Brake Tubing Repair/Tube Flaring

BRAKE TUBE REPAIR
This vehicle use two different size master cylinder brake tubes.

The master cylinder brake tubes used on this vehicle are different sizes. Vehicles that are not equipped with antilock brakes use double wall 4.75 mm (3/16 inch) brake tubes at all four ports on the master cylinder. On vehicles equipped with antilock brakes' the master cylinder brakes tubes between the master cylinder and the antilock brake hydraulic control unit are 6.00 mm (1/4 inch).

The chassis brake tubes used on all vehicles is double wall 4.75 mm (3/16 inch) steel tubing.

When replacing or repairing chassis brake tubes on this vehicle be sure that the correct size and type of tube nuts are to be used for replacement of a hydraulic brake tube.

All chassis brake tubes used on this vehicle are coated with Al-rich/ZN-AL alloy coating to prevent corrosion of the brake tubes.

Care should be taken when repairing brake tubing, to be sure the proper bending and flaring tools and procedures are used, to avoid kinking. Do not route the tubes against sharp edges, moving components or into hot areas. All tubes should be properly attached with recommended retaining clips.

Cutting And Flaring Of Brake Fluid Tubing:

Tube End Properly Prepared For Flaring:

Using Tubing Cutter, Special Tool C-3478-A or equivalent, cut off damaged seat or tubing. Ream out any burrs or rough edges showing on inside of tubing. This will make the ends of tubing square and ensure better seating of flared end tubing. Place tube nut on tubing before flaring the tubing.

DOUBLE INVERTED TUBING FLARES

Double Inverted Brake Tube Flare:

To make a double inverted tubing flare, open handles of Flaring Tool, Special Tool C-4047 or equivalent. Then rotate jaws of tool until the mating jaws of tubing size are centered between vertical posts on tool. Slowly close handles with tubing inserted in jaws but do not apply heavy pressure to handle as this will lock tubing in place.

Place gauge (Form A) on edge over end of brake tubing. Push tubing through jaws until end of tubing contacts the recessed notch in gauge matching the tubing size. Squeeze handles of flaring tool and lock tubing in place. Place the proper size plug in end of tubing. Swing compression disc over gauge and center tapered flaring screw in recess of disc. Screw in until plug gauge has seated on jaws of flaring tool. This action has started to invert the extended end of the tubing. Remove gauge and continue to screw down until tool is firmly seated in tubing. Remove tubing from flaring tool and inspect seat. Replace any damaged tube routing clips.