Brake Hose/Line: Service and Repair
Brake Lines, Repairing
Special tools, testers and auxiliary items required
• Brake line flaring appliance (VAS 6056)
• Brake filler/bleeder unit (VAS 5234)
• Flare brake lines with 5 mm outer diameter using Flaring Tool (VAS 6056) without damaging coating. In this way, brake lines can be inexpensively partially replaced in certain cases.
• Working with the flaring appliance (V.A.G 1356) is not permitted due to the coating and the diameter of the black brake lines.
• The brake lines may be bent maximum 90° otherwise they will break or be permanently deformed.
• If the brake line is bent more than 90°, the diameter of the line will be changed.
• Disconnect brake lines preferably at underbody.
• Position of intermediate pieces should be selected so that they cannot rub against moving parts.
• Do not lubricate spindle, clean only with mineral spirits.
Listing of Individual Tools
1 Flaring Appliance (VAS 6056/1)
• The flaring jaws (VAS 6056/6) are installed in the flaring appliance (VAS 6056/1).
2 Tube Cutter (VAS 6056/2)
3 Brake Line Shearing Tool (VAS 6056/3)
• The threaded pins (in shaft and at sides) are set and must not be adjusted!
4 Self-Grip Pliers with Plastic Clamping Jaws (VAS 6056/4)
5 Line Bending Tool (VAS 6056/5)
6 SW6 Angle Screwdriver
7 Flaring Jaws (VAS 6056/7)
Flaring Tool Overview
1 Upper Part of Flaring Tool
• Remove to change flaring jaws.
2 Hand Grip Mount
• must be removed to reach the upper section retaining bolt.
3 Bolt
• For upper part of flaring tool.
4 Flaring Jaws Threaded Pins
• Center and hold the flaring jaws.
• 2 mm hex socket head.
5 Flaring Jaws
• Various
Flaring Jaws Assembly Instructions
• (VAS 6056/6) (dark) for black brake lines
• (VAS 6056/7) (light) for green brake lines
• The arrow on the rounded side for the flaring jaws must point toward the edge of the housing.
• The straight side of the flaring jaws must be installed toward spindle, otherwise flared head will not be formed correctly.
Instructions
- Remove the brake line from the brake caliper or brake cylinder. Be sure to catch any leaking brake fluid and dispose of it correctly.
- Cut the brake line at a suitable place (straight, easily accessible piece) with the tube cutter - 2 -.
- Remove piece to be exchanged.
- Lubricate brake line surface.
- Pinch the brake line in a set of locking pliers - 4 - so that 50 mm is sticking out of the plastic jaws.
- Install the peeling tool - 3 - in a power drill and place it on the brake line.
- Shear coating from brake line at a slow drill RPM and with light pressure against the line.
• The length of the sheared-off portion is determined by the stop in the shearing tool.
- Remove shearing tool from brake line and remove shavings.
- Remove the locking pliers and push the tube fitting - D - onto the brake line.
- Push the brake line - B - against the stop - A - inside the flaring tool.
• Brake line must contact stop when hex socket heat screws are tightened, otherwise flared head will not be formed correctly.
- Pretension the brake line inside the flaring unit until the brake line can no longer be moved. Fold up the stop - A - and tighten the hex socket head bolts diagonally with a special long-reach wrench - C -.
- Turn the spindle all the way in the flange unit.
- Turn the spindle back.
- Loosen the hex socket head bolts diagonally.
- Remove the brake line from the flange unit.
- Check and clean the brake line and the flared head.
Briefly rinse part of brake line remaining in vehicle.
- Connect the (VAS 5234) , place the bleeder container hose on the flared head of the brake line and run the (VAS 5234) briefly until some brake fluid runs through.
- Clean the brake line with compressed air.
- Join brake lines with connecting piece - E -.
- Assemble brake line.
- Bleeding hydraulic system. Refer to => [ Hydraulic System, Bleeding ] Service and Repair.