Brake Line Repair

NOTE:
This procedure must only be performed if brake fluid leakage caused by brake tube contact with the floor pan is present in the area between the transmission crossmember and the floor pan and only if the brake tubes can be spliced.





1. Mark the location of the # 3 and # 4 bundle clips (nearest the transmission crossmember) on the frame rail and fuel tubes to assure proper positioning of the new clips. See Figure 5.





2. Remove the bolts for the # 3 and # 4 bundle clips. See Figure 6.

3. CAUTION: Do not damage the brake or fuel tubes while removing them from the clips.

Carefully pry the brake and fuel tubes out of the clips and remove the clips from the vehicle. Discard the clips.





4. Using a small-frame tube cutter, cut the brake tube(s) as shown in Figure 7.

5. Obtain the needed length of 6-mm bulk brake tubing and appropriate unions to replace the cut out section(s).

6. NOTE: Install the union fittings onto the tubes prior to making the flares.

Using a commercially available flare tool, make 45° (SAE) double flares on all tube ends.

7. Using the removed brake tube as a guide, bend the new brake tube to match the contour of the old brake tube.

8. Install the new tube(s) and tighten the union fittings hand tight.

9. CAUTION: Do not damage the brake, air or fuel tubes while installing them into the new clips.

CAUTION:
Position the new clips in the same location as the originals before installing any tubes. The clips will be very difficult to reposition once tubes are installed.





NOTE:
The new clips are designed to reposition the brake tubes away from the floor pan. Position the fuel, brake and air suspension tubes into the new # 3 bundle clip in the sequence shown in the illustration below. See Figure 8.

10. Install the bolts. Tighten to 15 Nm (11 lb-ft).





11. CAUTION: When tightening the brake tube union fittings, a crowfoot adapter must be used on a torque wrench. This increases the length of the tool and changes the actual torque value. To achieve the proper torque on the fasteners, you must use the formula provided in this document to calculate the proper setting for the torque wrench/crowfoot you are using. See Figure 9.

Tighten the brake tube union fittings to the calculated torque specification to achieve 16 Nm (12 lb-ft).

12. If necessary, adjust the brake tubes away from the floor pan and transmission crossmember. There should be at least 8 mm (approximately 3/8 inch) clearance between the tubes and floor pan or crossmember.

13. Lower the vehicle. Turn the air suspension switch ON,if equipped.

14. Proceed to Brake System Bleeding in this Attachment III.