Brake Hose/Line: Service and Repair

Brake Line Repairing

=> [ Flaring Tool Assembly Overview ]

=> [ Instructions ]

Flare brake lines with 5 mm outer diameter using the flaring tool (VAS 6056) without damaging the coating. In this way, the brake lines can be inexpensively partially replaced in certain cases.

Work with brake line kit (V.A.G 1356) is not permitted because of the coating and diameter of the black brake lines.

• Brake lines must not be bent more than 90°, otherwise they kink or deform causing a unacceptable constriction in the line.

• Disconnect the brake lines preferably at the vehicle floor.

• Position of intermediate pieces should be selected so that they cannot rub against moving parts.

• Do not lubricate the spindle, clean only with mineral spirits.

Special tools, testers and auxiliary items required

• Flaring Tool (VAS 6056)

• Brake Charger/Bleeder Unit (VAS 5234)

Listing of Individual Tools










• 1 The threaded pins (in shaft and at sides) are set and must not be adjusted!

Flaring Tool Assembly Overview





1 Upper Part of Flaring Tool

• Remove to change the jaws.

2 Hand Grip Mount

• Must be removed to reach the upper section bolt.

3 Retaining Bolt

• For the upper part of the flaring tool.

4 Flaring Jaws Threaded Pins

• Center and hold the jaws.

• 2 mm head.

5 Flaring Jaws

• Various

• Assembly instructions.

Flaring Jaws Assembly Instructions





• (VAS 6056/6) (dark) for black brake lines

• (VAS 6056/7) (light) for green brake lines

• The arrow on the rounded side of the flaring jaws must face toward the edge of the housing and the straight side of the flaring jaws must be installed toward the spindle, otherwise the flared head will not be formed correctly.

Instructions

- Remove the affected brake line from the brake caliper or wheel cylinder and collect any leaking brake fluid and dispose of it correctly.

- Cut the brake line at the appropriate location (straight, accessible part) with pipe cutter - 2 -.





- Remove the piece to be exchanged.

- Lubricate the brake line surface.

- Clamp the brake line in the pliers - 4 - so that 50 mm of the plastic clamping jaws show.





- Clamp the brake line scraper - 3 - in a drill and place it on the brake line.

- Scrape the coating from brake line at a slow drill speed and with light pressure against the line.

The length of the scraped off portion is determined by the stop in the scraper.

- Remove the scraper from the brake line and remove the scraped remains.

- Remove the pliers and the tube fitting - D - from the brake line.





- Slide the brake line - B - against the stop - A - in the flaring tool.





• Brake line must contact the stop when the hex socket head screws are tightened, otherwise the flared head will not be formed correctly.

- Clamp the brake line in the flaring tool until it cannot be moved any more. Fold the stop - A - up and tighten the hex socket head screws diagonally with the angled screwdriver - C -.





- Turn the spindle in the flaring tool until it stops.





- Turn the spindle back.

- Loosen the hex socket head screws diagonally.

- Remove the brake line from the flaring tool, clean and check the brake line and flared head.

Briefly rinse the part of the brake line remaining in the vehicle.

- Connect the (VAS 5234), place the bleeder container hose on the flanged head of the brake line and run the (VAS 5234) briefly until some brake fluid runs through.

- Clean the brake line with compressed air.

- Join the brake lines with a connecting piece - E -.





- Assemble the brake line.

- Bleed the brake system. Refer to => [ Brake System Bleeding ] Service and Repair.