Replacing brake lines on your car, especially if it’s an older model, can be a necessary but challenging task. Over time, brake lines can rust and corrode, leading to leaks and compromising your vehicle’s braking system. For car enthusiasts and DIY mechanics, tackling this job at home is entirely possible and can save significant costs. This guide, inspired by a real-world brake line replacement project, will walk you through the process, highlighting the importance of having the right tools, especially a Bending Tool For Brake Lines On A Car, to ensure a successful and safe repair.
One common approach to brake line replacement is to replicate the factory routing, ensuring a clean and professional finish. In a recent project on a 1992 Mitsubishi Galant VR4 (similar to a GSX), the first crucial step involved removing the engine, transmission, and subframes to gain full access to the brake lines. This allowed for the old, corroded lines to be removed and served as a template for the new ones. For this project, stainless steel lines were chosen as a superior alternative to standard lines due to their exceptional resistance to rust and corrosion, ensuring longevity and reliability for years to come. While stainless steel is more expensive upfront, the long-term benefits justify the investment, especially in regions prone to rust.
For those looking to simplify their brake system and remove outdated components, deleting the Anti-lock Braking System (ABS) can be considered, especially on older vehicles where the ABS technology may be less refined. Early 90s Mitsubishi ABS systems, for example, are often considered less effective by modern standards and can be cumbersome to work around during repairs. Removing the ABS system requires replacing the ABS proportioning valve with a standard proportioning valve from a non-ABS model. Ideally, sourcing a proportioning valve from a 1993 or 1994 model with factory “big brakes” can maintain optimal brake bias. However, a generic proportioning valve from a non-ABS Galant can also suffice for regular street driving.
Deleting the ABS system necessitates new front brake lines, specifically those running from the master cylinder to the distribution block and from the distribution block to the front wheels. These lines differ in non-ABS configurations. Interestingly, the rear brake lines remain the same across both ABS and non-ABS models. In non-ABS cars, a junction block on the firewall replaces the proportioning valve found in ABS-equipped vehicles. A practical tip to save time and potentially cost is to source good condition front brake lines and proportioning valve lines from a junkyard car – ideally a non-ABS model from the same vehicle family. Non-ABS DSM (Diamond Star Motors) brake lines from 1990-1994 are generally interchangeable, making parts sourcing easier.
When working with stainless steel brake lines, especially for creating flares, investing in a high-quality flaring tool is paramount. A hydraulic flaring tool, such as the Mastercool hydraulic flaring tool, is highly recommended for its precision and ease of use. These tools ensure perfect flares every time, minimizing the risk of leaks and ensuring a secure brake line connection. While more expensive than manual flaring tools, hydraulic options remove the guesswork and physical strain from the flaring process, especially crucial when working with stiffer stainless steel lines.
Reusing original equipment manufacturer (OEM) flare nuts for the brake lines is a recommended practice. A quick cleaning with a wire wheel can restore them to excellent condition. ABS-equipped cars typically provide enough clean flare nuts to assemble a non-ABS system with all-original hardware, further contributing to cost-effectiveness. For fuel lines, consider using tube nuts and sleeves from reputable brands like Summit Racing, allowing for the use of standard -6AN hardware for all flexible lines, which provides a robust and easily serviceable fuel system connection.
Budgeting for a brake line replacement project is important. Expect to invest a few hundred dollars for parts alone, excluding specialized tools like the flaring tool and, importantly, a bending tool for brake lines on a car. While the initial investment may seem considerable, the result is a completely renewed brake line system free from rust and corrosion, routed precisely as the original manufacturer intended, ensuring both safety and peace of mind. A bending tool for brake lines on a car is essential for shaping the new lines to match the original routing, preventing kinks and ensuring proper fitment within the vehicle’s chassis. This tool allows for precise bends without damaging the lines, contributing to a professional and reliable brake system overhaul.
