Brake Lines, Repairing

Special tools and workshop equipment required 

• Brake Line Tool Kit: VAS6056 

Flare the brake lines using the : VAS6056  without damaging the coating. This allows for partial sections of the brake lines to be inexpensively replaced in certain cases.

• Brake lines must not be bent more than a maximum of 90°, otherwise they kink or deform, which causes an unacceptable constriction in the line.
• Disconnect the brake lines preferably at the underbody.
• The position of intermediate pieces should be selected so that they cannot rub against moving parts.
• Do not lubricate the spindle, clean only with mineral spirits.

List of Individual Tools:

Item	Tools	Tool Number
1	Brake Line Tool Kit - Flanging Tool	VAS6056/1
2	Brake Line Tool Kit - Pipe Cutter	VAS6056/2
3	Brake Line Tool Kit - Brake Line Scraper 1)	VAS6056/3
4	Brake Line Tool Kit - Line Grips	VAS6056/4
5	Brake Line Tool Kit - Pipe Bending Tool	VAS6056/5
6	6 mm Offset Screwdriver	-
7	Clamp Jaws	VAS6056/6 VAS6056/7
1) The threaded pins (in shaft and at sides) are set and must not be adjusted!

Brake Line Tool Kit - Flanging Tool (Including Clamp Jaws VAS6056/6) 

1. Flanging Tool Upper Section
   • Remove to switch the clamp jaws
2. Handle Fastener
   • Must be removed to reach the upper section bolt
3. Bolt
   • For the flanging tool upper section
4. Threaded Pins for Clamp Jaws
   • Centering and holding the clamp jaws
   • 2 mm inner hex socket
5. Clamp Jaws
   • They vary
   • Assembly Instructions. Refer to Fig 3.

Clamp Jaw Assembly Instructions: 

• Brake Line Tool Kit - Clamp Jaws -VAS6056/6- (dark) for black brake lines
• Brake Line Tool Kit - Clamp Jaws - VAS6056/7 (light) for green brake lines

• The arrow on the rounded side of the flaring jaws must point toward the edge of the housing.
• The straight side of the clamp jaws must be installed toward the spindle, otherwise the flanged head will not be formed correctly.

Instructions 

-- Remove the affected brake line from the brake caliper. While doing so, collect the escaping brake fluid and dispose of it correctly.

-- Cut the brake line at a suitable location (straight, accessible part) with the pipe cutter -2-.

-- Remove the piece to be exchanged.

-- Grease the brake line surface.

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

-- Clamp the scraping tool -3- in a drill and position it on the brake line.

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

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

-- Remove the scraping tool from the brake line and remove the shavings.

-- Remove the locking pliers and slide the union bolt -D- onto the brake line.

-- Push the brake line -B- against the stop -A- in the flanging tool.

• The brake line must contact the stop when tightening the hex socket bolts, otherwise the flanged head will not be formed correctly.

C -  Long Reach Special Wrench

-- Pretension the brake line in the flanging tool until the brake line can no longer be moved. Fold the stop -A- upward and tighten the hex socket bolts diagonally with the long reach special wrench.

-- Turn the spindle all the way into the flanging tool.

-- Turn the spindle back.

-- Loosen the hex socket bolts diagonally.

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

-- Briefly rinse the part of the brake line still in the vehicle by connecting the : VAS6860  .

-- Connect the bleeder bottle to the flared head on the brake line and let the : VAS5234  run for a little bit until all of the brake fluid has flowed through.

-- Clean the new brake line to be inserted with compressed air.

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

-- Assemble the brake line.

-- Then bleed the brake system. Refer to HYDRAULIC SYSTEM, BLEEDING .