Brake Tube Flaring

Use only double wall 4.75 mm (3/16 inch) steel tubing with Nygal coating for hydraulic brake tube replacement. Nygal is nylon coated galvanized steel tubing.
Care must be taken when repairing brake tubing to avoid kinking the tube. Use the proper bending and flaring tools. Do not route the tubes against sharp edges, moving components, or into hot areas. All tubes should be attached with the recommended retaining clips.

PREPARING THE BRAKE TUBE FOR FLARING

Cutting And Flaring Of Brake Fluid Tubing:

1. Use Tubing Cutter, Special Tool C-3478-A, or an equivalent to cut off the damaged flare or tubing.

Tube End Properly Prepared For Flaring:

2. Make the ends of the tubing to be repaired square to ensure better seating of the flared end tubing.
3. Ream out any burrs or rough edges showing on the inside of the tubing to be flared.
4. Strip back enough of the nylon coating at the end of the length of tubing that will flared so it will not be in the flare itself. At least 5 mm should be removed.

NOTE: Place a tube nut on the tubing before flaring it. It cannot be done after the tube is flared.

DOUBLE INVERTED TUBING FLARES

Double Inverted Brake Tube Flare:

After preparing the tubing using the procedure in PREPARING THE BRAKE TUBE FOR FLARING, make a double inverted tubing flare using the following procedure.

CAUTION: When using brake tubing with Nygal coating, always use flare nuts designed for this coating. They have a larger hole in the center to accommodate the coating on the tube.






1. Install the replacement flare nut on the tube so the threads are facing the flare yet to be made.
2. Open the Flaring Tool, Special Tool C-4047 (or an equivalent), separating the tools vertical posts.
3. Place the tubing in the jawed hole between the two vertical posts.
4. Slowly bring the vertical posts together capturing the tube between the halves. Leave enough tubing sticking through the top of the vertical posts to allow for flaring. Apply only enough pressure to hold the tube in place.
5. Place the gauge (From A) over the end of the brake tube. Adjust the tube height in the tool's jaws until the end of the tube contacts the recessed notch in the gauge that matches the tubing size. Squeeze the handles of the flaring tool, locking the tubing in place. Remove the gauge.
6. Place the 3/16 inch plug gauge (A) down into the end of the tube. Tighten the flaring handle, pushing the gauge into the tube until the gauge contacts the vertical posts of the tool.
7. Release the flaring handle and remove the plug gauge from the partially flared tube.
8. Tighten the flaring handle down once more until the tools flaring tip has firmly seated the tube to the vertical posts, thus completing the flare.

CAUTION: When inspecting the flare, make sure no tubing Nygal coating has been involved in the flare.

9. Remove the flared tube from the flaring tool and inspect the flare to make sure it is uniform.