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post #1 of (permalink) Old 02-02-2001, 09:03 AM Thread Starter
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Can hard brake line be routed wo/disassembly?

I'm putting in SS brake lines and couldn't disconnect the old one at the rear bracket (mucho rust and rounded nut). I'm out of options now so here comes Mr. Dremel. I'm looking at replacing the long hard line going from the master cyl. to the bracket too. Can this be routed without disassembling anything?

'91 YJ, I-6, 2.5" lift, sway bar is in the trash, Currie Boomerang shackles, 31 Michelins, D30 front, D35c with Lock-Right and a light foot
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post #2 of (permalink) Old 02-02-2001, 09:12 AM
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Re: Can hard brake line be routed wo/disassembly?

If it's like my CJ you'll end up replacing the flex line to the rear end lines. That hose and fitting tends to rust together. I was able to get it apart with heat and then pull the retaining clip. I replace all the hard lines with new hard lines from the master cylinder to the proportioning valve and from there to along the frame to the front and the back. It's possible to do so without tub removal or bracketry removal, but it it a tight fit. Go slow, use a torch to free the existing lines and be prepared to sacrafice a part or too. Think before you route the tubes and watch what you're doing. You'll do fine.

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post #3 of (permalink) Old 02-02-2001, 09:22 AM
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Re: Can hard brake line be routed wo/disassembly?

it would be much easier to just replacethe old rusted lines. and in the long run it'll make any future mods. easier to install,if you don't have to fight with old rusted lines. it's not a hard job just take your time thats all. good luck, happy jeepin Gary

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post #4 of (permalink) Old 02-02-2001, 10:40 AM Thread Starter
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Re: Can hard brake line be routed wo/disassembly?

Yeah, get this: the long hard line cost $15 and the short hard line to the rear left drum cost $45 from the dealersip !!! [img]/wwwthreads_images/icons/shocked.gif[/img] Anybody get's this?!? Any other place to get the short line from?

'91 YJ, I-6, 2.5" lift, sway bar is in the trash, Currie Boomerang shackles, 31 Michelins, D30 front, D35c with Lock-Right and a light foot
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post #5 of (permalink) Old 02-02-2001, 11:22 AM
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Re: Can hard brake line be routed wo/disassembly?

If you've got to replace the hard lines accross the rear axle, it's an easy job. Again, heat up the old compression fittings on the wheel cylinder assembly and on the flex line "T". This should free it up. Then go to the autoparts store and get two 60" hard brake lines of the same diameter, a tubing cutter, flairing tool, and a hand bender. The total price for this will be about $25. Then, using your old lines for a form, reform the brake line to the old lines form, cut the tubes and reflair the ends. I'd highly advise coating the newly made tubes with a couple of coats of Hammerite before install. This keeps outside rust to a minimum. The re-install and you're done.... new brake lines on the cheap!

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post #6 of (permalink) Old 02-02-2001, 11:47 AM Thread Starter
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Re: Can hard brake line be routed wo/disassembly?

Thanks, I thought of this but the nut that screws into the wheel cylinder is not open on the inside. Another words, the tube is not going through it it ends inside somehow which is strange. I can't see the flared end of the tube so how is it sealed? I'll look into options of refitting the old lines although I already cut the one attached to the wheel cylinder. I also gotta get me some flare nut wrenches. I should've thought of that earlier (see rounded nut reference above). [sad]

'91 YJ, I-6, 2.5" lift, sway bar is in the trash, Currie Boomerang shackles, 31 Michelins, D30 front, D35c with Lock-Right and a light foot
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post #7 of (permalink) Old 02-02-2001, 01:01 PM
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Re: Can hard brake line be routed wo/disassembly?

On the CJ the tube enters the wheel cylinder from behind the backing plate. The wheel cylinder is held on with two bolts. The tube enter in from between these two bolts. The tube is surrounded by a nut. The nut is a standard type of compression fitting. That is the nut is surrounding the tube and the tube is flaired. The flair fits into the wheel cylinder assembly and then the nut compresses the flair against the machined surface of the wheel cylinder assembly. This forces the tub against the wheel cylinder assembly and prevents fluid leaks. I just looked at the YJ Parts Breakdown in the Quadratec catalog and it looks like the assembly is basically the same. Get a good break wrench that will remove that nut without rounding, apply a little heat to loosen it and you should have no problem removing the tube.

If worse comes to worse you can remove the two bolts, cut the tube and withdraw the wheel cylinder assembly. Remove the guts from the cylinder. Then put it in a vice and heat the bejezzzus out of the fitting and use a good old pair of vice grips tightened as tight as you can get it on the fitting and turn. It should come out. There's got to be a fitting.

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post #8 of (permalink) Old 02-02-2001, 02:52 PM
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Re: Can hard brake line be routed wo/disassembly?

Larry,
I'm assuming that your $25 means renting/borrowing the tools to do this. A quality double flaring tool runs $70 and up. If you do your own tubing you MUST use a double flare. The single ones will crack and your brakes will fail. No ifs, ands, or buts about it.

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post #9 of (permalink) Old 02-02-2001, 04:43 PM
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Re: Can hard brake line be routed wo/disassembly?

I agree, but if the fittings are that rusty, I'd just replace the wheel cylinders also. They aren't very expensive, so if you're going so far as to pull the old ones to get the fittings out it only makes sense.

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post #10 of (permalink) Old 02-02-2001, 07:20 PM
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Re: Can hard brake line be routed wo/disassembly?

Snowtow, explain a double flair. The hand flairing tool produced a flair equal to the OEM flair. I'd like to know more...

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