Brake lines and removal

Tiny
CORY2427
  • MEMBER
  • 2006 DODGE DAKOTA
  • 3.7L
  • 6 CYL
  • 4WD
  • AUTOMATIC
  • 98,245 MILES
Yesterday brake line to front busted. I notice all the lines coming from master cylinder down and ABS box down are rusted like crazy. I am trying to figure out how to remove all and replace and what size brake lines I need.
Thursday, September 13th, 2018 AT 6:47 AM

1 Reply

Tiny
JACOBANDNICKOLAS
  • MECHANIC
  • 108,164 POSTS
Hi and thanks for using 2CarPros. Com.

First, this issue is very common on these vehicles if you live in a snow area where roads are treated. As far as replacing all of the lines, it is a big job. What makes it more difficult is direct fit brake lines are most likely no longer available from the manufacturer. Thus, you need to make them yourself.

If you decide to do it, I strongly recommend getting a copper / nickle line. They will not rust. Next, you will need to purchase a spool of brake line. Take a piece of old line to the parts store with you so they can confirm the size. There are different options and size line used. Additionally, you will need a double flaring tool to make the ends.

If you are not familiar with making a double flare, you may not want to do this. If done incorrectly, they will leak. Once you get the new fittings and line, cut the line to the length needed, put the new fittings on each end, and make a double flare on the tubing. Then you carefully bend the new brake line to fit back into the same location the old one was.

The last thing to worry about is bleeding the system. If the brake lines are rusted, there is a good chance the bleeder valves are rusted too, so make sure to spray them down with penetrating oil and clean them with a wire brush. If the bleeder breaks, you will need to replace the caliper or wheel cylinder it came from.

Let me know if this helps, if you have other questions, or need additional information.

Take care,
Joe
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Thursday, September 13th, 2018 AT 8:01 PM

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