Brake Lines, Repairing: Instructions

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-- Remove the affected brake line at brake caliper or wheel brake cylinder and collect escaping brake fluid and dispose of it correctly.

-- Disconnect brake line at appropriate location (straight, accessible part) with line cutter -2-.

Fig 1: Disconnecting Brake Line At Appropriate Location With Line Cutter

Courtesy of AUDI OF AMERICA, LLC

-- Remove the piece to be exchanged.

-- Lubricate brake line surface.

-- Clamp the brake line in self-grip pliers -4- so that 50 mm of the plastic clamping jaws show.

Fig 2: Identifying Brake Line Clamped In Self-Grip Pliers

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-- Clamp the shearing tool -3- in a drill and place it on the brake line.

-- Shear the coating from the brake line at a slow drill RPM and with light pressure against the line.

The length of the sheared-off portion is determined by the stop in the shearing tool.

-- Remove the shearing tool from the brake line and remove the shearing remains.

-- Remove the self-grip pliers and the tube fitting -D- from the brake line.

Fig 3: Identifying Self-Grip Pliers, Tube Fitting And Brake Line

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-- Slide the brake line -B- against the stop -A- in flaring tool.

Fig 4: Sliding Brake Line Against Stop In Flaring Tool

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NOTE:

Brake line must contact stop when hex socket heat screws are tightened, otherwise the flanged head will not be formed correctly.

-- Clamp the brake line in the flaring tool until it cannot be moved any more. Fold the stop -A- up and tighten the hex socket head screws diagonally with the angle screw driver -C-.

Fig 5: Identifying Stop In Down Position

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-- Turn the spindle to stop in flaring tool.

Fig 6: Identifying Turning Spindle To Stop In Flaring Tool

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-- Turn the spindle back.

-- Loosen the hex socket head screws diagonally.

-- Remove the brake line from the flaring tool, clean and check the brake line and the flared head.

Briefly rinse the part of the brake line remaining in the vehicle:

-- Connect the Brake Charger/Bleeder Unit VAS5234, place the bleeder container hose on the flared head of the brake line and run the Brake Charger/Bleeder Unit VAS5234 briefly until some brake fluid runs through.

-- Clean the brake line with compressed air.

-- Join brake lines with connecting piece -E-.

Fig 7: Identifying Brake Lines Joined With Connecting Piece

Courtesy of AUDI OF AMERICA, LLC

-- Assemble brake line.

-- Then brake system must be bled.

-- Refer to BRAKE SYSTEM, BLEEDING