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Standard Procedure - Underbody Line Repair

WARNING: This page is about a different car, the 2016 Dodge Durango. However, it is still accessible from the selected car via links, so may be relevant.
WARNING:

This procedure is intended for underbody line repair only. Use of the connector fittings and A/C Line Repair Tools on any other type of vehicle tubing may cause tube failure resulting in possible serious or fatal injury.

Fig 1: Identifying Tube Cut Length Locations
GC0105566Courtesy of CHRYSLER GROUP, LLC
  1. If repairing an underbody refrigerant line, recover the refrigerant from the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
  2. If repairing an underbody coolant line, drain the engine cooling system. Refer to STANDARD PROCEDURE .
  3. Disconnect and isolate the negative battery cable.
  4. Raise and support the vehicle.
  5. Remove the underbody mounting brackets as necessary to gain access to the underbody line(s) needing repair. Refer to LINES, A/C UNDERBODY, REMOVAL .
  6. Mark the cut location(s) on the underbody line(s) needing repair. Check the Tube Length table for the minimum amount of straight tube required (dimension A) for proper connector fitting installation.
  7. Using a small pipe cutter or another suitable tool, carefully cut the underbody line(s) needing repair at the location(s) previously marked.
    TUBE LENGTH

    Tube Size Minimum Tube Length Required
    Dimension A Standard Installation Dimension A Jaw Reversed Installation
    3/8 in 28.5 mm (1 1/8 in) 19 - 28.5 mm (3/4 - 1 1/8 in)
    1/2 in 28.5 mm (1 1/8 in) 19 - 28.5 mm (3/4 - 1 1/8 in)
    5/8 in 31.7 mm (1 1/4 in) 22.2 - 31.7 mm (7/8 - 1 1/4 in)
    Fig 2: Dimension A
    GC0145811Courtesy of CHRYSLER GROUP, LLC
  8. Size a replacement line, same size diameter and length as the portion of the line(s) removed.
    NOTE:

    A minimum of 28.5 mm (3/4 in) of the line end must be cleaned in order for the connector fitting to properly seal the repair area.

  9. Clean the ends of the line(s) a minimum of 28.5 mm (3/4 in) (dimension A) using the Scotch-Bright® pad provided with A/C Line Repair Tool Kit (special tool #8456A, A/C Line Repair Tools). Clean the line end(s) with a rotational motion around the line to avoid longitudinal scratches in the line.
    Fig 3: Locating Connector Fitting
    GC0105567Courtesy of CHRYSLER GROUP, LLC
  10. Select the proper connector fitting (1) for the size of the underbody line being repaired. See CONNECTOR FITTING  .
  11. Apply one drop of Lokprep® sealing compound provided with A/C Line Repair Tool Kit (special tool #8456A, A/C Line Repair Tools) onto each line end (2).
  12. Insert the line ends into the selected connector fitting and rotate the connector fitting a complete turn to evenly distribute the sealing compound.
    CONNECTOR FITTING

    Description Mopar Part Number
    3/8 in 5069 002AA
    1/2 in 5069 003AA
    5/8 in 5069 004AA
    Fig 4: Jaws, Tool Body & Rubber Gripping Pads
    GC0145812Courtesy of CHRYSLER GROUP, LLC
  13. Select the proper size jaws (1) for the line being repaired from the A/C Line Repair Tool Kit (special tool #8456A, A/C Line Repair Tools). See JAW SIZE  .
  14. Assemble the jaws into Tool Body (special tool #8456-3, Installer Body) (2) (in Kit 8456A).
    1. For standard installation, install the jaws with the rubber gripping pads (3) facing outward. See the Tube Length chart.
    2. For reversed installation, remove the rubber gripping pads and install the jaws with the rubber gripping pad area facing inward. See TUBE LENGTH  .
    JAW SIZE

    Description Miller Part Number
    3/8 in 8456-1
    1/2 in 8456-4
    5/8 in 8456-2
    Fig 5: Connector Fitting, Line Ends, Tool Body, Screw & Jaws
    GC0145813Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The connector fitting ends must be positioned into the counterbore of the jaws in order for the connector fitting to properly seal the repair area.

  15. Install the connector fitting (1) and the line ends (4) into the counterbore of the jaws (5).
  16. Hold Tool Body (special tool #8456-3, Installer Body) (2) with a 3/8 inch breaker bar and turn the forcing screw (3) clockwise.
    Fig 6: Bottoming Out Connecting Fitting Collars
    GC0105568Courtesy of CHRYSLER GROUP, LLC
    NOTE:

    The lines must be kept fully inserted into the connector fitting to obtain a leak free joint.

  17. Turn the forcing screw (1) clockwise until both connector fitting collars (2) have bottomed out on the center shoulder of the connector (3).
  18. Loosen the forcing screw and remove Tool Body (special tool #8456-3, Installer Body) (4) and the jaws (5) from the repaired line(s).
  19. Install the underbody mounting brackets as necessary. Refer to LINES, A/C UNDERBODY, INSTALLATION .
  20. Lower the vehicle.
  21. Reconnect the negative battery cable.
  22. If repairing an underbody coolant line, refill the engine cooling system. Refer to STANDARD PROCEDURE .
  23. If repairing an underbody refrigerant line, evacuate and charge the refrigerant system. Refer to PLUMBING, STANDARD PROCEDURE .
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