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Old 10-18-2009, 04:51 PM   #1
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Default Rusty brake lines

Hi guys, I have been asking a few questions about this Bonneville my bro in law gave me and your help has been greatly appreciated. My biggest hurdle will be the brake tubing lines. This car is in great shape but sat a lot in an old garage here in NW PA while my brother in law spent his winters in Fla. All of the lines are scaly and I see a line weeping fluid under the air box just before the ABS box I believe. They still work but I am afraid to drive it anywhere until I replace these. As nice as the rest of the under carriage is I just can't believe how rusty the brake lines are. And there are so dang many of them! How would you guys approach this? Forget taking it to the shop as I figure this would be a LOT of labor time replacing these. Would you remove them one at a time and bend a new one as close as possible to that line then install the new one and move on to the next? I do have a little hand bender my dad gave me along with a nice little double flare tool set.

I also was wondering if it would be easier to find a set off a car from out west or a non salt area and have them shipped to me and I could just install those used but non rusty ones on this car.....? bad idea? Let me know what you guys would do. Thanks


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Old 10-18-2009, 05:01 PM   #2
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If you really want to fix it right, and I do suggest fixing brakes right. You said you have a bender, as long as it'* the correct size and type. Get a flare tool, and some tubing. Remove one line, then make a new line to match it, flare the ends and install. then move on to the next. Bleed the brakes real good when done.
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Old 10-19-2009, 11:03 AM   #3
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I've been fixing some lines lately and would offer this advice. Depending on how bad the lines are, I'd cut and patch or replace the whole run. You will find that there'* only 2-3 different types of fittings on the car depending whether it'* a bubble flare or double flare. Having a double tool, you should be able to do both types.

One line at a time is the best suggestion and try to pull the clips off the body to reuse them to hold the lines once you are done.

As for getting lines from out west/south, it'* probably cost prohibitive because of how long each line would be.
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Old 10-28-2009, 09:30 PM   #4
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Just wanted to update on the brake lines. Got a roll of the 3/16 brake tubing line and replaced every single hard metal line on the car. Practiced my flares on a couple pcs and soon they were looking pretty good. Took an entire weekend but the brakes are finished and work real well. Had to replace wheel cylinders while I was in there too. Sure feels a lot better now knowing all those lines are new! Fuel lines look pretty rusty as well but no leaks there yet. May have to tackle that one at a shop as my garage is right under my kitchen and the wife does not like the smell of gas. LOL. Thanks for the advice fellas.

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Old 10-28-2009, 10:00 PM   #5
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That'* awesome Dave. Good job. Now you know it'* done, and done right.
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Old 10-30-2009, 11:44 AM   #6
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i've got the exact same problem that you had. car sat for a couple years and the brake llines just crumbled. i'm 90 percent done with fixing them, i ended up taking the entire bundle of lines out from the abs controler back and bent new lines one at a time so it looks completely stock. i had to do new wheel cylinders and rubber hoses also, when i'm done every single line on the car will be brand new.

one question tho, as i was taking out the lines i cut the two lines that go to the rear wheels right below the passengers seat. i'm planning on just flairing them right there and running them back, but i forgot to lable which line goes to which wheel.

would someone mind looking at their car and tell me which port on the abs controler goes to which wheel? i'm kind of stuck until i get this straightened out. thanks for any help
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Old 10-30-2009, 12:44 PM   #7
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Originally Posted by imdawrlus View Post
i've got the exact same problem that you had. car sat for a couple years and the brake llines just crumbled. i'm 90 percent done with fixing them, i ended up taking the entire bundle of lines out from the abs controler back and bent new lines one at a time so it looks completely stock. i had to do new wheel cylinders and rubber hoses also, when i'm done every single line on the car will be brand new.

one question tho, as i was taking out the lines i cut the two lines that go to the rear wheels right below the passengers seat. i'm planning on just flairing them right there and running them back, but i forgot to lable which line goes to which wheel.

would someone mind looking at their car and tell me which port on the abs controler goes to which wheel? i'm kind of stuck until i get this straightened out. thanks for any help

Please add your year and trim of your vehicle to your signature line. That way when you start asking questions in other areas of the forum, we all have a better idea on how to assist you. Click on "Quick Links" above, go down to "User Control Panel" and then click on "Edit your Signature" It'* pretty straight forward from there.
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Old 10-30-2009, 02:25 PM   #8
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i'm trying to figure that out right now...until then its a 95 bonneville non supercharged 3.8 liter
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Old 10-30-2009, 04:41 PM   #9
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i added a picture diagram of the lines and setup for a 95 bonnie in your thread... hopefully that will be able to help

i work at a dealership and am at work if you need to know what numbers are what just holler
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Old 10-30-2009, 04:46 PM   #10
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TL, where did you add the pic? I don't see it.
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