Procedure I Brake Line Replacement/Work Procedure

TOOLS REQUIRED:

- 13 mm wrench - flare nut type preferred
- 15 mm open wrench
- 5/8" open wrench
- diagonal cutters
- Vice-grip or similar locking pliers

WORK PROCEDURE

With vehicle on hoist and brake pedal pumped 3O-40 times to depressurize system:








1. Using Vice-grip pliers or equivalent, crush and completely flatten the brake line at 2 points - see Illustration # 1 and # 2. This will minimize fluid loss and make the job less messy.

2. Using diagonal pliers, cut the brake line across the center of each crimp and remove the long piece of line.

3. With caps still in place, route new brake line on vehicle. Do not clip to body at this time.

NOTE :
Line fits above fuel line in area of right rear shock absorber (1991 models).

Using illustrations #'s 1 and 2 as a guide:

4. Loosen and remove cut line/fitting at Point C while counterholding at Point D.

5. Remove cap and loosely hand tighten rear of new line to brake hose.

6. Loosen and remove cut line/fitting at Point A. Counterhold at Point B.

7. Connect and fully tighten front of new line to connector. Counterhold at Point B.

8. Allow rear fitting to drip bleed for one minute to purge air from the line. Catch spilled fluid with a rag.

9. Fully tighten rear fitting while counterholding at Point D.

10. Clip line in place along body and floor crossmember. Replace any loose or damaged clips.

11. Top up reservoir with DOT 4 brake fluid and bleed system per the Workshop Manual:

- ABS Vehicles: Section 70- p.55, 56

- Hunter Vehicles: Section 70- p.34, 35

12. Perform Procedure II- Brake Line Bracket Installation.