WARNING: COPPER TUBING SHOULD NOT BE USED IN THE HYDRAULIC SYSTEM. USE ONLY SAE J526 OR J527 OR EQUIVALENT STEEL TUBING.Section 06-06: Brake System, Hydraulic | 1996 F-150, F-250, F-350, Bronco and F-Super Duty Workshop Manual |
Steel tubing is used in the hydraulic lines between the brake master cylinder (2140) and the front brake tube connector and between the rear brake tube connector and the rear wheel cylinder (2261). Steel tubing is also used to connect the brake master cylinder to the flexible brake hose at the rear axle. Flexible hoses connect the brake tube to the disc brake calipers (2B120) and to the rear brake tube connector.
When replacing hydraulic brake tubing, hoses or connectors, tighten all connections securely. After replacement, bleed the brake system at the rear wheel cylinders, the disc brake calipers and at the brake master cylinder. Refer to Hydraulic System Bleeding in this section.
WARNING: COPPER TUBING SHOULD NOT BE USED IN THE HYDRAULIC SYSTEM. USE ONLY SAE J526 OR J527 OR EQUIVALENT STEEL TUBING.
NOTE: If a section of the brake tube is damaged, replace the entire section with tubing of the same type, size, shape and length. Be careful not to kink or crack the tubing when bending it to fit the frame or rear axle forms.
Double flared brake tubing should provide good leakproof connections.
NOTE: Always clean the inside of a new brake tube with clean isopropyl alcohol.
Flaring a Line (Split Die Type)
Cut off and straighten the required length of tubing (a tubing cutter tool will simplify making a clean and square cut).
Square off the ends of the tubing with a file, and chamfer the ends of the tubing to be flared.
Select the split die for the size of the tubing to be used, clean out all filings and insert the die into the tapered hole in the body of the flaring tool.
Push the tube through the die until the end of the tube is even with the face of the die. Lock the tube in this position by tightening the wing nut securely.
The punches are marked Op. 1 and Op. 2. Slide the first operation punch into the hole in the center of the body and tighten the screw securely to form the single flare.
Release the screw and replace the first operation punch with the second punch and tighten the screw to form the double flare.
Release the screw, wing nut, punch and dies.
NOTE: The finished flare must be square with the line, free of cracks and have a smooth mating surface to ensure a leakproof connection.
Remove the line and inspect the flare for cracks or poor flare form. If the flare is not correct, cut it off and repeat the process.
After flaring one end of the tubing, position the brake line fittings on the tubing in their correct order.
Repeat Steps 3 through 8 to flare the other end of the tubing.
Flaring Brake Line Tubing (Flaring Bar Type)
Cut off and straighten the required length of tubing. (A tubing cutter tool will simplify making a clean and square cut.)
Square off the ends of the tubing with a file, and chamfer the ends of the tubing to be flared. Make sure to clean out all filings.
Insert the tubing through its appropriate ribbed hole in the bar assembly until the end of the tubing sticks out about as far as the thickness of the adapter above the bar, or even with the bar, depending on the tool used.
Fit the adapter onto the tubing and slide the bar into the yoke. Lock the bar in position with the tubing beneath the yoke screw.
Form the single flare by tightening the yoke screw securely.
Release the screw and remove the adapter.
Form the double flare by tightening the yoke screw again, with second adapter fitted, depending on the tool used.
Release the screw bar and flared tubing.
Inspect the flare for cracks or poor flare form, and repeat the process if the flare is not correct.
After flaring one end of the tubing, position the brake line fittings on the tubing in their correct order.
Repeat Steps 3 through 9 to flare the other end of the tubing.
