Page 3 of 3 FirstFirst 123
Results 61 to 81 of 81

Thread: Broken brake line... AND HOW TO FIX IT !!

  1. #61
    SLi O.G. d1giPhux's Avatar
    Join Date
    Dec 2005
    Posts
    3,263
    Points
    20,084
    Level
    89
    Points: 20,084, Level: 89
    Level completed: 47%, Points required for next Level: 266
    Achievements:
    10000 Experience PointsO.G.Overdrive

    Re: Broken brake line... AND HOW TO FIX IT !!

    Got some new NiCopper brake line so that I could complete the rear lines replacement since they are super rusty and I don't want to trust them after all this work.

    This new brake line is a 'copper-nickel ferrous alloy'. Its rust resistant and DOT approved. PLUS.. its SUPER SUPER easy to bend. WAY WAY easier then steel line, and your flares come out INCREDIBLE. If i had to do this all again, I would have just bought a roll of this stuff to begin with!

    A view of the Nickel-copper brake line. Cost $34 for a 25' Roll:




    A view of just how good the flares come out. Didn't have to torque down on my tool AT ALL to hold this stuff either while making the flare:


    ----------------------------------------------------------------------------------------------
    NOTE: THIS IS HOW YOU SHOULD BEND BOTH LINES BEFORE INSTALLING:

    1. Bend the first 'C' section. I used my cheap $3 bending tool like so:




    2. Then use the tool backwards like this to bend the line back vertically:


    3. Once you are done, the line should look like this:




    If you bend BOTH lines like this before installing them into your car, it will allow you to tighten both to the 4-way fitting underneath easily. Then after you can bend them down INSIDE the car under the rear seat.
    ---------------------------------------------------------------------------------------------------------
    Got a bit carried away. Decided I would make new lines with the NiCopper brake line. Just because.
    I did this in under an hour for both lines. Removed old lines, flared new 12" lines, bent them, then installed. All super fast!


    A view of the new line on the left installed:


    Removing 2nd line:


    After cutting 2nd line down to proper size and then flaring it:






    Second line Installed!:




    View from bottom of the car:


    So basically I didn't get a whole lot accomplished in terms of running the new lines to the rear wheels, but I did get to play with a couple feet of the new brake line, and this stuff ROCKS! If you have to do this, I suggest just buying a roll of this stuff from the start. You will save $ and have extra!
    --99 Legacy GT Limited Edt. (Silver ! )

    99 Subaru Legacy FSM Download:
    http://tinyurl.com/2u8cbx

  2. #62
    OMFGAWD phi11's Avatar
    Join Date
    Jul 2005
    Location
    Apple Valley, MN
    Posts
    869
    Points
    10,878
    Level
    69
    Points: 10,878, Level: 69
    Level completed: 7%, Points required for next Level: 372
    Achievements:
    O.G.10000 Experience Points

    Re: Broken brake line... AND HOW TO FIX IT !!

    Omg! Great job!!!!!
    I will be buying this stuff.

  3. #63
    SLi O.G. d1giPhux's Avatar
    Join Date
    Dec 2005
    Posts
    3,263
    Points
    20,084
    Level
    89
    Points: 20,084, Level: 89
    Level completed: 47%, Points required for next Level: 266
    Achievements:
    10000 Experience PointsO.G.Overdrive

    Re: Broken brake line... AND HOW TO FIX IT !!

    Thanks man!

    Yeah, its wicked easy stuff to bend.. wish I would have bought it to begin with, but I was pre-occupied with buying 1 foot steel sections in order to try and fix the lines under the rear seat first.

    Then i realized all the rest of the lines are rusty as hell too.. so I'm gonna replace them. The NAPA brake flaring tool was also a big helper. It kicks ass, a $30 well spent!


    ----------------------------------------------------------------------------------------------------------
    Now I'm just trying to figure out which lines run to which sides on this 4-way connector.

    Looks like both the left and right rear lines run over the gas tank and subframe area and then connect to the 4-way box. Here is a picture of what I mean:




    I'm not sure how I'm going to route the new lines yet. Need to find somewhere safe to route them.. and NO WAY am i gonna try and push them over the gas tank and crap.

    ANY SUGGESTIONS ANYONE?
    --99 Legacy GT Limited Edt. (Silver ! )

    99 Subaru Legacy FSM Download:
    http://tinyurl.com/2u8cbx

  4. #64
    SLi O.G. d1giPhux's Avatar
    Join Date
    Dec 2005
    Posts
    3,263
    Points
    20,084
    Level
    89
    Points: 20,084, Level: 89
    Level completed: 47%, Points required for next Level: 266
    Achievements:
    10000 Experience PointsO.G.Overdrive

    Re: Broken brake line... AND HOW TO FIX IT !!

    Been taking the last few days off since its been snowing, and I can't really work outside im the freezing cold AND snow.

    Need some help on figuring out how to run these new lines.


    Does anyone have any pictures of where the rear lines run under the gas tank? Anyone ever removed their gas tank?

    I'm trying to figure out which side of the 4 way connector connects to which rear wheel? Or does it not matter? Picture:

    --99 Legacy GT Limited Edt. (Silver ! )

    99 Subaru Legacy FSM Download:
    http://tinyurl.com/2u8cbx

  5. #65
    t3h ub3r m3mber StatGSR's Avatar
    Join Date
    Dec 2006
    Location
    Duluth MN
    Posts
    1,494
    Points
    9,798
    Level
    66
    Points: 9,798, Level: 66
    Level completed: 37%, Points required for next Level: 252
    Achievements:
    5000 Experience PointsO.G.

    Re: Broken brake line... AND HOW TO FIX IT !!

    Loosen one or both, open bleeders, then apply air, see what side i comes out of, or remove one and plug the other, and open both bleeders, see where the fluid comes out. these are just some ideas to save you a lot of time and effort... don't over think it..
    97 Legacy Brighton w/ EG33 swap.... still a work in progress
    05 Outback XT - DD
    94 Integra GSR - Track Car
    03 Silverado 2500HD Duramax - Tow Rig
    97 Integra GS - Future Track Car

    Quote Originally Posted by Reason
    Quote Originally Posted by tekkitan
    Quote Originally Posted by Svenerachi
    why was ^ statgsr banned? or is that just his unique status thing?
    he was a naughty monkey
    naughty monkeys are not tolerated here

  6. #66
    SLi O.G. d1giPhux's Avatar
    Join Date
    Dec 2005
    Posts
    3,263
    Points
    20,084
    Level
    89
    Points: 20,084, Level: 89
    Level completed: 47%, Points required for next Level: 266
    Achievements:
    10000 Experience PointsO.G.Overdrive

    Re: Broken brake line... AND HOW TO FIX IT !!

    Thanks.. yeah I was actually thinking about doing that. Only problem being, where the lines connect to the 4-way connector, they are SO rusted, that I know they wont easily be unscrewed. In fact, the only way I was able to get the other 2 lines out was by cutting the lines, and then using a 6pt socket on them, as well as heat. So.. i guess I COULD do that, but then id be up the river without a paddle, or whatever the saying is.

    I guess if I'm replacing the lines anyways, that wouldn't be a huge deal. Hmm, might have to consider that.
    --99 Legacy GT Limited Edt. (Silver ! )

    99 Subaru Legacy FSM Download:
    http://tinyurl.com/2u8cbx

  7. #67
    t3h ub3r m3mber StatGSR's Avatar
    Join Date
    Dec 2006
    Location
    Duluth MN
    Posts
    1,494
    Points
    9,798
    Level
    66
    Points: 9,798, Level: 66
    Level completed: 37%, Points required for next Level: 252
    Achievements:
    5000 Experience PointsO.G.

    Re: Broken brake line... AND HOW TO FIX IT !!

    You could disconnect it on the new side you just put in and get the same results....
    97 Legacy Brighton w/ EG33 swap.... still a work in progress
    05 Outback XT - DD
    94 Integra GSR - Track Car
    03 Silverado 2500HD Duramax - Tow Rig
    97 Integra GS - Future Track Car

    Quote Originally Posted by Reason
    Quote Originally Posted by tekkitan
    Quote Originally Posted by Svenerachi
    why was ^ statgsr banned? or is that just his unique status thing?
    he was a naughty monkey
    naughty monkeys are not tolerated here

  8. #68
    Administrator Huffer's Avatar
    Join Date
    Sep 2005
    Location
    Eastlake, OH / Wellington, NZ
    Posts
    13,329
    Points
    44,297
    Level
    100
    Points: 44,297, Level: 100
    Level completed: 0%, Points required for next Level: 0
    Achievements:
    25000 Experience PointsO.G.SocialOverdrive

    Re: Broken brake line... AND HOW TO FIX IT !!

    That 4 way connector is likely a passthrough - the fluid probably doesn't pool inside there - the lines should run straight through the box. You may just want to replace that at the same time.
    - Roger - Site Admin
    My signature is now a shout-out to the SLi veterans who keep this site flowing with good knowledge and informative opinion. You KNOW who you are, so keep it up!
    USDM 98 GT Wagon - Pandgrish - RIP; USDM 98 GT Sedan - 216k RIP; NZDM 99 GF8 - retired
    USDM 03 Honda Accord Sedan LX, 210k; USDM 03 Honda Odyssey LX, 190k - Mrs Huffer;
    Live Like No One Else - Debt Free

  9. #69
    SLi O.G. d1giPhux's Avatar
    Join Date
    Dec 2005
    Posts
    3,263
    Points
    20,084
    Level
    89
    Points: 20,084, Level: 89
    Level completed: 47%, Points required for next Level: 266
    Achievements:
    10000 Experience PointsO.G.Overdrive

    Re: Broken brake line... AND HOW TO FIX IT !!

    huffer: So what your saying is, I could do like statGSR said and just disconnect the other side of the 4 way to try and figure out which lines are going to the wheels?

    Hmm, sounds like an idea, i think i may just have to do that. The 4way itself is in okay condition, its just the lines that are rusted / mangled.
    --99 Legacy GT Limited Edt. (Silver ! )

    99 Subaru Legacy FSM Download:
    http://tinyurl.com/2u8cbx

  10. #70
    Administrator Huffer's Avatar
    Join Date
    Sep 2005
    Location
    Eastlake, OH / Wellington, NZ
    Posts
    13,329
    Points
    44,297
    Level
    100
    Points: 44,297, Level: 100
    Level completed: 0%, Points required for next Level: 0
    Achievements:
    25000 Experience PointsO.G.SocialOverdrive

    Re: Broken brake line... AND HOW TO FIX IT !!

    Yep.
    - Roger - Site Admin
    My signature is now a shout-out to the SLi veterans who keep this site flowing with good knowledge and informative opinion. You KNOW who you are, so keep it up!
    USDM 98 GT Wagon - Pandgrish - RIP; USDM 98 GT Sedan - 216k RIP; NZDM 99 GF8 - retired
    USDM 03 Honda Accord Sedan LX, 210k; USDM 03 Honda Odyssey LX, 190k - Mrs Huffer;
    Live Like No One Else - Debt Free

  11. #71
    SLi O.G. d1giPhux's Avatar
    Join Date
    Dec 2005
    Posts
    3,263
    Points
    20,084
    Level
    89
    Points: 20,084, Level: 89
    Level completed: 47%, Points required for next Level: 266
    Achievements:
    10000 Experience PointsO.G.Overdrive

    Re: Broken brake line... AND HOW TO FIX IT !!

    Found a good thread that is related to this brake job:

    viewtopic.php?f=12&t=20529

    Now if only I could get a hold of the thread creator! I've Pm'ed him on several msg boards.. but no luck. Anyone know his email?? I want to ask him how he routed his rear lines, and if he has any pictures!
    --99 Legacy GT Limited Edt. (Silver ! )

    99 Subaru Legacy FSM Download:
    http://tinyurl.com/2u8cbx

  12. #72
    SLi O.G. d1giPhux's Avatar
    Join Date
    Dec 2005
    Posts
    3,263
    Points
    20,084
    Level
    89
    Points: 20,084, Level: 89
    Level completed: 47%, Points required for next Level: 266
    Achievements:
    10000 Experience PointsO.G.Overdrive

    Re: Broken brake line... AND HOW TO FIX IT !!

    ...Update! I Figured out how the REAR BRAKE LINES (from each wheel) connect to the 4-way connector!!

    Here is how the REAR brake lines run from each wheel TO the 4-way connector:




    ----------------------------------------------------------------------------------------------------
    Here is how I found out which lines ran where:

    1. Disconnected the new lines from the 4-way.
    2. Attached brake fitting w/line.
    3. Put balloons over line.
    4. Disconnected brake hose from caliper (remove (1) 14mm bolt from caliper).
    5. Spray compressed ait into brake hose (the one you just removed).
    6. This is the remaining balloon. This shows us which side the PASS side is on. So now we can assume the drivers is the other one.
    ----------------------------------------------------------------------------------------------------


    Here are the brake fittings and balloons:


    Removing the new lines from the 4-way connector:


    Connecting the fittings to the 4-way so you can use balloons in next step:


    Put balloons over fitting:


    Blue balloon remains. This shows you that the side the yellow was connected to is PASS side where you are blowing air into:



    A video of the compressed air blowing out the balloon:
    http://tinyurl.com/7ao2hgm

    So.. as you can see, when we look at the brake line routing with the NEW lines coming from under the seat.. the TOP line is the DRIVERS, and the BOTTOM lines is the PASS.

    --99 Legacy GT Limited Edt. (Silver ! )

    99 Subaru Legacy FSM Download:
    http://tinyurl.com/2u8cbx

  13. #73
    "FNG"
    Join Date
    Oct 2010
    Location
    North Bay, ON, Canada
    Posts
    29
    Points
    3,242
    Level
    35
    Points: 3,242, Level: 35
    Level completed: 28%, Points required for next Level: 108
    Achievements:
    Veteran1000 Experience Points

    Re: Broken brake line... AND HOW TO FIX IT !!

    I just had to replace my LR brake line. I ran it over the diff. No way can it go over the tank without dropping the tank.

  14. #74
    SLi O.G. d1giPhux's Avatar
    Join Date
    Dec 2005
    Posts
    3,263
    Points
    20,084
    Level
    89
    Points: 20,084, Level: 89
    Level completed: 47%, Points required for next Level: 266
    Achievements:
    10000 Experience PointsO.G.Overdrive

    Re: Broken brake line... AND HOW TO FIX IT !!

    Yeah I'm gonna have to run mine over the diff.

    Did you use the subaru 4-way connector however? I guess my biggest problem now is just getting the end of the lines to line up with the connector. I guess the only reason they seem hard right now is because the other lines are in the way. Its supposed to be nice today and I hope to get this done, or close to done!
    --99 Legacy GT Limited Edt. (Silver ! )

    99 Subaru Legacy FSM Download:
    http://tinyurl.com/2u8cbx

  15. #75
    SLi O.G. d1giPhux's Avatar
    Join Date
    Dec 2005
    Posts
    3,263
    Points
    20,084
    Level
    89
    Points: 20,084, Level: 89
    Level completed: 47%, Points required for next Level: 266
    Achievements:
    10000 Experience PointsO.G.Overdrive

    Re: Broken brake line... AND HOW TO FIX IT !!

    After cleaning the REAR lines off with a wire brush, I've come to the realization that i DO NOT need to replace the rear lines going to the wheels.

    I'm going to tighten everything back up, and bleed them. I will test them with pressure as if I were under ACCIDENT situation. If they hold up, I'm going to call this job DONE.

    I've been messing with this entirely too long and I'm ready to bring it to an end. I'll post back with the results.

    If the lines happen to leak from anywhere in the rear, or I notice anything off.. I will continue with replacing the REAR lines going to the wheels. Until then.. I'm going to roll with it how it is and HOPE they don't pop any new holes like they did in the spot i repaired.
    --99 Legacy GT Limited Edt. (Silver ! )

    99 Subaru Legacy FSM Download:
    http://tinyurl.com/2u8cbx

  16. #76
    SLi O.G. d1giPhux's Avatar
    Join Date
    Dec 2005
    Posts
    3,263
    Points
    20,084
    Level
    89
    Points: 20,084, Level: 89
    Level completed: 47%, Points required for next Level: 266
    Achievements:
    10000 Experience PointsO.G.Overdrive

    Re: Broken brake line... AND HOW TO FIX IT !!

    Got the lines back together, and bled.. NO LEAKS! So.. maybe I'll be okay!! If i don't report back at a later time, its because i crashed
    --99 Legacy GT Limited Edt. (Silver ! )

    99 Subaru Legacy FSM Download:
    http://tinyurl.com/2u8cbx

  17. #77
    t3h ch33se Wiscon_Mark's Avatar
    Join Date
    May 2005
    Location
    Plover, WI
    Posts
    9,867
    Points
    43,397
    Level
    100
    Points: 43,397, Level: 100
    Level completed: 0%, Points required for next Level: 0
    Achievements:
    25000 Experience PointsO.G.Overdrive

    Re: Broken brake line... AND HOW TO FIX IT !!

    Did you crash or is it all OK? It looks like you did a really nice job with all of this. And I think a lot of us learned a lot (I did). Kudos.
    ~Mark [SLi Admin]
    2015 Dodge Charger AWD
    2008 Subaru Tribeca Limited, 7 passenger w/ Navigation

    Former vehicles:
    03 Forester
    95 Legacy Outback

  18. #78
    SLi O.G. d1giPhux's Avatar
    Join Date
    Dec 2005
    Posts
    3,263
    Points
    20,084
    Level
    89
    Points: 20,084, Level: 89
    Level completed: 47%, Points required for next Level: 266
    Achievements:
    10000 Experience PointsO.G.Overdrive

    Re: Broken brake line... AND HOW TO FIX IT !!

    Thanks! Hopefully this info will help people in the future.

    Tomorrow I will take it out for a test drive. I didn't today.. because i forgot I had to put all the interior back together!

    So tomorrow will be the test day. However, I pressed on the pedal as hard as possible and NO leaks, so thats a good sign!
    --99 Legacy GT Limited Edt. (Silver ! )

    99 Subaru Legacy FSM Download:
    http://tinyurl.com/2u8cbx

  19. #79
    "FNG"
    Join Date
    Oct 2010
    Location
    North Bay, ON, Canada
    Posts
    29
    Points
    3,242
    Level
    35
    Points: 3,242, Level: 35
    Level completed: 28%, Points required for next Level: 108
    Achievements:
    Veteran1000 Experience Points

    Re: Broken brake line... AND HOW TO FIX IT !!

    Yes, I used the connector. It is a bit of a PITA to line them up because the it is not lined up with the subframe rail that the brake lines come down, but a quick tweak with a pair of pliers to bend the brake line and I had it back together.

  20. #80
    SLi nOOb jjay03's Avatar
    Join Date
    Jan 2012
    Location
    Cincinnati
    Posts
    177
    Points
    3,128
    Level
    34
    Points: 3,128, Level: 34
    Level completed: 52%, Points required for next Level: 72
    Achievements:
    Veteran1000 Experience Points

    Re: Broken brake line... AND HOW TO FIX IT !!

    Where do you buy this line at??
    Red 1998 LGT Limited
    CWP 2016 FXT Premium

  21. #81
    New User
    Join Date
    Jul 2017
    Posts
    1
    Points
    1
    Level
    1
    Points: 1, Level: 1
    Level completed: 0%, Points required for next Level: 1
    Thanks for this post, as been a great help.
    My line bursted after the abs module, there's a 90° turn near the passenger wall, then bursted near the 4 way in the back.
    I'm almost done, getting ready to bleed and found some more line in bad shape, under the brake booster. (I had only replaced where was corroded)
    Would also like to point that the manual contradicts it self on bleeding, page 87 and page 4182.
    Removing also the lines at the booster to bleed as the manual indicates, doesn't air goes back in when removing finger to insert the line connector?

    Thanks
    Last edited by Poveiro; 08-10-2017 at 06:06 AM. Reason: spelling

Page 3 of 3 FirstFirst 123

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •