22. Install the right-hand side wheelhouse panel. Refer to Wheelhouse Panel Replacement in SI.
23. Install the front air deflector. Refer to Front Air Deflector Replacement in SI.
24. Install the right front tire and wheel. Refer to Tire and Wheel Removal and Installation in SI.
25. Lower the vehicle.
26. Bleed the brake system. Refer to Hydraulic Brake System Bleeding in SI.