Brake Tube Replacement
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 near the transmission crossmember and only if the brake tubes cannot be spliced. Both rear brake tubes will be replaced from the ABS hydraulic control unit (HCU) to their connections with the rear brake tubes in the area near the left rear wheel. The original tubes will be cut out and the new lines will be installed in three (3) sections, eliminating the need to remove the vehicle body.
REMOVAL
1. Open the hood.
2. Remove the air cleaner assembly and outlet tube.
3. CAUTION: Use caution to avoid damaging tubes that are not being serviced when removing tubes from any of the separator or bundle clips.
NOTE:
There are a total of six (6) brake tubes attached to the ABS HCU.
^ The two (2) on the very top are the supply tubes.
^ The four (4) tubes on the side are the "delivery" tubes leading to front and rear wheels.
^ The two (2) "rear" delivery tubes that are being replaced are located on the side of HCU closest to the front of the vehicle.
NOTE:
Before disconnecting or removing any brake tubes, note the routing and location of the tubes in relation to other tubes and nearby components.
Disconnect the two (2) tubes for the rear brakes from the ABS HCU. See Figure 10.
4. Note the positions of the brake tubes in the black separator clips, then disengage the two (2) rear brake tubes from the black separator clips in the engine compartment. Keep the separator clips attached to the other tubes. See Figure 10.
5. Remove the bolt for the # 1 bundle clip (located on the frame rail in front of the dash panel below the brake booster). See Figure 11.
6. Partially raise the vehicle on the hoist.
7. Remove the left rear wheel and tire assembly.
8. Mark the location of the # 7, # 8 and # 9 bundle clips on the frame rail, then remove the bolts for the # 7 and # 9 bundle clips (located on the frame around the left rear wheel area - accessible once the wheel is removed). The # 8 clip has no bolt. See Figure 12.
9. Disengage the small white separator clip from the brake tube near the fuel filler neck. Retain the clips for reuse. See Figure 13.
10. Disconnect the brake tubes at the left rear brake jounce hose and at the brake crossover tube leading to the right rear brake assembly. See Figure 13.
11. Remove the fuel tank side shield, held in place on the frame with two (2) pushpins. See Figure 13.
12. CAUTION: Prior to removing the brake tubes from the # 7, # 8 and # 9 bundle clips, pay close attention to the position of the tubes in the clips.
^ The outboard tube is connected to the crossover tube leading to the right rear brake.
^ The inboard tube is connected to the left rear brake jounce hose.
Upon installation of the new tubes, this positioning must be maintained. Do not allow the tubes to crisscross.
Carefully pry the brake tubes out of the # 7, # 8 and # 9 bundle clips. Remove the # 7 bundle clip from the vehicle.
13. Raise the vehicle on the hoist.
14. Disconnect the left heated oxygen sensor (HO2S) and catalyst monitor sensor (CMS), then remove the left catalytic converter.
15. NOTE: The # 3 and # 4 bundle clips are supplied with the newtubes. Separator clips (small white clips and larger black clips) are supplied on the new tubes primarily to maintain their orientation during shipment. Except in locations that interfere with tube positioning or bundle clip installation, these clips may remain on the tubes after installation.
To gain access to the # 2 bundle clip bolt, pull the noise shield down from between the frame rail and the floor pan and let it hang near the transmission. See Figure 14.
16. Mark the locations of all the bundle clips on the frame and on the fuel tubes.
17. Remove the # 2 bundle clip bolt. See Figure 14.
18. Remove the bolts for the # 3, # 4, # 5 and # 6 bundle clips. See Figure 15.
19. Carefully pry the air, fuel and brake tubes out of the bundle clips.
20. NOTE: It is recommended that the old tubes be cut in the same locations as the union fittings located on the new service tubes. This will allow you the opportunity to remove the old lines in the reverse direction of the new lines to be installed. These locations are at left front "torque box", or above where the cross brace is bolted to the underside of the square section of frame, and above the fuel filter mounting area where the brake tubes bend upwards to cross over the frame.
Using side cutters or equivalent, and following the new brake tubes as a guide, cut the brake tubes into sections. See Figure 16.
19. Carefully pry the air, fuel and brake tubes out of the bundle clips.
20. NOTE: It is recommended that the old tubes be cut in the same locations as the union fittings located on the new service tubes. This will allow you the opportunity to remove the old lines in the reverse direction of the new lines to be installed. These locations are at left front "torque box", or above where the cross brace is bolted to the underside of the square section of frame, and above the fuel filter mounting area where the brake tubes bend upwards to cross over the frame.
Using side cutters or equivalent, and following the new brake tubes as a guide, cut the brake tubes into sections. See Figure 16.
21. NOTE: While removing the front section of brake tubes, do not remove the brake tubes from the #1 bundle clip. It will be necessary to transfer the bundle clip to the new tube assembly prior to installation and having the clip in the original position will assist in proper positioning onto the new tubes.
NOTE:
During tube removal, try not to bend the lines or force them out of the vehicle. Pay particular attention to how the tubes must be positioned and rotated or maneuvered in order to install the new tubes into their proper locations. This is most important when installing the rear sections over the frame rail and the front sections up along the frame into the engine compartment
Remove the brake tube sections as follows:
^ Front Section -
a) Remove this section from beneath the vehicle, noting the location of surrounding components such as the steering shaft, shift cable, wire harnesses, fuel, air and other brake tubes.
^ Center Section -
a) Remove this section sliding it from behind the body mount then around the transmission crossmember.
b) The crossmember and parking brake cable DO NOT have to be removed.
^ Rear Section -
a) Partially lower the vehicle if necessary.
b) Gently maneuver the rear-most end of the brake tubes up and around the frame behind the axle first.
c) Carefully twist the tube to free it from around the frame forward of the axle and remove it from the vehicle from the wheel house area.
INSTALLATION
For detailed views of the new brake tubes installed, see figures 17 through 26.
1. CAUTION: Keep all caps in place in the tube ends during installation to avoid getting foreign material in the brake tubes.
CAUTION:
Do not force or bend the brake tubes during installation.
Install the new brake tubes as follows:
^ Rear Section -
a) Start by carefully inserting the tubes in over the frame in front of the rear axle, twisting the tubes over the frame.
b) Maneuver the tubes over the frame behind the axle.
c) The tubes should not be under stress when positioned. They should rest naturally in place on the frame rail and should align with their corresponding connectors.
d) Make sure the tubes are positioned and installed in the # 7, # 8 and # 9 clips as the original tubes were (parallel to each other and do not crisscross).
^ The outboard tube must be connected to the crossover tube leading to the right rear brake.
^ The inboard tube must be connected to the left rear brake jounce hose.
e) Remove the shipping caps and loosely connect the tubes to their corresponding connectors. Do not fully tighten at this time.
f) Inspect the area of the new brake tubes where the # 8 bundle clip was originally located on the frame. The black plastic coating on the brake tubes will interfere with installation of the # 8 bundle clip. Avoid installing the clip over the plastic coating by positioning the clip rearward a few millimeters. DO NOT trim the plastic coating. Damage to the corrosion protection beneath the plastic coating may occur. See Figure 26.
^ Center Section -
a) Partially raise the vehicle, if necessary.
b) Guide this section up and over the transmission crossmember and parking brake cable, then through the body mount.
c) Position the fuel, brake and air suspension tubes into the new # 3 bundle clip in the sequence shown in the illustration. See Figure 20.
d) Position the new fuel, brake and air suspension tubes into the # 4 bundle clip into the appropriate slots of the new clips.
e) Remove the shipping caps then loosely connect the tubes to their corresponding connectors on the rear section of the brake tubes. Do not fully tighten at this time.
f) Position onto the frame rail, but do not install the bolts for the # 5 and # 6 bundle clips, and carefully clamp all tubes into their proper slots of the clips.
^ Front Section -
NOTE:
Once the tubes are installed into the bundle clips, it is very difficult to reposition the clips along the tubes. Be sure the bundle clips are positioned properly along the tubes before snapping the tubes into the clips.
a) Transfer the # 1 bundle clip onto the new tube assembly using the removed tube section as a guide.
b) From beneath the vehicle, guide the forward tube section up between the frame rail and the engine.
c) If necessary, have an assistant on a ladder or platform to help guide the tube section in place.
d) Position the tube section properly around the other tubes, the shift cable, steering shaft and the wire harnesses.
e) Position the # 1 bundle clip between the frame rail and the fuel tubes, but DO NOT engage the tubes into the clip at this time.
f) Remove the shipping caps then loosely connect the tubes to their corresponding connectors on the center tube section.
g) Partially lower the vehicle.
h) Loosely connect the tubes to the HCU fittings.
i) Inspect the existing black bundle clips. Replace only if damaged. It is recommended that the original clips be used to minimize any possible damage that could occur while prying the other tubes out of the clips. Discard the unused black bundle clips and secure all brake tubes to the remaining clips.
j) Install the bolt at the # 1 bundle clip.
k) Raise the hoist.
l) Remove the small white separator clip from the lower end of the tube assembly.
m) Remove the shipping caps and loosely connect the tubes to the center tube section.
n) Install the # 2 bundle clip, then engage the fuel, air and brake tubes to it.
o) Engage the fuel tubes to the # 1 bundle clip.
^ Final Assembly -
a) With all brake tube sections installed and loosely connected to each other, install the remaining bundle clip bolts. Tighten the bolts to 15 Nm (11 lb-ft). Note: Bolts for # 1, # 2, # 3, # 7 and # 9 bundle clips will not be accessible with a torque wrench. Using hand tools, be sure these are sufficiently hand tightened.
b) Inspect that all necessary small white separator clips and black rubber insulators are in place and properly secured to the brake tubes. See Figures 13, 17, 18, 19 and 23. Four (4) extra rubber grommets are provided in the service kit. These grommets are to be used to assure brake tube-to-brake tube clearance, along with brake tube clearance to fuel tubes, vapor tubes, air suspension tubes and the vehicle frame rail. They ARE NOT to be used to provide clearance between the brake tubes and the floor pan. If the brake tubes are within 8 mm (approximately 3/8 inch) of the floor pan, manually adjust the tubes to obtain the minimum clearance.
c) Inspect the entire length of the newly installed brake tubes for any contact with the frame or surrounding components. Adjust tubes as necessary to obtain at least 8 mm (approximately 3/8 inch) clearance from any stationary object.
d) Reposition the noise shield back above the frame rail.
e) Install the plastic fuel tank shield using the two (2) pushpins.
f) Tighten all brake tube union connections to 16 Nm (12 lb-ft).
g) Install the left catalytic converter using a new flange gasket and new attaching hardware. Tighten the flange bolts and the manifold nuts to 41 Nm (30 lb-ft). Connect the HO2S and CMS sensor connectors.
h) Install the left rear wheel and tire assembly. Tighten the wheel nuts to 129 Nm (95 lb-ft).
i) Install the air cleaner assembly and outlet tube. Tighten tube clamps and assembly nuts to 3Nm (27 lb-in).
j) Proceed to Brake Bleeding in this Attachment III.