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Hydraulic pipes and hoses - inspection, removal and refitting
Braking system / Hydraulic pipes and hoses - inspection, removal and refitting


Inspection
1 Jack up the front and rear of the vehicle, and support on axle stands.

2 Check for signs of leakage at the pipe unions, then examine the flexible hoses for signs of cracking, chafing and fraying.

3 The brake pipes should be examined carefully for signs of dents, corrosion or other damage. Corrosion should be scraped off, and if the depth of pitting is significant, the pipes renewed. This is particularly likely in those areas underneath the vehicle body where the pipes are exposed and unprotected.

4 Renew any defective brake pipes and/or hoses.

Removal
5 If a section of pipe or hose is to be removed, loss of brake fluid can be reduced by unscrewing the filler cap, and completely sealing the top of the reservoir with cling film or adhesive tape. Alternatively, the reservoir can be emptied (see Section 11).

6 To remove a section of pipe, hold the adjoining hose union nut with a spanner to prevent it from turning, then unscrew the union nut at the end of the pipe, and release it.

Repeat the procedure at the other end of the pipe, then release the pipe by pulling out the clips attaching it to the body (see illustrations). Where the union nuts are exposed to the full force of the weather, they can sometimes be quite tight. If an openended spanner is used, burring of the flats on the nuts is not uncommon, and for this reason, it is preferable to use a split ring (brake) spanner, which will engage all the flats. If such a spanner is not available, selflocking grips may be used as a last resort; these may well damage the nuts, but if the pipe is to be renewed, this does not matter.

14.6A Unscrewing a brake pipe union nut using a split ring spanner
14.6A Unscrewing a brake pipe union nut using a split ring spanner

14.6B Pulling out a brake pipe mounting clip
14.6B Pulling out a brake pipe mounting clip

7 To further minimise the loss of fluid when disconnecting a flexible brake line from a rigid pipe, clamp the hose as near as possible to the pipe to be detached, using a brake hose clamp or a pair of self-locking grips with protected jaws.

8 To remove a flexible hose, first clean the ends of the hose and the surrounding area, then unscrew the union nuts from the hose ends. Recover the spring clip, and withdraw the hose from the serrated mounting in the support bracket. Where applicable, unscrew the hose from the caliper.

9 Brake pipes supplied with flared ends and union nuts can be obtained individually or in sets from Ford dealers or accessory shops.

The pipe is then bent to shape, using the old pipe as a guide, and is ready for fitting. Be careful not to kink or crimp the pipe when bending it; ideally, a proper pipe-bending tool should be used.

Refitting
10 Refitting of the pipes and hoses is a reversal of removal. Make sure that all brake pipes are securely supported in their clips, and ensure that the hoses are not kinked.

Check also that the hoses are clear of all suspension components and underbody fittings, and will remain clear during movement of the suspension and steering.

11 On completion, bleed the brake hydraulic system as described in Section 15.


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