Procedures

Brake Lines, Repairing

Special tools, testers and auxiliary items required

• Flaring Tool For Brake Lines (VAS6056)

• Brake Filling and Bleeding Equipment (VAS 5234)

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


Working with the (V.A.G 1356) is not permitted due to the coating and the diameter of the black brake lines.

• The brake lines may be bent maximum 90° otherwise they will break or be permanently deformed.

• If the brake line is bent more than 90°, the diameter of the line will be changed.

• Disconnect brake lines preferably at underbody.

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

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

Listing of Individual Tools






1 Flaring Tool (VAS6056/1)

• The flanging unit (VAS 6056/6) are installed in the (VAS 6056/1)

2 Tube Cutter (VAS 6056/2)

3 Brake Line Scraper (VAS6056/3)

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

4 Set Of Grips With Plastic Jaws (VAS6056/4)

5 Pipe Bending Tool (VAS 6056/5)

6 SW6 Angle Screwdriver

7 Flaring Jaws (VAS 6056/7)

Flaring Tool, Assembly Overview






1 Upper Part Of Flaring Tool

• Remove to change flaring jaws.

2 Hand Grip Mount

• Must be removed to reach the upper section retaining bolt.

3 Bolt

• For upper part of flaring tool.

4 Flaring Jaws Threaded Pins

• Center and hold the flaring jaws.

• 2 mm hex socket head

5 Flaring Jaws

• Various

• Assembly instructions, refer to.

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 for the flaring jaws must point toward the edge of the housing.

• The straight side of the flaring jaws must be installed toward spindle, otherwise flared head will not be formed correctly.

Instructions

- Remove the brake line from the brake caliper or brake cylinder. Be sure to catch any leaking brake fluid and dispose of it correctly.

- Cut the brake line at a suitable place (straight, easily accessible piece) with the tube cutter - 2 -.






- Remove piece to be exchanged.

- Lubricate brake line surface.

- Pinch the brake line in a set of locking pliers - 4 - so that 50 mm is sticking out of the plastic jaws.






- Install the peeling tool - 3 - in a power drill and place it on the brake line.

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

• The length of the sheared-off portion is determined by the stop in the shearing tool.

- Remove shearing tool from brake line and remove shavings.

- Remove the locking pliers and push the tube fitting - D - onto the brake line.






- Push the brake line - B - against the stop - A - inside the flaring tool.






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

- Pretension the brake line inside the flaring unit until the brake line can no longer be moved. Fold up the stop - A - and tighten the hex socket head bolts diagonally with a special long-reach wrench - C -.

- Turn the spindle all the way in the flange unit.






- Turn the spindle back.

- Loosen the hex socket head bolts diagonally.

- Remove the brake line from the flange unit.

- Check and clean the brake line and the flared head.

Briefly rinse part of brake line remaining in vehicle.

- Connect the (VAS 5234) , place the bleeder container hose on the flared 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 brake lines with connecting piece - E -.






- Assemble brake line.

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