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Brake line replacement

 
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Brake line replacement - 19/5/2012 16:01:40  2 votes
chevychase


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Right guys i promised the low down on the vans brake line replacement once i had done my van, only the large pipe was picked up on the MOT but since i was disturbing the system quite drastically decided to go with replacing it all.

Apologies for the simple diagram but gives you an idea.


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RE: Brake line replacement - 19/5/2012 16:06:48   
chevychase


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As you can see 2 sizes of brake pipe used. Americans use steel pipe but i used copper kunifer pipe which is very easy to bend.

You require 1/4" pipe - the main pipe front to back that goes over the fuel tank and usually the main culprit for MOT faliures.
and 3/16" pipe that goes to all calipers/drums.

Take note that both 1/4" and 3/16" pipe go from the master cylinder to the ABS control module.




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RE: Brake line replacement - 19/5/2012 16:10:20   
chevychase


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Next there are the rubber hoses that go directly to the front calipers and one that goes to the rear axle, this one has the block that takes the 1/4" pipe in and the 2 3/16" pipes out to the rear drums (check out my diagram).
All avaliable from USautomotive.


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RE: Brake line replacement - 19/5/2012 16:15:16   
djmadwon


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Great post, keep on with your updates

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RE: Brake line replacement - 19/5/2012 16:16:04   
chevychase


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And finally the brake line nuts. This was a real pain to get the sizes, not even the US forum had this info!

For the 1/4" pipe you require 7/16"-24 tpi UNF short nuts.

For the 3/16" pipe you require 3/8"-24 tpi UNF short nuts

Very important the short nuts as you can see by the pictures as standard European nuts are long and have a small wasted bit at the end.

All availiable from USautomotive.
(apologies for the blurred photos!)


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RE: Brake line replacement - 19/5/2012 16:24:20   
chevychase


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And finally the master cylinder nuts which are larger than the other nuts as they have a 9/16" head. Could only get one for the 3/16" pipe as the 1/4" one is still a mystery. Managed to reuse my nuts from the master cylinder thankfully.

This was quite an undertaking and took about 10 hours hard graft and alot of bleeding but the system should be good for many years to come. No need to drop the fuel tank as you can manoeuvre the 1/4" pipe through no problems, all the plastic clips were good too and where the odd one died used cable ties of which MOT man was happy.

Hope this helps anyone in the same position.


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RE: Brake line replacement - 26/5/2012 10:07:28   
bowtie262


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Fantastic work,

this is a really informative post,
with information that is almost impossible to find elsewhere on the internet.

I know, I tried, and posted a question asking for the information,, without sucess.
Eventually, after quite a time I managed to clean up the hexagons of my old brake-line nuts
to a point where I felt happy that they'd be 'up to' the important job they have to do.

Getting the correct brake line nuts is vital for safety,
using 'something-similar' that threads on,, is just NOT SAFE.

So, well done, Chevychase for finding and sharing this information with us.

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RE: Brake line replacement - 26/5/2012 14:48:39   
yankee doodle


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Well done Jim, a very informative post. Great work.

Can I ask you what lengths of 1/4 and 3/16 copper pipe did you use? Presumably you have to buy the pipe by the metre?


John

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RE: Brake line replacement - 26/5/2012 15:53:32   
chevychase


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I bought a 25 FT roll of each so had lots to play with and mess up. Loads on EBAY anywhere from £15 to £25.
For the 1/4" pipe you only really need half that amount its the 3/16" you will use a lot of.
Drove her around for a couple of days and gave her another good bleed and she stops real sweet now.

Amazing what a complete change of fluid in the whole system can do. Just need to treat her to new discs later in the year now!

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