Brake Lines, Repairing

Special tools and workshop equipment required 

• Brake Charger/Bleeder Unit :VAS5234  with Brake Bleeder Adapter :VAS5234/1A 
• Brake Line Tool Kit :VAS6056 
• Drill, commercially available

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

Fig 1: Brake Line Repair Tools

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1. Brake Line Tool Kit - Flanging Tool :VAS6056/1 
   • The Clamp Jaws :VAS6056/6  are included in the 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 :VAS6056/3 
   • The threaded pins (in shaft and at sides) are set and must not be adjusted.
4. Brake Line Tool Kit - Grips with Line Grips :VAS6056/4 
5. Brake Line Tool Kit - Pipe Bending Tool :VAS6056/5 
6. 6 mm Offset Screwdriver
7. Flaring Jaws
   • Brake Line Tool Kit - Clamp Jaws :VAS6056/6  for black brake lines
   • Brake Line Tool Kit - Clamp Jaws :VAS6056/7  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.

Procedure 

-- Remove the corresponding brake line on the brake caliper. Be sure to catch any leaking brake fluid and dispose of it correctly.

-- Cut through the brake line -1- at a suitable position (Restrictor, accessible position) with a suitable :VAS6056/2  -B-.

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-- Remove the piece to be exchanged.

-- Grease the brake line surface.

-- Clamp the brake line -1- in the locking pliers -D- so that approximately 50 mm is sticking out of the plastic clamping jaws.

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-- Mount the shearing tool -C- in a drill -H- 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 brake line.

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

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-- Remove the shearing tool from the brake line -1- and remove the shavings.

-- Remove the locking pliers and push the union bolt -2- onto the brake line.

-- Push the brake line -1- against the stop -arrow- inside the flanging tool -A-.

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

-- Pretension the brake line -1- in the flanging tool -A- until the brake line can no longer be moved. Then fold up the stop and tighten the hex socket bolt diagonally using the long reach special wrench -F-.

-- Turn the spindle -arrow- all the way in the flanging tool -A-.

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-- 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 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.

-- Push together the brake lines -1- using the union bolts -2- using the connecting piece -3-.

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-- Assemble the brake line.

-- Bleed the brake system. Refer to HYDRAULIC SYSTEM, BLEEDING .